E-Series HR Escalator With S-Controller Service Guide

E-SERIES HR Escalator with S-controller
TM
Service Support Guide

1
Electrical System:
H1 - Electrical system
E-SERIES HRTM escalator
2
with S-controller
7
Montgomery KONE
TM
PSM5-706 (10/98)
63113-364 (R1)
Montgomery KONE
TM
1
Electrical System
Purpose
1 This service support guide provides a brief description of the features and
components of the Electrical System of an E-SERIES HRTM escalator with
a S-controller. This service support guide also provides Field Personnel
2 with information on safety testing procedures, adjusting procedures, and
removing and replacing procedures.
7
©1998, 1997 MONTGOMERY KONE INC.
Unpublished work. All rights reserved. No portion of this volume may be reproduced or used in any manner without
written permission from Montgomery KONE Inc. -- One Montgomery Court; Moline, IL 61265
2 PSM5-706 (10/98)
TM
Electrical System:
E-SERIES HR™ escalator with S-controller
1
1. Safety concerns & equipment operation 5
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1
Controller annunciator display . . . . . . . . . . . . . . . . . . . . . . . . . 9
Junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Annunciator boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step demarcation lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Handrail speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Comb lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2. Safety testing procedures 25

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Emergency stop switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2
Key start switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Skirt switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3
Step demarcation lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3. Adjusting procedures 28
Brake controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Step out-of-position switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3
Combplate impact device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Skirt switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Access cover switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Out-of-level step detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4
Broken step-chain switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Missing step detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Step upthrust safety switches . . . . . . . . . . . . . . . . . . . . . . . . . 39
Controller - initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inspect mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Soft start motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4. Removing & replacing procedures 54

Microswitch wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5
Access cover switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 4
Out-of-level step detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Skirt switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Alarm switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Key start switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Handrail inlet switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Broken step-chain switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Combplate impact device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Step demarcation lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6
Step out-of-position switches . . . . . . . . . . . . . . . . . . . . . . . . . 65
Step upthrust safety switches . . . . . . . . . . . . . . . . . . . . . . . . . 66
5. Alphabetical index 68
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Service guide 70
Montgomery KONE
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Electrical System
BLOCK DIAGRAM OF S-CONTROLLER ELECTRICAL SYSTEM. Diagram does not include safety switches.
6 For information on these components, refer to sections on SAFETY SWITCHES.
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4 PSM5-706 (8/97)
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Safety concerns & equipment operation

Before servicing Electrical systems, the Service
Technician must understand the operation of the
equipment and the safety measures required to
safely service this equipment.
1
➠ Make sure mainline disconnect is OFF, ➠ Before starting an escalator, make sure no
locked out, and tagged anytime you are in bystanders have entered around safety
the step band (you break the plane of the barricades at either end of the escalator.
steps). ➠ Use a circuit tester to be certain the circuit is not
active before working on or around it.
Safety lock and tag out procedures
are always required before The following describes the equipment operation for:
performing any kind of service, 2
repair, adjustment, lubrication, or ■ Controller
inspection of power-driven ■ Brake controller board
equipment. These procedures help to
■ Controller annunciator display
prevent injury or death caused by
power-driven equipment. ■ Junction boxes
➠ Always place barricades in front of both ■ Annunciator boards
the upper and lower ends of the escalator ■ Safety switches
whenever service is being performed. Do 3
■ Step demarcation lights
not open or remove access covers from
either end without having barricades in ■ Encoder
place. ■ Handrail speed sensor
➠ Safety circuits must be kept in operation. ■ Comb lights
➠ Make sure escalator cannot start when S704-001 (5/97)
access covers are removed unless

switches are depressed. Access cover 4
switches must be operational.
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Montgomery KONE
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Electrical System
CONTROLLER
The controller uses a micro-processor to supervise The controller contains the following components.
escalator operation and main drive motor. ● Main CPU board (1)
● Brake control board (2)
The controller also contains a pair of safety relays.
Each safety switch is hard-wired in series to these ● Annunciator display (3)
1 safety relays in the controller. If a safety switch is ● Starter panel (4)
actuated, the safety relay actuates and shuts down
● Wiring diagram (5)
the escalator independently of the micro-processor.
● Motor overload settings label (6)
The micro-processor’s main function is to monitor ● Controller temperature switch (7)
all safety devices and to data log faults and events ● Current sensor (8)
and to communicate with a service tool, annunciator
display, or RS-232 port. ● CT1 control transformer (9)
2 ● CT2 24V Class 2 transformer (10)
The micro-processor performs all supervisory ● Power supply board (11)
functions for the escalator and provides the
● 24V isolation transformer (12)
following functions:
The main micro-processor also displays the last fault on
➤ Stores and controls setup information
the annunciator display.
➤ Records fault codes with time stamp
➤ Controls start-up sequence main drive For more information on the annunciator
3 motor display, refer to section titled: Controller
annunciator display.
➤ Data logs current draw during S704-002 (5/97)
operation
➤ Polls external electrical devices during
operation to ensure continual proper
operation of these devices
➤ Monitors speed of handrails and step
4 band
➤ Communicates with a service tool,
annunciator display, and RS-232 port
(for down loading logged data)
The micro-processor stores all data in a battery

backed RAM.
5
To provide direction and speed feedback a two-
channel sensor mounted on the drive motor
provides a four-channel output to the micro-
processor as well as the brake board(s).
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6 PSM5-706 (8/97)
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Electrical System
BRAKE CONTROLLER BOARD

The escalator uses permanent magnet type brakes.
Each brake is controlled by a brake board. The
brake board plugs into the main CPU board, and the
CPU board can accommodate up to four brake
1 control boards.
The brake board provides the following features.
➤ Uses a micro-processor. ➤ The main CPU board will initiate a burnish

