AS-11.65.031 KDL32 Repair

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
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installation and have received proper training on methods and safety as specified by KONE.
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P i l o
1054qqq.wmf
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© 2009 KONE Corporation AS-11.65.031
All rights reserved. 1 (48) (-) 2009-03-04
Disclosure prohibited
KDL32
CONTENTS
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1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.3 Modules in the elevator shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Main components of drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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1.5 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2 ENVIRONMENTAL ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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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 . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Before switching OFF the power from the drive module . . . . . . . . . . . . . . . . . . . . . 13
5.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Replacing KDL32 drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 REPLACEMENT OF POWER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.3 Replacing control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4 Replacing DC-link capacitor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.5 Replacing power module (MCDM board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7 REPLACEMENT OF BRAKE CONTROL-, CONTACTOR MODULES AND DRIVE FAN . 28
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3 Replacing brake control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4 Replacing contactor module components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5 Replacing drive fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8 REPLACEMENT OF DYNAMIC BRAKING CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.3 Replacing dynamic braking contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9 REPLACEMENT OF BRAKING RESISTOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.3 Replacing braking resistor module (machineroomless elevators) . . . . . . . . . . . . . . 41
9.4 Replacing braking resistor module (elevators with machine room) . . . . . . . . . . . . . 43
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10 UPDATE OF DRIVE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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10.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.3 Updating drive software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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11 APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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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
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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:
• AM-01.03.001 Use of fall arrest systems on elevator construction and modernization sites
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• 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
1.2 Abbreviations
The following abbreviations are used in this instruction
Abbreviation
CWT Counterweight
LWD Load Weighing Device
MAP Maintenance Access Panel
ESD Electrostatic Discharge
LCE Lift Controller Electrification
RDF Recall Drive Feature
SEPt Shaft Electrification Panel top
PCB Printed Circuit Board
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1.3 Modules in the elevator shaft
Modules in the elevator shaft in the KONE

MonoSpace® elevators
1. Drive module (385)

2. LCE and optional boards
t i ng Shaft electrification panel in the KONE

MonoSpace® Special and TranSys™
elevators
1. Drive module (385)
2. Main switch module
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3. Main switch (220:1)
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4. LCE and optional boards
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1.4 Main components of drive module
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Table 1: KDL32 drive module
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Pos Name Illustration
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1 Dynamic braking contactor
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2 LOP-ADA module
3 Main circuit and driver board (MCDM-C)
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4 Control module
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5 DC-link capacitor module
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6 Backup power module
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7 Contactor module
8 Network filter module
9 Brake control module
10 Fan
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Table 2: Braking resistor modules

Pos Name Illustration
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1, 2 Braking resistor
1 2
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module
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(not included in
the drive
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assembly)
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1.5 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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3 SAFETY
3.1 General safety precautions
Safety precautions
t i ng Note
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Follow your national lift codes and other safety In case of conflict between the Code and the
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related regulations. present instructions, rely on your national code.
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Follow your local hot work procedures.
The local safety codes and rules must be Refer to your local procedures for the type of
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obeyed at all times. entrance protection required.
Follow the safe working methods. Use barriers and warning signs to inform
and protect the building users.
Follow this instruction. Do not skip any step, Warning signs highlight possible hazards.
otherwise there may be a potentially dangerous
situation which you have not considered.
ENSURE THAT ELECTRICAL EQUIPMENT Do not connect or disconnect any connectors

AND CONDUCTORS ARE SAFELY DE- when the power is ON.
ENERGISED 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 Refer to the list of Personal safety items on the
and used as required. next chapter.
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 For using fall prevention systems refer to AM-
the elevator. 01.03.001.
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 In particular keep access ways and fire exits
to others. clear.
Keep the entrance and emergency exits clear. Refer to AS-01.01.004 Take Care End user
Prevent unintentional access to working area safety in elevator maintenance.
with additional fences.
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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 AM-
01.03.001.
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Dust mask, suitable for working with mineral
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wool insulation in landing doors
First aid kit
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Safety goggles
Safety gloves
Rubber gloves for cleaning rails
Hearing protection
Hard hats
Work clothes / overalls
Safety shoes with ankle protection P15000060.wmf
3.3 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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WARNING
Inverter drives usually remain energized for about 5 minutes after the power
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has been disconnected.
DO NOT work on the drive, hoisting motor or braking resistors until you have
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verified that this energy has been discharged.
Test equipment must be set to the 1000 VDC range. The test equipment must
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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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4 TOOLS
Part number
Test weights
Multimeter
Tool
Normal hand tool set
t i ng Illustration/Note
For LWD setup, according to rated load

