Escalera Kone 67 - 30 - 0-2 [PDF]

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TECHNICAL INFORMATION PUBLICATION TIP 67.30.0-2

Kone Escalator Error Codes November 2, 2011

REQUIRED READING:

REVISION HISTORY:

SYSTEM:

COMPONENT/SUBSYS.: SUBASS./PARTS: SAFETY CONCERNS:

Field Operations Manager Maintenance Supervisor Construction Superintendent Subject Matter Expert Russell Delemos

Low-Rise Escalator

Date November 2, 2011

Mid-Rise All

High-Rise None

All Traction Other:

Safety Devices Potential Hazards:

Equipment Category: Glasses/Face Shield Ear Protection Gloves Harness/Coveralls Safety Shoes Other

SUMMARY:

Reason for Revision New TIP

Escalator/Moving Walks

Fall Crush Mechanical Electrical Chemical Other PPE REQUIRED:

Modernization Supervisor Repair Supervisor Field Engineer

Refer to Section: None None

None None Specific Type of Equipment: None None None None

This TIP documents fault code information for the Thyssen Krupp Velino escalators

Warning: This work, and the information contained herein, is the proprietary, confidential property of the Otis Elevator Company, and is made available here to Otis’ employees solely for use on behalf of the Otis Elevator Company. This work, and the information contained herein, shall not be used for any purpose, reproduced, distributed, or disclosed by or to anyone not having a specific need to use this work, and the information contained herein, on behalf of the Otis Elevator Company, without the express written permission of the Otis Elevator Company. Any unauthorized reproduction, disclosure, or distribution of copies by any person of any portion of this work may be a violation of the copyright law of the United States of America and other countries, and could result in the awarding of statutory damages for infringement, as well as further civil and criminal penalties. Unpublished Work - © Copyright 2011, Otis Elevator Company

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TECHNICAL INFORMATION PUBLICATION

Contents Description .................................................................................................................... 3 Reading Error Codes on a Kone Escalator/Walk ........................................................ 3 Using the Kone Service Tool ........................................................................................ 4 Using the SW4 and SW5 Buttons................................................................................. 6 Error Codes ................................................................................................................... 7 Table 1: Safety Circuit Error Code Definitions and Corrective Actions....................... 7 Table 2: Sensor, Brake, Machine, Contactor, and CPU Error Code Definitions and Corrective Actions .................................................................................................... 10 Appendix A: Part Numbers ........................................................................................ 15

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TECHNICAL INFORMATION PUBLICATION

Page 3 TIP 67.30.0-2 November 2, 2011

All jobsite work activity must be in full compliance with Otis Worldwide Jobsite Safety Standards (WWJSSS). When carrying out this procedure, pay particular attention to controlling the escalator, LOTO, ensuring public safety (signs and barriers), working in close proximity of unguarded rotating equipment (sheaves), and wearing appropriate PPE (hand gloves, etc.). The mechanics carrying out the repair should complete a formal written JHA to familiarize themselves with the work environment and the task at hand. Some hazards include hand cuts, sprains and strains from lifting and stretching, building and truss obstacles, confined spaces, and other running escalators and in adjacent trusses. If you are unsure of the WWJSSS regarding the task at hand, immediately stop and consult your supervisor.

Description Kone escalators/walks have an on-board annunciator, which displays error codes. This document is intended to help you understand the error codes, identify the causes of errors, and clear errors once the cause has been corrected, so the escalator/walk can run normally again.

Reading Error Codes on a Kone Escalator/Walk There are two ways to read the error codes on a Kone escalator/walk. •

The first way is to use the Kone service tool (p/n MTGMP-31552).

•

The other way is to use the SW4 and SW5 buttons on the CPU in conjunction with the white annunciator display button in the controller (see Fig. 1)

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TECHNICAL INFORMATION PUBLICATION

Using the Kone Service Tool 1. Plug the service tool into the J5 service tool port on the CPU board (see Fig. 1).