➤ Provides a consistent deceleration cycle upon start if the number of Burnish
rate from no load to full rated load on Cycles parameter is set to a value greater
the escalator. than zero. The Burnish Cycles parameter
2 can be viewed and modified by the service
➤ The main CPU board monitors the
tool’s Option Adjust-Modify Parameters
speed of the escalator and if during a
function.
stop the escalator over speeds by
15% the main CPU board will cause ➤ Provides constant current to the brake coil
the brake to apply maximum brake while the escalator is running—eliminating
torque. the need for adjustments because of
fluctuations in brake coil temperatures.
➤ Provides a brake burnish function,
3 either manually or automatically upon For more information on adjusting the brake
escalator start-up. controller board, refer to section titled:
Adjusting procedures/Brake controller board.
73-H67 (8/97)
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8 PSM5-706 (8/97)
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CONTROLLER ANNUNCIATOR
DISPLAY
The main micro-processor displays the last fault on
the annunciator display. Pushing a button on the
annunciator display board scrolls the display
through the last eight faults. A Service Tool is
1
required to view all stored faults with time stamp in
memory. If a manual reset type fault has occurred,
that fault is displayed on the screen and the red
LED1 next to the manual reset push button is
illuminated.
After servicing the cause of the manual reset fault, 2

the manual reset fault flag needs to be cleared in
the main CPU’s memory. To reset the manual reset
fault flag in the main CPU’s memory, press the
reset push-button (SW5) on the main escalator CPU
board and then press the button on the annunciator
display. If the annunciator display is blanked, the
annunciator display push-button will have to be
pressed twice after pressing SW5. Only the fault 3
displayed on the annunciator display will be reset.
After the fault is reset, the annunciator will still
display the fault code but the red LED1 will have
gone out. The manual reset type fault can also be
reset via the SERVICE MODE service tool menu.
If the annunciator display’s button is

not pressed for 20 seconds, the 4
annunciator display will go blank. If
the display is blank and the button is
pressed, all four digits of the display
should illuminate with the number 8
for one second. It then displays the
fault that was last displayed before the
display went blank.
73-H21 (4/97) 5
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Electrical System
JUNCTION BOXES
There are three junction boxes serving the S-
controller electrical system. They are the high
voltage junction box, upper junction box, and
lower junction box.
1 High voltage junction box

The high voltage junction box provides terminations
for the following.
❍ main drive motors

❍ brake power
2 ❍ optional automatic oiler

❍ upper demarcation light
❍ output power to upper junction box for
lower demarcation light
In addition to these terminations, the high voltage

junction box contains the following components
3 ● terminal strip (1)

● step down transformer(s) (2)
● fuses (3)
Upper junction box

The upper junction box provides terminations for the
4 following.
❍ left and right handrail speed sensors

❍ motor encoder
❍ controller control cable
❍ lower junction box control cable
❍ upper end safety switches
5 ❍ upper missing step detector sensor
❍ upper alarm and alarm switch
❍ upper key start switch
❍ upper inspect switch
❍ upper pit switch
In addition to these terminations, the upper junction

6 box contains the following components.
● terminal strip (1)

● annunciator board (2)
● upper inspect switch (3)
● upper pit switch
7
10 PSM5-706 (8/97)
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Lower junction box

The lower junction box provides terminations for the
following.
❍ lower junction box control cable

❍ lower end safety switches 1
❍ lower missing step detector sensor
❍ lower alarm and alarm switch
❍ lower key start switch
❍ lower inspect switch
❍ lower pit switch
❍ lower demarcation light 2
In addition to these terminations, the lower junction
box contains the following components.
● terminal strip (1)

● annunciator board (2)
● lower inspect switch (3)
3
● lower pit switch (4)
S704-003 (8/97)
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Electrical System
ANNUNCIATOR BOARDS
The following describes how annunciator boards and
safety switches function together. The following
also describes safety switch connections and LED
indications on annunciator boards.
❏ Annunciator boards & safety switches

1 ❏ Annunciator board connections
❏ LED indications
Annunciator boards Annunciator board connections

& safety switches Each annunciator board has inputs for 22 safety switches
and one missing step detector sensor. Safety switches
2 The controller is tied into two safety strings through plug into connectors 1 through 22. The missing step
the upper and lower junction boxes. Each of the detector wires into connector J26, and the main controller
upper and lower junction boxes contain an plugs into connector J25. The flying jumper plugs into the
annunciator board. The safety strings are made up lowest unused safety switch connector on the board. (The
of safety switches which are mounted in various flying jumper is used so unused connectors do not reflect
locations on the escalator. an open in the circuit. If all connectors, 1 through 22, are
used, the flying jumper is not used.)
For more information on safety switches,
refer to Equipment operation/Safety
3 switches in this chapter.
LED indications
Each lower end safety device is sequentially The following conditions are present when the following
plugged into the lower annunciator board, and each LEDs are ON.
upper end safety device is sequentially plugged into
the upper annunciator board. Each annunciator ➤ LEDs 1 through 22: indicates the
board monitors the state of each switch and reports associated safety switch is open.
that information to the main controller whenever the ➤ LED 23: indicates 24 VAC is applied to
4 controller polls the annunciator board. connector J27
➤ LED 24 (when flashing): indicates that the
A safety string of switches, wired in series, is annunciator board is communicating with
formed when all safety devices are in their closed the main controller.
state and are plugged into the annunciator board(s).
If a safety switch is actuated, the safety relays in ➤ LED 25: Indicates the step bolt is in front of
the controller will open and remove power to the missing step detector proximity sensor.
motor and brake board(s). (During normal running operation, LED 25
5 will illuminate every time a step bolt passes
in front of the proximity sensor.)
➤ LEDs 26 and 27: indicates 15 VDC and 24
VAC is being received from the controller,
and circuit breakers CB1 and CB2 are not
actuated.
➤ LED 28: indicates the missing step detector
6 is actuated.
S704-004 (5/97)
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12 PSM5-706 (8/97)
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Annunciator board (located in upper and lower junction boxes)
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Montgomery KONE
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Electrical System
SAFETY SWITCHES
Safety switches are connected to annunciator
boards located in the upper and lower junction
boxes. The safety switches tied to the lower
junction box comprise safety circuit string #1, and
the safety switches tied to the upper junction box
comprise safety circuit string #2.
1
The following describes the operation of safety switches.
❏ Missing step detector (1) ❏ Out-of-level step detector (9)