Fluke 179 (or equivalent) with insulated test
probes (min. L = 100 mm) specified to 1000
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VDC voltage
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Work stool Height approximately 700 mm
1007089.wmf
Chain hoist Capacity 100 kg
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Safety barriers
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Part number Tool Illustration/Note

ESD protection kit
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Torque wrench
o Torque range 2 - 20 Nm
1030228.wmf
Cleaner Alcohol based, locally supported

For cleaning heatsink surface
KM969444 Heat conducting paste Austerlitz WPS II
KM994397R01 Paste stencils
Metal trowel
KM953527R01 Programming kit DCBM Includes a PCB and wires (2 pcs.)
KM959231H01 KDL32 software package Includes design document 959231D01 with
instructions.
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5 REPLACEMENT OF COMPLETE KDL32 DRIVE MODULE
5.1 Before switching OFF the power from the drive module
t i ng
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:
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• Elevators with machine room AM-11.65.029(-USK)
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• Machineroomless elevators AM-11.65.030(-USK)
5.2
5.3
Tools
•
•
•
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Following tools are recommended to be used when replacing the drive module:
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 Action Illustration/Note

1 Ensure that the car is empty. Take the elevator out of use.
2 Open the control panel.
Switch OFF the main switch (220:2) and
main switch light (262).
Lock and tag them.
Close the control panel.
3 Disconnect and prevent reconnection of the
possible emergency power supplies.
4 Wait for 5 minutes.
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5 Test by using the multimeter that AC voltage The exact location of the cable ends
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is not supplied to the drive. depends on the electrification.
Check the operation of the multimeter
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NOTE! Check the AC voltage (400 VAC) at
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the end of the power supply cables
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which inside the drive cabinet are
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connected to the RFI filter (389).
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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.
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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

1 Ensure the car and car roof are empty. Take the elevator out of use.
2 Open the MAP. Move the car using RDF to a If the elevator does not move using RDF,
suitable working level with access to continue by switching OFF power (Step 3)
topmost landing and car roof. and then move the car by opening the brake
or lifting the counterweight (Step 4).
3 Switch OFF the main switch (220:2) and When the MAP is located at the second
main switch light (262). topmost floor, the SEP and drive module can
Lock and tag them. be disconnected from the power supplies
Close the MAP. using switches (220:1) and (290:1), located
in the shaft near the SEP.
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4 If the elevator could not be moved to a The power must be switched OFF (Step 3)
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suitable working level using RDF (in Step 2), before moving the car!
do one of the following:
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• Empty car upwards:
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Open the machine brake. Move the
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car upwards in small steps.
• Empty car downwards:
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Use CWT lifting device, refer to
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operation instruction AS-01.05.001.
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8 Remove the covers of the drive module. Loosen the fixing screws.
9 Test by using the multimeter that there is no
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5.5 Replacing KDL32 drive module
Step
1
2
Action
Install the chain hoist above the drive
module.
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Disconnect the motor cable, the power
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supply cable, the braking resistor cable and
Illustration/Note
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the control cables from the drive module.
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NOTE! Mark the wires!
3 Attach the chain hoist above the drive
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module.
NOTE! Attach the cover plates of the drive
module before lifting out.
4 Loosen the nuts of the fixing bolts.
NOTE! The drive module weighs
approximately 30 kg.
5 Lower the drive module to the car roof or
machine room floor.
6 Attach the chain hoist to the new drive
module.
7 Lift the drive module up and lower it to the
wall fixing bolts.
8 Tighten all nuts of the fixing bolts.
9 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 supply-
and the motor side.
10 Close the covers of the drive module.
11 Set the recorded drive parameters by the
user interface.
12 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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6 REPLACEMENT OF POWER COMPONENTS
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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
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exceptional cases where a single part can be replaced with a spare part.
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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 Tools
•
•
•
•
•
• P i l
ESD protection kit
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Following tools are recommended to be used with the replacement work:
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)
6.2 Safety measures