Figure 1: CPU Board and Annunciator

2. Once the tool is plugged in, the screen will display: Press menu for more F1= Miprom 21 CPU F2= AC Drive F3= Escalator 3. Press F3 for escalator. The tool will display “Select Function”. Select SERVICE LOG, which will result in the following display: F1= View Faults F2=View Events F3=View Stopping F4=View Loading

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TECHNICAL INFORMATION PUBLICATION

Page 5 TIP 67.30.0-2 November 2, 2011

4. Press F1= View Faults, and the faults will be displayed. The screen will show the date and time the error occurred, the error code, and a three-digit number identifying the escalator status when the fault occurred (NNN). •

The first digit indicates the mode the escalator was in when the error occurred: 1 = Normal 2 = Inspection 3 = Construction

•

The second digit shows the running stage the escalator was in at the time of the error. 0 = Stop Mode 1 = Start-Up Mode 2 = Brake Burnish 3 = Run Mode

•

The third digit is for direction the escalator was going at the time of the error. 0 = Stopped 1 = Up 2 = Down

NOTE: If the error code displayed is a manual reset error (refer to Tables 1 and 2 for error codes) you will need to reset the error electrically. You can do this using the Kone service tool or the SW4 and SW5 buttons along with the white button on the annunciator display (discussed later in this TIP). 5. On the Kone service tool, press the F8 key to navigate back to the Select Function screen, and hit the service mode button to see the screen below. Now press F1 for Manual Reset. F1= Manual Reset F2= Master Reset F3= Test Spd Detect F5= Download Data 6. At this time the screen will list display a manual reset fault if one is present. If you press the ENTER button the fault will be reset and the screen will either show the next manual reset fault if there is one. If another manual fault is displayed, press the ENTER button again to clear it. Continue this process till there are no more faults to be reset.

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TECHNICAL INFORMATION PUBLICATION

NOTE: Only manual reset faults will show up on this screen if the fault that is keeping the escalator from running is not a manual reset fault it will not show up on this screen. You will need to go back to the view faults screen to see what faults need to be corrected.

Using the SW4 and SW5 Buttons When the escalator is in a fault mode the annunciator displays an error code. Error codes are shown in Tables 1 and 2. The errors in Table 1 are all related to the safety circuit. The errors in Table 2 are related to sensors, brakes, machine, contactors, and CPU failures. The error code displayed on the annunciator is the most recent error that the escalator is experienced. Remember there may be more than one error affecting the escalator. 1. To view all the errors press the white button on the annunciator (see Fig. 1). The annunciator can display up to eight errors. Pressing the white button will scroll through the errors. 2. If the error displayed is a manual reset error, you will need to reset that error. To reset, push the SW5 button and hold for 5 seconds (located in the center of the board just above LED 1). If you have a manual reset error this LED will be illuminated. Make sure the annunciator is on the error you intend to reset. LED 1 will extinguish. 3. Press the white annunciator button to scroll to the next manual reset error. 4. The red LED #1 will again illuminate. 5. Press and hold the SW5 button for five seconds, which will again the error and extinguish LED #1. 6. Repeat this process till all the manual rest errors have been reset and LED #1 is extinguished. When all the manual reset faults are reset the annunciator will display 1000. 7. To reset the CPU without resetting the annunciator or the service tool, press and hold the SW4 button. This will help if you are experiencing locked program errors or communication errors that are not manual reset errors.

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TECHNICAL INFORMATION PUBLICATION

Page 7 TIP 67.30.0-2 November 2, 2011

Error Codes Table 1: Safety Circuit Error Code Definitions and Corrective Actions Error Code No.

Description

L1

Lower out of level switch right

Type of Reset

Probable Cause • Broken step roller

Manual

• Track needs adjusting • Broken step

Troubleshooting Check for 24 VAC between 194 & 195

• Check for broken switch Lower skirt switch right

NonManual

L3

Lower comb plate impact switch left

Manual

L4

Lower comb plate impact switch right

Manual

L5

Lower handrail inlet switch right

Manual

L2

• Check for debris stuck between step and skirt panel. • Check for proper spacing between skirt panel and step • Check for debris on step • Check for broken comb plate • Check for debris on step • Check for broken comb plate • Check for broken switch. • Check for debris on handrail • Check for damaged handrail

Check for 24 VAC between 196 & 197

Check for 24 VAC at between 202 & 203 Check for 24 VAC at between 202 & 203 Check for 24 VAC between 192 & 193