❏ Handrail inlet switch (2) ❏ Emergency stop switch (10)
❏ Combplate impact device (3) ❏ Alarm switch (11)
2 ❏ Step upthrust safety switch (4) ❏ Broken step-chain switch (12)
❏ Skirt switch (5) ❏ Key start switch (13)
❏ Pit stop switch (6) ❏ Brake temperature switch (14)
❏ Motor pit stop switch (7) ❏ Step out-of-position switch (15)
❏ Access cover switch (8) ❏ Inspection switch (16)
S76-H07 (8/97)
5
The above indicates approximate location of various safety switches.
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14 PSM5-706 (8/97)
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Missing step detector

The missing step detector opens the safety circuit
and shuts down the escalator if a step is missing.
It is composed of two 30 MM proximity sensors.
The 30 MM proximity sensors are mounted on the
first half track brackets on the right hand lower 1
return, and on the left hand upper return. The
missing step detector is a manual reset device.
73-H49 (4/95)
Handrail inlet switches

The function of the handrail inlet switch (1) is to 3
open the safety circuit if any object follows the
handrail path in towards the interior of the
escalator. These switches are plunger type and are
located behind a split door (2) arrangement where
the handrail enters and exits from the frontplate (3).
The handrail inlet switch is a manual reset device.
700-L11 (4/97)
4
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Electrical System
Combplate impact device

Combplate impact devices are located behind the
end skirts on both sides of the combplate at both
the upper and lower end. The combplate impact
device switches actuate and open the safety circuit
when any of the following conditions occur. The
combplate impact device is a manual reset device.
1
➤ A predetermined upward vertical force
is applied along the front of the
combplate.
➤ A predetermined horizontal force is
applied to the front edge of the
combplate.
2 Applied forces are based on
applicable code requirements. Check
your local governing authority for
applied forces required in your area.
700-L37 (4/97)
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16 PSM5-706 (8/97)
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Step upthrust safety switches

The step upthrust switches (1) are plunger type,
and are mounted directly to brackets (2) on the
bottom of the upper lip track (3) of the lower
curves. The switch actuator for each switch is
aligned with a keystock (4) piece, and is designed
to stop the escalator in the event a step becomes
vertically displaced at the lower curve area.
1
700-L12 (2/95)
Skirt switches
Skirt switches (1) are plunger-type microswitches
designed to open the safety circuit when something
is wedged between the step (2) and skirt (3). Skirt
switches are also designed to actuate if sufficient 3
pressure is applied to the skirt board itself causing
the skirt board to deflect over a given amount.
Two of the six skirt switch actuators (4) are

installed directly behind the skirt boards at the
lower curve, and function only when the skirt board
itself deflects. The remaining four skirt switches
Lower end skirt switch
are located in the upper and lower end, and are set 4
against separate switch actuators (5). The actuator
has a pin that projects through a clearance hole in
the skirt board with the plunger set just below top of
step tread. Depression of either the tip of the pin or
deflection of the skirt actuates the switch.
700-L08 (2/95)
Upper end skirt switch
7
Lower curve skirt switch
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Electrical System
Pit & motor stop switches

The lower pit stop switch (1) is a push/pull (ON/
OFF) switch that opens the safety circuit at the
lower end of the escalator and prevents the
escalator from being turned on.
1 When required, the drive motor area of the escalator

also contains a push/pull (ON/OFF) stop switch (2)
which will open the safety circuit and prevent the
escalator from being turned on.
703-E08 (4/95)
2 Access cover switches

The access cover switch is designed to open the
safety circuit which will cause the escalator to stop
when the access cover is opened. Access cover
switches are located under each access cover.
700-L10 (11/95)
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18 PSM5-706 (8/97)
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Out-of-level step detectors

Out-of-level step detectors (1) are wand-actuated
(2) microswitches located at both upper and lower
ends. The switch is designed to open the safety
circuit to stop the escalator when a step (3) is
vertically displaced 1/8 inch [3.2 mm]. After
actuation, these switches must be reset in the
controller.
1
Out-of-level step detector is a manual

reset device.
73-H68 (6/95)
3
Cast step
Fabricated step
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Electrical System
Emergency stop switches

Emergency stop switches are manually operated
push buttons designed to open the safety circuit
which will cause the escalator to stop for either
routine or emergency use. Stop buttons are located
at both ends of the escalator. The clear plastic
hinged cover, over the stop button, is to discourage
1 nuisance stops.
700-L13 (8/96)
Alarm switches
The alarm switch is designed to sound an alarm
horn any time the hinged plastic cover over the
2 emergency stop button is lifted. An alarm is
mounted at both ends of the escalator. The alarm
sounds to discourage nuisance stops.
700-L14 (8/96)
Broken step-chain switches

The broken step-chain switch (1) is a plunger-type
microswitch, designed to be manually reset to
comply with ANSI Safety Code. There is one
4 located on each side of the lower end, and are
activated by actuators (2) located on threaded bolts
(3) connected to the lower reversing station (4).
They are designed to open the safety circuit if the
lower reversing station moves more than the normal
amount in either a forward or backward direction.
700-L09 (9/95)
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20 PSM5-706 (8/97)
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Key start switches

The key start switch is a spring-loaded momentary
contact switch, and is designed to start the
escalator and determine the direction of travel.
These switches are located at both the upper and
lower ends of the escalator.
700-L16 (11/95) 1
Brake temperature switch 3