Lock and tag them.
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6
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1062680.wmf

6.2.2 Safety measures for machineroomless elevators

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6.3 Replacing control module
Step
1
2
Action
Mark and disconnect the wiring of the
control module.
Loosen the fixing screws (4 pcs.).
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NOTE! Be carefully to not drop the fixing
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screws.
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3 Lift the old module out of the drive module.
4 Install new module into the drive module.
5 Reconnect the wiring.
6 Install the covers of the drive module.
7 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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6.4 Replacing DC-link capacitor module
Step
1
Action
Mark and disconnect the wiring of the
control module.
Note the cable routing in order to
reassemble the components correctly.
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Remove the cable clamp plate.
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Loosen the fixing screws (5 pcs.) of the
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protection plate.
Remove the control module together with
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protection plate.
2 Loosen the Allen screws (2 pcs.).

NOTE! Be careful not to drop the screws.
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3 Remove the M3 fixing screws (6 pcs.).
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NOTE! Be careful not to drop the screws.
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Lift the old DC-link capacitor module out of
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the drive module.
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4 Install new DC-link capacitor module into
the drive module.
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NOTE! Do not damage MCDM board when
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installing the DC-link capacitor
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module.
5 Attach the M3 fixing screws (6 pcs.).
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Tighten the Allen screws (2 pcs.) to 1.8 Nm
tightness, use torque wrench.
6 Install the control module and protection

plate.
Tighten the fixing screws (5 pcs.)
7 Reconnect the wiring to the control module Ground the resolver and encoder cables to
using cable ties. the protection plate.
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6.5 Replacing power module (MCDM board)
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6.5.1 Removing power module
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The power module assembly includes MCDM board and copper bus bars (2 pcs.).
Step
1
2
Action
Remove DC-link capacitor module
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according to section 6.4.
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Mark and disconnect the wiring of the power
module.
Illustration/Note
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3 Remove Allen screws (6 pcs.) of the
semiconductors.
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4 Remove the six M3 fixing screws (A) and six
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spacers (B).
A
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NOTE! Keep the screws and spacers in
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safe.
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B
B
1055063.wmf 1062703.wmf
A B B
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.
NOTE! Be careful not to drop parts to the
shaft.
7 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.
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6.5.2 Applying heat conducting paste to IGBT modules
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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
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work. Paste must be applied and IGBT module fixed to the heat sink within 10 minutes from taking the
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paste out of the tube. Hardened or dry paste must not be used. Once the new paste tube is opened, it
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must be used within the next 5 days.
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1 Clean the surface of the heatsink and IGBT Surfaces should be free of heat conducting
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modules with alcohol based cleaner. paste, grease and impurities.
2 Clean the stencil from both sides using Do not use dirty stencils.
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cleaning agent which does not leave any The stencil must fit well on top of the IGBT
residue on the stencil. module.
Check that the stencil is not scratched or
mechanically damaged.
3 Place the cleaned paste stencil on the IGBT
module.
4 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).
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.
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.
FOR PILOTING
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6.5.3 Reinstalling power module
g
n
1 Install the power module into the drive
i
module and fix the Allen screws (6 pcs.) to
t
the semiconductors. Tighten the screws to
hand-tightness.
2 P i l o
Install the six M3 fixing screws (A) and six
spacers (B). Tighten the screws to hand-
tightness.
A
A
B
B
1055063.wmf
1062703.wmf
A B B
FOR PILOTING
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3 Tighten the six Allen screws, M3 fixing
g
screws and spacers fully. 4 1
n
NOTE! Tighten the Allen screws of the little
i
by little to the final torque:
t
• First torque: 1 Nm.
• Second torque: 2-3 Nm.
o
• Final torque: 4 Nm.
i l
Tighten to each torque in the order
displayed in the illustration!
P 2 3
5 6
1062064.wmf

5 Install the DC-link capacitor module and
control module according to section 6.4.
FOR PILOTING
KDL32
7 REPLACEMENT OF BRAKE CONTROL-, CONTACTOR MODULES AND DRIVE

FAN
7.1
are followed.
Tools
t i ng
Replacement tasks of these modules are technically easy but they require that strict safety procedures
7.2
•
•
Safety measures
P i l
ESD protection kit
o