• Check for proper alignment of step chain switch L6

Lower broken step chain switch right

Manual

• Check for broken step chain switch

Check for 24 VAC between 200 & 201

• Check for broken, damaged step chain L7

Lower pit stop switch

NonManual

• Check for broken switch • Check for switch in stop position

Check for 24 VAC between 204 & SAF

L8

Lower emergency Stop switch

NonManual

• Broken switch

Check for 24 VAC between150 & 191

L9

Lower access cover

NonManual

• Check if cover is off bottom pit

Check for 24 VAC between 191 & 192

L11

Lower handrail inlet switch right

NonManual

• Check for broken switch • Check for broken switch • Check for debris on handrail • Check for damaged handrail

Check for 24 VAC between 193 & 194

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Page 8 TIP 67.30.0-2 November 2, 2011

Error Code No.

Description

TECHNICAL INFORMATION PUBLICATION

Type of Reset

Probable Cause

Troubleshooting

• Check for broken switch L12

Lower skirt switch left

NonManual

• Check for proper spacing between skirt panel and step • Broken step roller

Lower out of level switch left

Manual

L14

Lower step upthrust right

NonManual

L15

Lower step upthrust right

NonManual

L13

• Check for debris stuck between step and skirt panel

• Check track for proper adjusting • Check for broken step

Check for 24 VAC between 197 & 198

Check for 24 VAC between 195 & 196

• Check for debris on step track • Check for broken track • Check for proper alignment of upthrust track

Check for 24 VAC between 203 & 204

• Check for debris on step track • Check for broken track • Check for proper alignment of upthrust track

Check for 24 VAC between 203 & 204

• Check for broken switch L16

Skirt switch intermediate right

NonManual

• Check for debris stuck between step and skirt panel • Check for proper spacing between skirt panel and step

Check for 24 VAC between 198 & 199

• Check for broken switch L17

L18

Skirt switch intermediate left

NonManual

Lower step out of position

NonManual

•

Check for debris stuck between step and skirt panel

• Check for proper spacing between skirt panel and step • Check track for proper adjustment • Check for broken step

Check for 24 VAC between 199 & 200

Check for 24 VAC at SAF

• Check for broken or missing step L61

Missing step detector

U1

Upper handrail inlet right

Manual

Upper comb plate impact switch left

Manual

U2

Manual

• Check for bad switch or sensor • Check for proper adjustment on sensor • Check for broken switch • Check for debris on handrail • Check for damaged handrail • Check for debris on step • Check for broken comb plate

Check for 24 VAC between A3 & LRS

Check for 24 VAC between 146 & 147 Check for 24 VAC between 145 & 146

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Error Code No. U3

Description Upper comb plate impact switch right

Type of Reset

Probable Cause • Check for debris on step

Manual

• Check for broken comb plate

Page 9 TIP 67.30.0-2 November 2, 2011

Troubleshooting Check for 24 VAC at 146 & 147

• Check for broken switch U4

Upper skirt switch right

NonManual

• Check for debris stuck between step and skirt panel • Check for proper spacing between skirt panel and step

Check for 24 VAC between 142 & 143

• Check brake for excessive heat U5

Brake temperature switch

Manual

U6

Motor area stop switch

NonManual

U7

Upper access cover switch

NonManual

U8

Upper out of level switch right

• Check for faulty switch • Check brake for proper lift and adjustment

Check for 24 VAC between

• Check for broken switch or switch in stop position

Check for 24 VAC between L3A & 141 (optional)

• Check if cover is off bottom pit

Check for 24 VAC between 141 or L3A & 142

• Check for broken switch • Broken step roller

Manual

• Check track for proper adjusting • Check for broken step

Check for 24 VAC between 144 & 144A

• Broken step roller U9

Upper out of level switch left

Manual

• Check track for proper adjusting • Check for broken step

Check for 24 VAC between 144A & 145

• Check for broken switch U10

Upper skirt switch left

NonManual

• Check for debris stuck between step and skirt panel • Check for proper spacing between skirt panel and step

Check for 24 VAC between 143 & 143A

• Check for broken switch U11

U12

Upper handrail inlet switch left

Manual

Upper pit stop switch

NonManual

• Check for debris on handrail • Check for damaged handrail • Check for broken switch or switch in stop position

Check for 24 VAC between 147 & 148 Check for 24 VAC between 149 & 150

• Check for broken or missing step U62

Missing step detector

Manual

• Check for bad switch or sensor • Check for proper adjustment on sensor

Check for 24 VAC between UPC & LRS

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Page 10 TIP 67.30.0-2 November 2, 2011

TECHNICAL INFORMATION PUBLICATION Table 2: Sensor, Brake, Machine, Contactor, and CPU Error Code Definitions and Corrective Actions

Error Code No.