The brake temperature switch is imbedded in brake
housing. If the brake(s) become overheated, the
brake temperature switch actuates, opens the
safety circuit, and stops the escalator.
73-H14 (4/95)
4
Step out-of-position switches
The step out-of-position switch opens the safety
circuit to stop the escalator if a step is out of
position at either the upper or lower end pits. There
is a wand microswitch located at both the upper and
lower ends where the steps turn around. The step
out-of-position switches are manual reset switches.
5
73-H12 (8/96)
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Electrical System
STEP DEMARCATION LIGHTS

Step demarcation lights are green lights required by
ANSI code at both landings of the escalator under
the comb segments. One purpose for these lights
is to break the hypnotizing effect caused by the
step’s continuous movement. The step
demarcation light operates on 24 VAC which is
1 supplied by a Class 2 transformer in the upper
junction box.
The lamps should be replaced on an annual basis,

before lamps burn out, in order to help ensure long
ballast life.
73-H63 (4/95)
2
ENCODER
The encoder provides a quadrature output which
3 provides the main CPU board with the direction and
speed of the step band. The brake controller also
uses the output of the encoder to determine the rate
at which the escalator is decelerating during the
stop sequence.
The encoder is wired into the upper junction box,

and is mounted onto the drive motor.
4
S76-H06 (8/97)
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HANDRAIL SPEED SENSOR

The handrail speed sensor employs a cluster roller
with 12 steel pins embedded in the roller, and a
proximity sensor. To monitor the speed of the
handrail, the magnetic proximity sensor senses the
presence of the cluster roller’s steel pins as they
pass by the end of the proximity sensor.
1
Both the left and right handrail speed sensors are
wired into the upper junction box. The signals from
the handrail speed sensors and the encoder are
sent to the controller through one cable.
If the handrail speed slows by 5 percent to 15

percent for longer than 10 seconds, a 5 percent 2
error is recorded in the Service Tool error log. The
escalator will continue to run.
If handrail speed varies +/- 15 percent in

comparison to step speed, a two second buzzer
sounds. If this error persists, the escalator will
shut down. The error is then recorded in the
Service Tool Error Log. 3
Handrail speed sensors are located as follows.

Handrail speed sensor - glass escalator
● GLASS BALUSTRADE (1). On escalators
with glass balustrades, the handrail speed
sensor is located on the truss just below
the upper curve.
● SOLID BALUSTRADE (2). On escalators
4
with solid balustrades, the handrail speed
sensor is located on the handrail take-up
device.
S76-H08 (8/97)
Handrail speed sensor - solid escalator

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Electrical System
COMB LIGHTS
Comb lights are mounted to the upper and lower end
skirts in the area above the comb segments. These
lamps are used to illuminate the area where steps
and comb segments meet.
S704-021 (5/97)
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24 PSM5-706 (8/97)
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Safety testing procedures

Complete the following safety testing procedures for:
● Controller ● Skirt switches

● Emergency stop switches ● Step demarcation lights
● Key start switches
1
CONTROLLER
Visually examine the controller for the following
conditions.
➤ Controller cabinet and controller

components must be clean and free
of dust and moisture.
➤ Contacts on contactors, relays, and
2
all electrical connections must be in
good condition.
➤ Fuses must be in place, and must not
be jumped or show evidence of
tampering.
➤ All electrical cabinets must be closed
and latched to prevent shock hazard 3
and entry of dirt and water.
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Electrical System
EMERGENCY STOP SWITCHES

Make sure each emergency stop switch operates
and will stop the escalator. Also, make sure the
emergency stop switches are covered and
labeled. Lift the cover and make sure the alarm
will sound. The escalator must not restart when
the emergency stop switch is released.
KEY START SWITCHES

3 Check the key start switch in the run position. The
key should start the escalator in both directions.
➤ The key should not remain in

direction start position, but return to
neutral position when hand pressure
is removed.
➤ The key should only be removable
4 from switch when the key is in the
neutral position.
26 PSM5-706 (8/97)
7
TM
SKIRT SWITCHES
Check the skirt switches by physically tripping the
switch with a nonmetallic probe. Make sure the
manual actuation causes the opening of the safety
circuit and removes power to the escalator.
STEP DEMARCATION LIGHTS 1

Examine the step demarcation lights. They must
be operating. Also, examine for the proper caution
signs installed on the escalator.
73-H19 (5/94)
Montgomery KONE
TM
27
7
Electrical System
Adjusting procedures
Complete the following adjusting procedures for:
■ Broken step-chain switch
■ Brake controller board
■ Missing step detector
■ Step out-of-position switch
■ Step upthrust safety switch
■ Combplate impact device
■ Controller - initial start-up
■ Skirt switches
■ Inspect mode
■ Access cover switches
■ Soft start motor controller
■ Out-of-level step detector S706-001 (8/97)
1
BRAKE CONTROLLER BOARD
Complete the following to adjust the brake current. This
adjustment procedure affects the opening of the
permanent magnet brake only. The deceleration rate is
a fixed 2 ft/sec/sec, and cannot be adjusted. 7. Move construct switch to the RUN position and
2 start the escalator in either direction.
1. Move construct switch located on controller main
➤ Both brakes should open cleanly.
CPU board to the center (OFF) position.
➤ If either brake does not open cleanly,
2. Turn potentiometer R10 (1) on both brake control complete the following.
boards fully counter clockwise.
8. Adjust R8 (4) on the corresponding brake board
3. Place leads of a digital volt meter on test points one half turn in either direction.
labeled current + (2) and current - (3) on brake
control board number 1. ➤ This adjustment corresponds to plus or
3 minus 10mV on the digital voltmeter.
4. Move construct switch to the CONSTRUCT
position. Some 12 inch brakes require less than
250mA to open cleanly. If 12 inch brake
5. Turn R10 on brake board number 1 clockwise until does not open cleanly at 250mA, slowly
the digital voltmeter reads: adjust current down until brake opens
➤ WARNER 12 INCH BRAKES: 250mV cleanly.
➤ WARNER 8 INCH BRAKES: 285mV
4 9. Make sure DIP switch SW 3 on main controller
➤ MATRIX BRAKES: 230mV board is set for the proper number of brake
6. Adjust brake board number 2 by placing the digital boards.
voltmeter leads on test points current + and current For more information on setting DIP switch
- on brake board number 2. Then, adjust R10 on SW 3, refer to table titled DIP Switch SW 3
brake board number 2 until the digital voltmeter Settings.
reads: 73-H70 (10/98)
➤ WARNER 12 IN.: 250mV (+10mV, -20mV)