Lock and tag them.
FOR PILOTING
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7.3 Replacing brake control module
Step
1
2
Action
Disconnect the wiring of brake control
module.
Open the fixing screws.
o
NOTE! Be careful not to drop the fixing
l
screws.
i
3 Lift the old brake control module out of the
drive module.
P
4 Install new brake control module to its place
and tighten the fixing screws.
5 Reconnect wiring to the brake control
module.
6 Install the upper and lower cover plates.
7.4 Replacing contactor module components

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

damaged part.
FOR PILOTING
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4 Replace damaged part(s) of the contactor
g
module.
n
Spare parts for the contactor module:
i
1 Main contactor
t
2 Control voltage transformer
3 Circuit breaker
o
4 Relay
l
5 Main contactor control board
P i
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:
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.
5 Install the contactor module. Only when replacing control voltage
transformer!
7 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.
FOR PILOTING
KDL32
7.5 Replacing drive fan
Step
1
Action
Open the cover of the drive fan.
t i ng Note / Illustration
Disconnect cable of the backup power
module, if applicable. The back up module is
fixed to the cover of the drive fan.
P i l o
2 Remove locking plate of the fan.
3 Replace the old fan with a new one.
NOTE! Check that blowing direction is

upwards and outwards from inside
the drive cabinet.
4 Install locking plate of the fan. Do not damage the fan cable.
5 Attach cover of the fan. Reconnect cable of the backup power
module, if applicable.
6 Attach covers of the drive module.
7 Switch ON the main power. The drive fan blows in full power for 10
seconds after switching ON the power.
FOR PILOTING
KDL32
8 REPLACEMENT OF DYNAMIC BRAKING CONTACTOR
8.1 Tools
t i ng
o
• ESD protection kit
8.2 Safety measures
P i l

Lock and tag them.
FOR PILOTING
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8.3 Replacing dynamic braking contactor
Step
1
Action
Remove the fixing screw and fixing
screw for earthing cable of top noise
reduction module.
t
Remove the top noise reduction module
i ng Illustration/Note
o
from dynamic braking contactor.
P i l
2 Disconnect the wires from the dynamic
braking contactor (A).
3 Replace the old contactor with new one.
Move the auxiliary contact block to new
contactor.
5 Install the top noise reduction module,

Tighten the fixing screw and fixing screw for
earthing cable.
FOR PILOTING
KDL32
9 REPLACEMENT OF BRAKING RESISTOR MODULE
9.1 Tools
t i ng
o
9.2 Safety measures
P i l

Lock and tag them.
FOR PILOTING
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9.3 Replacing braking resistor module (machineroomless elevators)
g
9.3.1 Connecting new braking resistor module
i n
In order to replace the braking resistor module in the shaft, the new braking resistor module must be
t
connected to the drive before moving the elevator.
o
l
1 Lift the new braking resistor module on to
i
the car roof.
P
2 Disconnect and remove the cable of the old
braking resistor module from the terminals
on the top of the drive module.
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).
FOR PILOTING
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4 Connect the cable to the terminals. Shielding of the resistor cable is terminated
g
5 Tighten the cable clamp. and earthed to the cable clamp. The full
width of the shielding should made contact to
n
the earthed cable clamp.
i
9.3.2 Replacing braking resistor module
Step
i l Action
ot Illustration/Note
P
1 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).
2 Drive the car on inspection drive to a level
where the braking resistor module can be
replaced from the car roof.
NOTE! Keep the cables clear when moving
the car.
3 Push down the stop button on the car roof.
3 Remove the upper fixing screws of the old
braking resistor module.
Loosen the lower fixing screws.
4 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 Fix the new cable properly.
shaft wall. Be careful when guiding the box from the
side of the ropes.
FOR PILOTING
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9.4 Replacing braking resistor module (elevators with machine room)
Step
1
Action
ng
Disconnect and remove the cable of the old
on the top of the drive module.