Description

63

Annunciator communication failure lower end

64

Annunciator communication failure upper end

66

Safety string open

Type of Reset

Probable Cause

CPU

Lose of +15 VDC at annunciator board

CPU

Lose of +15 VDC at annunciator board

Manual

Lose of communication from annunciator board to CPU

Troubleshooting • Check heartbeat LED 26 on lower annunciator board • Check +15 VDC supply at CB2 on board • Check heartbeat LED 26 on upper annunciator board • Check +15 VDC supply at CB2 on board • Check LED 2 (STR1) and 3 (STR2) are lit on CPU • Check 24 VDC LED at U37 is on • Check 24 VDC supply at pin 5 of J25 plug • Check 15 VDC test point on CPU

67

Computer safe relay

CPU

K2 relay on CPU not functioning

68

Overload relay contact open

CPU

Overload tripped

• Reset overload contact on overload relay

69

100 VAC supply missing

CPU

Rectifier BR1 open

• Check F2 fuse

70

Shorted construct switch

Manual

Bad K1–K7 relays

• Check CPU board for debris or trace burn near K1–K7 relays

71

Brake capacitor (K9) relay failure

Manual

Welded contacts

• Check K9 relay

72

K1–K7,K15 relay not released

Manual

Welded contacts

• Check K1–K7, K15 relay contacts

74

Keyswitch not centered

CPU

Broken keyswitch

• Check for 24 VAC at pin 2 on the J2 plug on CPU

75

Brake board #1 communication error

76

Brake board #2 communication error

Manual

Manual

Bad brake board

Bad brake board

• Check K2 relay for open coil

• Ensure heartbeat LED on brake board is lit • Ensure BCOP LED on brake board is lit • Ensure heartbeat LED on brake board is lit • Ensure BCOP LED on brake board is lit

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Error Code No.

Description

Type of Reset

Probable Cause

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Troubleshooting • Check fuse 2 in controller

79

No current brake #1

Manual

• Bad brake board • Bad brake

• Check 142 VDC on CPU test point 100 V • Check brake open brake coil • Check fuse 2 in controller

80

No current brake #2

Manual

• Bad brake

83

Brake wear

85

Brake burnish #1 brake failure

Manual

Open brake coil

86

Brake burnish #2 brake failure

Manual

Open brake coil

89

Manual

• Bad brake board

Brake worn down

• Check 142 VDC on CPU test point 100 V • Check brake open brake coil • Check pin 9 on the J2 plug is not grounded • Inspect brake for wear

Brake #1 over current

• Check for brake coil • Check for proper brake current • Check for brake coil

Manual

Improper brake current setting

• Check for proper brake current • Verify brake current is 250 ma for 12 in. brake and 280 ma for 8.5 in. brake • Use TP2 and TP3 on brake board to check for proper current • Use P3 to adjust current

90

Brake #2 over current

Manual

Improper brake current setting

• Verify brake current is 250 ma for 12 in. brake and 280 ma for 8.5 in. brake • Use TP2 and TP3 on brake board to check for proper current • Use P3 to adjust current

93

Faulty P1 contactor

95

Faulty D contactor

CPU

CPU

• Blown fuse • Open coil • Blown fuse • Open coil

• Check fuse 7 and 8 • Check for 120 VAC output from CTX transformer • Check fuse 7 and 8 • Check for 120 VAC output from CTX transformer

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Page 12 TIP 67.30.0-2 November 2, 2011

Error Code No.