5 DIP SWITCH SW 3 SETTINGS
➤ WARNER 8 INCH BRAKES: 285mV (+/- 10mV)
➤ MATRIX BRAKES: 230mV (+/- 10mV) Switch settings
Number of brake boards
1 2 3*
1 ON ON ON
2 OFF ON ON
6 3 OFF OFF ON
4 OFF OFF OFF
DIP switch 3 is located on main CPU board.
S73H-T05 (4/95)
28 PSM5-706 (10/98)
TM
CAUTION: Damage to the brake control board will occur if

the following instruction is not followed -- Make sure you
turn power OFF and wait 120 seconds, before removing
brake control board from the main CPU board.
BRAKE CONTROLLER BOARD LED

LED Ind
Amber ’+5V’ Brake control board is receiving +5V from
Amber ’+100V’ Brake control board is receiving +100V fr

5
Green ’BCOP’ Brake control board is operating properly
Red ’HEART’ When blinking, indicates brake controller

S73H-T54 (11/95)
BRAKE CONTROLLER BOARD LED 6

INDICATIONS
Montgomery KONE
TM
29
Electrical System
STEP OUT-OF-POSITION SWITCH

Perform the following to adjust step out-of-
position switch.
1. Barricade both ends of the escalator.

2. Remove access covers.
3. Turn mainline disconnect OFF.
4. Loosen wand switch bracket mounting bolts
(1) at lower end pit.
1 5. Rotate bracket (2) until switch actuator (3) is
1/2 inch [13 mm] from step nose line (5).
6. Tighten wand switch bracket mounting bolts.
7. Loosen carriage bolt (6) on upper end wand
bracket (7).
8. Slide bracket on return lip track until wand
actuator (8) is 1/2 inch [13 mm] from step line
2 (10).
Lower end step out-of-position switch
The step out-of-position switch is
manually reset in the controller and
by pressing the button on bottom of
switch.
73-H27 (5/94)
Upper end step out-of-position switch

5
30 PSM5-706 (10/98)
TM
COMBPLATE IMPACT DEVICE

The following describes procedures for adjusting
combplate impact device switch tripping
distance and trip load.
73-H51 (6/94)
Setting switch tripping distance

Before attaching combplate impact device tool kit
to set trip load, complete the following to set
1
switch tripping distance.
1. Check initial spring washer (5) compression 3. Place a feeler gauge between microswitch actuator
setting, and set if necessary. (2) and head of adjustment screw (3). Set
➤ Spring washer compression must be adjustment screw (3) so switch WILL trip at 0.76 mm
set at 25.58 mm [1-1/8 inch]. [.030 inch], but WILL NOT trip at .50 mm [.020 inch].
2. Position switch (1) to align microswitch ➤ An audible click is heard when switch trips. 2
actuator (2) against trip arm adjustment screw 4. Lock adjustment screw in position with 1/4 inch nut
(3). (4).
Montgomery KONE
TM
31
Electrical System
Setting trip load

Set combplate impact device to trip microswitches
for the horizontal force and vertical force described
as follows.
➤ A horizontal force in the direction of travel

is applied which exceeds 400 lbf at either
side of the combplate.
➤ A resultant upward vertical force is applied
which exceeds 150 lbf at the front center
of the combplate.
1
HORIZONTAL FORCE HORIZONTAL FORCE AT CENTER OF COMBPLATE
1. Remove a comb segment from each side of By setting the horizontal trip load for each side of the
combplate. combplate at 400 lbf, it becomes unnecessary to set
2. Assemble force gauge (6) to hook (7) with a horizontal trip load in the center of the combplate. As
quick release pin (8). you set the trip load for each side at 400 lbf, the
opposite side has no pressure applied to it, and it
2 3. Mount test plate (9) to one side of combplate. requires only 400 lbf to actuate the switch for that side.
4. Mount sheave (10) to test plate (9). To actuate the switches on both sides from the center of
the combplate, requires the combined trip load of both
5. Thread cable (11) through sheave (10).
switches (800 lbf) be applied. The resultant horizontal
6. Connect cable (11) to force gauge (6) and force required at the center of the combplate is 800 lbf, if
clamp (12) with quick release pins (8). both sides are set at 400 lbf.
7. Position hook (7) on access frame.
3 8. Position clamp (12) with adjustment end VERTICAL/UPWARD FORCE
against inside edge of access frame and with a The vertical/upward force of 150 lbf is also a result of
gap of 25.4 mm to 50.88 mm [1 inch to 2 setting the horizontal trip load for each side of the
inches] between the access frame and cable combplate at 400 lbf.
end of tool. Keep tool parallel to combplate
supports (13).
This can be tested by using the same force gauge, and
9. Insert a flat object (14) beneath cable end of pulling up on the test plate until switch trip is heard. Use
4 tool to prevent scarring of combplate surface. a single cable to get a straight line pull, which should
10. Turn adjusting end of tool to apply force to read true value on the force gauge dial.
combplate. 700-L30 (9/96)
11. Observe force gauge (6), and record force