WARNING!Before disconnecting the
t i
braking resistor module from the terminals
Illustration/Note
l o
cable ensure that terminals are
i
safely de-energized.
3
P
Loosen the fixing screws of the old braking
resistor module.
Lower the old braking resistor module and
cable to the machine room floor.
4 Install new braking resistor module to its Fix the new cable properly.
place.
5 Connect the cable to the terminals on the Shielding of the resistor cable is terminated
drive module. and earthed to the cable clamp. The full
6 Tighten the cable clamp. width of the shielding should made contact to
the earthed cable clamp.
FOR PILOTING
KDL32
10 UPDATE OF DRIVE SOFTWARE
10.1 Tools
t i ng
o
l
• Programming kit, DCBM, KM953527R01
i
• KDL32 software package, KM959231H01
10.2
10.2.1
Safety measures
P
Safety measures for elevators with machine room

Lock and tag them.
FOR PILOTING
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10.3 Updating drive software
Step
1
Action
ng
Connect the software updating tool to the
connectors XPR5 (DCBM MCB) and XPR2
(DCBM CPU).
t i
Illustration/Note
P i l o
1064345.wmf
2 Switch ON the main switch. Go back to the landing, if machineroomless

elevator.
3 Update the drive software. Refer to 959231D01 for exact procedures.
4 Switch OFF the main swtich. Ensure the power is OFF. Refer to section
10.2.
5 Remove the software updating tool.
6 Install covers of the drive module.
7 Switch ON the main switch. Go back to the landing, if machineroomless
elevator.
8 Return the elevator to service. Refer to 959231D01 for exact procedures.
FOR PILOTING
KDL32
11 APPROVALS AND VERSION HISTORY
g
Compiled by: Information Product Author Janne Kaskimies
n
Checked by: SEB Maintenance Specialist Jukka Lindberg
i
Product Change Manager Pasi Raassina
t
Approved by: SEB Maintenance Development Manager Seppo Valliovuo
Translation approved by:
Issue
-
Date
i
2009-03-04
P l First issue
o
Description of Change Ref CR Approved by
Seppo Valliovuo
FOR PILOTING

AS-11.65.031 KDL32 Repair

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KDL32

REPAIR INSTRUCTION FOR KDL32 DRIVE MODULE

10 UPDATE OF DRIVE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.1 Related documents

The following abbreviations are used in this instruction

1.3 Modules in the elevator shaft

Modules in the elevator shaft in the KONE

1. Drive module (385)

t i ng Shaft electrification panel in the KONE

1.4 Main components of drive module

Table 2: Braking resistor modules

Fixing screws in mechanical assembly

3.1 General safety precautions

ENSURE THAT ELECTRICAL EQUIPMENT Do not connect or disconnect any connectors

3.2 Personal safety

3.3 Maintenance method safety

1 Disconnect all power supplies.

For LWD setup, according to rated load

Chain hoist Capacity 100 kg

Part number Tool Illustration/Note

Cleaner Alcohol based, locally supported

5 REPLACEMENT OF COMPLETE KDL32 DRIVE MODULE

5.3.1 Safety measures for elevators with machine room

Step Action Illustration/Note

Step Action Illustration/Note

Loosen the fixing screws.

Check the operation of the multimeter

5.4 Safety measures for machineroomless elevators

Step Action Illustration/Note

Step Action Illustration/Note

5.5 Replacing KDL32 drive module

6 REPLACEMENT OF POWER COMPONENTS

Torque wrench (for DC-link capacitor and power module replacements)

6.2 Safety measures

6.2.1 Safety measures for elevators with machine room

Step Action Illustration/Note

Step Action Illustration/Note

Loosen the fixing screws.

Check the operation of the multimeter

6.2.2 Safety measures for machineroomless elevators

Step Action Illustration/Note

Step Action Illustration/Note

6.3 Replacing control module

6.4 Replacing DC-link capacitor module

2 Loosen the Allen screws (2 pcs.).

Step Action Illustration/Note

6 Install the control module and protection

6.5 Replacing power module (MCDM board)

Step Action Illustration/Note

6 Remove copper bus bars (2 pcs.) opening

6.5.2 Applying heat conducting paste to IGBT modules

5 Spread the paste with metal trowel over the

6 Remove the stencil.

6.5.3 Reinstalling power module

Step Action Illustration/Note

4 Reconnect the wiring.

7 REPLACEMENT OF BRAKE CONTROL-, CONTACTOR MODULES AND DRIVE

7.2.1 Safety measures for elevators with machine room

Step Action Illustration/Note