Description

TECHNICAL INFORMATION PUBLICATION

Type of Reset

Probable Cause • Blown fuse

96

Faulty U contactor

CPU

97

P1 contactor did not release

Manual

Welded contacts

99

D contactor did not release

Manual

Welded contacts

100

U contactor did not release

Manual

101

Construction mode

102

Inspection mode

• Open coil

Troubleshooting • Check fuse 7 and 8 • Check for 120 VAC output from CTX transformer • Check P1 contactor • Check for no voltage at pin 8 on the J8 plug • Check D contactor • Check for no voltage at pin 6 on the J8 plug • Check P1 contactor

Welded contacts

• Check for no voltage at pin 7 on the J8 plug

No

Construction switch in wrong position

• Ensure construct LED is not lit

No

Inspection switch in wrong position, blown fuse

• Ensure RNMODE- LED is on • Check fuse F1 • Check speed of escalator

103

104

105

Encoder fault

Reverse direction

Step band under speed

Manual

Manual

Manual

• Bad encoder • Escalator stalling • Encoder wired backwards • Motor leads are backwards • Encoder setting parameter wrong • Escalator stalling • Brake not picking

106

Step band over speed

Manual

Encoder setting parameter wrong

• Ensure LED 9 (Enc-A) and 10 (Enc-B) are turning off and on while escalator is running • Ensure LED 4 (amber) is lit when escalator is running up • Go into parameters and check encoder PPR is 95 for 875 RPM motor / 60 for 1750 RPM motor • Go into parameters and check encoder PPR is 95 for 875 RPM motor / 60 for 1750 RPM motor

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Page 13 TIP 67.30.0-2 November 2, 2011

TECHNICAL INFORMATION PUBLICATION

Error Code No.

Description

Type of Reset

Probable Cause

Troubleshooting • Check for proper tension

107

Handrail left not within 15% of rated speed

• Handrail tension not proper Manual

• Bad handrail speed sensor

Manual

108

• Bind in handrail drive

• Handrail tension not proper • Bind in handrail drive

Handrail right not within 15% of rated speed

• Bad handrail speed sensor

• Check LHR to ground should be 22.9 Hz for 90 FPM and 24.5 Hz for 100 FPM escalators • Check encoder frequency parameter is 1705 for 875 RPM motor / 1800 for 1750 RPM motor • Check for proper tension • Check LHR to ground should be 22.9 Hz for 90 FPM / 24.5 Hz for 100 FPM escalators

• Encoder frequency parameter wrong

• Check encoder frequency parameter is 1705 for 875 RPM motor / 1800 for 1750 RPM motor

Bad CPU

• Check whether you can go into parameters and modify but do not modify—just see if tool will communicate

Manual 112

RAM error

113

Power loss

No

Main line pulled

• N/A

114

Brake burnish

No

Recorded event

• N/A

Computer safe relay did not release

Manual

115

Bad K2 relay

• Ensure K2 relay is out when power is disconnected

K11—K12- and or K14 did not release

Manual

117

Bad K11, 12, and/or 14 relay

• Check to see if relays are dropped when power is disconnected

118

Safety reset relay did not make up

119

P1 aux did not release

Manual Bad K10 relay

• Check for 24 VAC at SAF Manual Band P1 aux relay Manual

121

Controller over temperature

122

Power on

• Check to see if relay picks when safety circuit is made

• Heated motor • Heated brake • Excessive heat in upper pit area

N/A

• Check to see if relay is dropped when power is disconnected

N/A

• See wiring diagram

N/A

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TECHNICAL INFORMATION PUBLICATION

Error Code No.

Description

Type of Reset

Probable Cause

Troubleshooting

124

Start up

N/A

N/A

N/A

125

Running mode

N/A

N/A

N/A

Broken keyswitch

• Check LED 3, 4, 5 on CPU for proper function o 3 = Up o 4 = Center o 5 = Down

Malfunction in communication of safety circuit

• LED 2 on CPU should be off when escalator not running and on when escalator begins to run

Bad K9 relay

• Check whether K9 coil is open

Bad K10 relay

• Check whether K10 coil is open

Manual 126

Keyswitch malfunction

Manual 127

Stop signal

130

K9 relay malfunction

Manual

131

K10 relay malfunction

Manual

132

Soft start contact malfunction

Manual

• Improper parameter setting • Bad soft start

• Ensure there is no voltage between J3-30 and J430 on CPU when start is initiated

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Appendix A: Part Numbers The following table lists all part numbers this document mentions. Table 3: Related Part Numbers Description Kone Service Tool

Part Number MTGMP-31552

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