reading when switch trips.
12. Adjust spring washers (5) until the switch trips
at 200 lbf.
5
➤ By using the sheave, force is applied
in a 2:1 ratio. When force gauge
reads 200 lbf, actual force applied is
400 lbf.
13. Repeat procedure for opposite side of
combplate.
32 PSM5-706 (10/98)
TM
To prevent scarring of combplate surface, 3

place a flat object (14) underneath cable end of tool.
Depending upon your contract-specific specifications, the combplate impact devices may or
may not have manual reset buttons. If you do not have manual reset buttons, the combplate
impact device is reset in the controller.
Montgomery KONE
TM
33
Electrical System
SKIRT SWITCHES
Complete the following procedures to adjust lower
end skirt switches, lower curve skirt switches,
and upper end skirt switches.
Adjusting upper & lower end skirt

switches
The upper and lower end skirt switches (1) are set
against switch actuators (2). The actuator has a
1 pin which extends through an isolation hole (3)
drilled in the skirt (4). The actuator pin must not
extend more than 1/32 inch [0.8 mm] beyond the
face of the skirt.
1. Mount switch (1) to skirt bracket (5), but do

not tighten switch mounting screws (6) on skirt
bracket.
2
2. Place a straight edge (7) over outside of
isolation hole (3) in skirt (4).
3. Adjust switch in or out until switch actuates.
Then adjust switch slightly from the actuation
point.
4. Tighten mounting screws in skirt bracket.
3 5. Push skirt in towards microswitch.
➤ The switch should actuate with only
a slight deflection of the skirt.
6. Mount and set the opposite side lower end
skirt switch and both upper end skirt switches
in the same manner.
4
Adjusting lower curve skirt switches
1. Mount switch (1) to skirt bracket (2), but do
not tighten switch mounting screws (3) on skirt
bracket.
2. Adjust switch so actuator (5) just touches the
back of the skirt (4), and tighten mounting
5 screws.
3. Mount and set opposite side lower curve skirt
switch in the same manner.
700-L25 (5/94)
34 PSM5-706 (10/98)
TM
ACCESS COVER SWITCHES

Complete the following to adjust access cover
switches.
1. Loosen microswitch mounting screws (1).

2. Place a straight edge (2) above the
microswitch (3), and across adjoining floor.
3. Adjust microswitch so actuator (4) is located
3/16 inch [4.8 mm] below straight edge.
4. Tighten microswitch mounting screws. 1
700-L24 (5/94)
Montgomery KONE
TM
35
Electrical System
OUT-OF-LEVEL STEP DETECTOR

Complete the following to adjust the out-of-level
step detector.
The out-of-level step detector

microswitch is designed to be
manually reset. After actuation, the
switch must be reset by pushing the
button located on the bottom of the
switch.
1 1. CAST STEP: Place a 3.2 mm [1/8 inch] shim
(1) between the step side plate (2) and the
microswitch wand actuator (3).
FABRICATED STEP: Place a 3.2 mm [1/8
inch] shim (1) between the trailing wheel axle
(2) and the microswitch wand actuator (3).
➤ The microswitch should trip. If it does
2 not, adjust in the following manner.
2. Loosen the microswitch mounting screws (4)
connecting the switch (5) to the out-of-level
step detector bracket (6).
3. CAST STEP: Adjust the switch up or down to
achieve a gap of 2.79 mm [7/64 inch] between
the step side plate and the microswitch wand Cast step
3 actuator.
FABRICATED STEP: Adjust the switch up or
down to achieve a gap of 2.79 mm [7/64 inch]
between the trailing wheel axle and the
microswitch wand actuator.
➤ The switch should actuate when a
3.2 mm [1/8 inch] shim is placed
4 between the step side plate and
microswitch wand actuator. If the
switch does not actuate, move the
switch upward slightly.
4. Use same procedure to examine and adjust
the upper and lower end out-of-level step
detectors.
700-L27 (9/96)
5
Fabricated step
6
36 PSM5-706 (10/98)
TM
BROKEN STEP-CHAIN SWITCH

The broken step-chain switch (1) is installed at the
factory, but must be set in the field. In order for the
broken step-chain switch to function, the lower
reversing station (2) spring tension load must be
set. This spring tension load is created by a
threaded rod (3) with a spring (4). The
compressed spring length should measure 12-3/4
inches [323.8 mm].
Complete the following to adjust broken step-

chain switches.
1
1. Measure the compressed spring length from

the chain adjustment holder (7) to the flat
washer (8).
2. Turn the jam nut (9) until the spring length is
12-3/4 inches [323.8 mm].
3. Visually check the location of the broken step- 2
chain switch.
➤ The broken step-chain switch must
be perpendicular to the actuator (6)
and set in the center with 1/8 inch
[3.1 mm] clearance to each side of
the actuator. This will set the switch
so it will actuate if the lower 3
reversing station moves forward or
back 1/8 inch [3.1 mm].
4. Readjust switch location, if necessary, by
loosening the microswitch fastenings, and
moving the microswitch perpendicular and
centered to the actuator with 1/8 inch [3.1 mm]
clearance to each side of the actuator.
4
Broken step-chain switches are reset
manually at the switches.
700-L29 (5/95)
Montgomery KONE
TM
37
Electrical System
MISSING STEP DETECTOR

Complete the following to adjust the missing step
detector.
Do not jumper-out missing step

detectors. If the sensor is jumpered,
damage will occur to the annunciator
board.
1 2. Remove access covers.

3. Remove three steps, and position hole in step
band above upper end missing step detector.
5. Check clearance between proximity sensor (1)
and tapered flat head screw of trailing wheel
(2).
2 ➤ Sensor should be centered and 1/4
inch [6.4 mm] from tapered flat head
screw of trailing wheel.
6. If proximity sensor must be adjusted loosen
nuts (3) on sensor, and adjust until sensor is
centered and 1/4 inch [6.4 mm] from tapered
flat head screw of trailing wheel.
3 7. Tighten nuts (3) on sensor.
8. Turn mainline ON, and position hole in step
band above the lower end missing step
detector.
9. Turn mainline OFF.
10. Use same procedure to examine and adjust
4 the lower end missing step detector as was
used for the upper end missing step detector.
11. Replace steps and access covers.
73-H74 (4/97)
38 PSM5-706 (10/98)
TM
STEP UPTHRUST SAFETY

SWITCHES
Complete the following to adjust step upthrust 4. Then slide the mounting bracket downhill to tighten
safety switches. the switch mounting screws.
1. Make sure the trailing wheel hold-down track Switch mounting screws CANNOT be
(1) is adjusted properly. If adjusted correctly, reached when switch is in the uphill
you can observe the following conditions. position. Be careful, when moving the
switch downhill, to keep the switch
➤ The top of the three studs (2) of the
position toward the switch mounting
hold-down track should be
bracket. This ensures the switch actuator
approximately 3/8 inch [9.5 mm] 1
is centered on the apex of the keystock
from the bottom of the step riser.
when the switch mounting bracket is
➤ The end of the hold-down track moved back uphill.
should have approximately 1/32 inch
[0.8 mm] clearance to the trailing 5. Slide the switch and switch mounting bracket uphill
wheel. until the switch actuator is depressed and centered
on the keystock.
2. Loosen switch mounting screws (3), and
switch bracket (4) carriage bolts. 6. Tighten switch mounting bracket carriage bolts.
2
3. Slide switch mounting bracket uphill till switch 7. Make sure the switch will actuate properly.
actuator (5) is centered on apex of keystock
The step upthrust safety switch should
(6).
actuate when the hold-down track is
displaced 1/16 inch [1.5 mm], and
automatically reset when the hold-down
track springs back to its proper position.
700-L26 (8/97) 3
Montgomery KONE
TM
39
Electrical System
CONTROLLER - INITIAL START-UP

Complete the following to check the S-controller
operation.
❏ Begin initial start-up

❏ Check annunciator boards
❏ Check brake control boards
❏ Check CPU board - run mode
❏ Check CPU board - inspect mode
1 ❏ Check brake release
❏ Check encoder feedback
❏ Check handrail speed sensor
feedback
❏ Check operation of key start switch
& inspect switches
❏ Check run mode operation of
2 escalator
40 PSM5-706 (10/98)
TM
Begin initial start-up

1. Before applying power, check all wiring to and
from controller. Make sure all high voltage
wires are tightly secured to the correct
terminals.
➤ Loose wires will over heat.
2. Switch construct switch to the RUN position.
3. Make sure the correct brake board and
quantity of boards are correctly installed into
the CPU board.
1
4. Make sure DIP switches (SW3) are set DIP SWITCH SW 3 SETTINGS
according to the contract wiring diagram. Switch settings
For more information on setting DIP Number of brake boards
switch SW 3, refer to table titled DIP 1 2 3*
Switch SW 3 Settings. 1 ON ON ON
5. Switch controller power ON. 2 OFF ON ON
➤ If the alarm sounds three times then 2
3 OFF OFF ON
a communication fault exists with
one of the annunciator boards. 4 OFF OFF OFF
Follow Fault Code Corrective Actions DIP switch 3 is located on main CPU board.
for fault codes 63 and 64.
S73H-T05 (4/95)
➤ If the alarm sounds once for two
seconds then the controller has
entered the Inspect Mode and the
annunciator should be displaying 102 3
which also indicates the Inspect
Mode.
6. Put all inspect switches in the RUN position,
and observe the annunciator display.
➤ Annunciator should no longer display
102.
4
Montgomery KONE
TM
41
Electrical System
Check annunciator boards

Check the following LEDs on annunciator boards.
✔ LED24 on each annunciator board should
✔ LED26 (+15V) on each annunciator
be blinking at a rate of 1 hz. If the blinking
board should be illuminated. If
is much slower than 1 hz then the other
LED26 is not illuminated, determine
annunciator is not communicating with the
cause of loss of 15vdc to board.
controller. Follow Fault Code Corrective
✔ LED27 (24VSAFE) on each Actions for fault codes 63 and 64.
annunciator board should be
✔ E-SERIES 5000® escalators: LED23
illuminated. If LED27 is not
(24VDC) on the lower annunciator board
illuminated, determine cause of loss
1 should be illuminated. If not, check wiring
of 24vac safety circuit voltage.
to connector J27.
If a safety switch at the lower end is ✔ LED25 on each annunciator board should
open, then LED27 on the upper be illuminated whenever the MSD (missing
annunciator board will be OFF or step detector) sensor senses a step trailing
dim. Follow the next set of wheel bolt and OFF whenever the MSD
instructions. sensor does not sense a step trailing wheel
bolt.
2 ✔ LEDs 1 through 22 should be OFF. If
any of these LEDs are illuminated,
find associated switch and correct
reason switch is open.
42 PSM5-706 (10/98)
TM
Check brake control board(s)

Check the following LEDs on the brake control
board(s).
✔ LED HEART should be blinking at a ✔ LED BCOP should be illuminated.

rate of 1 hz.
✔ LED 100V should be off unless the
➤ If more than one brake board is escalator is running or is in the construct
installed then the service tool mode.
parameter Number Of Brakes
✔ LED 5V should be illuminated.
needs to be set to the correct
number of brakes to make all brake
board HEART LEDs blink. 1
➤ If any HEART LEDs do not blink,
then follow Fault Code Corrective
Actions for fault codes 75 through
78.
Montgomery KONE
TM
43
Electrical System
Check CPU Board - RUN Mode

1. Switch all inspect switches and construct
switch to the RUN position.
2. LED2 should be illuminated. If LED2 is not
illuminated, correct lower safety string fault.
3. LED3 should be illuminated. If LED3 is not
illuminated, correct upper safety string fault
after lower safety string fault has been
corrected.
1 4. LED1 next to DIP switch SW3 should be OFF.

Locate, correct, and reset fault if LED1 is
illuminated.
5. Check the following LEDs.
✔ LED CONST should be OFF.
✔ LED SAFEON should be OFF until
escalator is started.
2 ✔ LED UP_KY should be OFF until the
key start switch is turned to the up
start direction position.
CONST
✔ LED CTR_KY should be illuminated. SAFEON
✔ LED DN_KY should be OFF until key UP_KY
start switch is turned to the down CTR_KY
DN_KY
start direction position.
BRNISH
3 ✔ LED BRNISH should be OFF. AIR_PR
PWROFF
✔ LED AIR_PR should be OFF. RHR
✔ LED PWROFF should be OFF. LHR
K2_ON = LED may be off or illuminated
✔ LED RHR should flicker as the right 24VAC = LED is off
handrail speed sensor roller is UP_ON = LED is illuminated
rotated. At this time the LED may be DN_ON
ON or OFF. P1_ON
4 P2_ON
RHR will be checked later in the OLR_OK
initial start-up procedure. RNMODE
ENC_A
✔ LED LHR should flicker as the left ENC_B
handrail speed sensor roller is K1K7ON
rotated. At this time the LED may be K2_ON
K3_ON
ON or OFF.
K4_ON
5 K5_ON
LHR will be checked later in the initial
K6_ON
start-up procedure. K8_ON
K10_ON
✔ LED K2_ON should be OFF until the
K9_ON
escalator is started. +15V
✔ LED 24VAC should be illuminated.
✔ LED UP_ON should be OFF until
C703-D19 (10/97)
escalator is started inthe up direction.
6
✔ LED DN_ON should be OFF until LEDs at a glance:
escalator is started in the down CPU LEDs with all inspect switches and construct
direction. switch set to the RUN position.
44 PSM5-706 (10/98)
TM
✔ LED P1_ON should be OFF until ✔ LED K2_ON should be OFF until the
escalator is started. escalator is started. 4
✔ LED P2_ON should be OFF until ✔ LED K3_ON should be OFF until the
escalator is started. escalator is started.
✔ LED OLR_OK should be OFF until ✔ LED K4_ON should be OFF until the
escalator is started. escalator is started.
✔ LED RNMODE should be ✔ LED K5_ON should be OFF until the
illuminated. escalator is started in the up direction.
✔ LEDs ENC_A and ENC_B should ✔ LED K6_ON should be OFF until the 5
flicker 90 degrees out of phase as escalator is started in the down direction.
the encoder is rotated. At this time
✔ LED K8_ON should be OFF until the CPU
the LED may be ON or OFF.
sounds the alarm buzzer.
ENC_A and ENC_B will be checked ✔ LED K10_ON should be OFF until the
later in the initial start-up procedure. escalator is started.
✔ LED K1K7ON should be OFF until ✔ LED K9_ON should be OFF until the
escalator is started. escalator is started. 6
✔ LED +15V should be illuminated.
Montgomery KONE
TM
45
Electrical System
Check CPU board - inspect mode

Switch one inspect switch into the INSPECT
position.
➤ The alarm buzzer should sound for CONST

two seconds. SAFEON
UP_KY
➤ The annunciator display should CTR_KY
display 102. DN_KY
BRNISH
➤ All of the LEDs described in the
AIR_PR
section Check CPU Board - RUN PWROFF
1 Mode will remain the same except RHR
LED RNMODE should not be LHR
illuminated. K2_ON = LED may be off or illuminated
24VAC = LED is off
UP_ON = LED is illuminated
DN_ON
P1_ON
P2_ON
OLR_OK
2 RNMODE
ENC_A
ENC_B
K1K7ON
K2_ON
K3_ON
K4_ON
K5_ON
K6_ON
K8_ON
3 K10_ON
K9_ON
+15V
C703-D20 (10/97)
4 LEDs at a glance:
CPU LEDs with one inspect switch in INSPECT position.
46 PSM5-706 (10/98)
TM
Check brake release

(all Inspect switches in the RUN position)
CONST
1. Switch all inspect switches to the RUN SAFEON
position, and switch the construct switch to the UP_KY
CONSTRUCT position. CTR_KY
DN_KY
2. Check the following. BRNISH
AIR_PR
✔ All of the LEDs described in the
PWROFF
section Check CPU Board - RUN RHR
Mode will remain the same except LHR
LEDs CONST and K9_ON should K2_ON = LED may be off or illuminated
illuminate. 24VAC
1
= LED is off
UP_ON = LED is illuminated
✔ The annunciator display should DN_ON
display 101. P1_ON
✔ Brake board LED 100V should P2_ON
OLR_OK
illuminate.
RNMODE
3. Adjust brake current according to adjusting ENC_A
procedures for brake. ENC_B
K1K7ON 2
For more information on adjusting K2_ON
procedures for brake current, refer to K3_ON
Adjusting procedures/Brake controller K4_ON
board, in this chapter. K5_ON
K6_ON
➤ Brake should be released. K8_ON
4. Switch construct switch to the RUN position. K10_ON
K9_ON
+15V 3
C703-D21 (10/97)
LEDs at a glance:
CPU LEDs with all inspect switches in the RUN position,
and construct switch in the CONSTRUCT position. 4
Montgomery KONE
TM
47
Electrical System
Check encoder feedback Check handrail speed sensor feedback

1. Switch inspect switch to the INSPECT position 1. Switch inspect switch to the INSPECT position and
and switch the construct switch to the RUN switch the construct switch to the RUN position.
position.
2. Check that LEDs RHR and LHR flicker as the
2. Start the escalator in the DOWN direction. handrail speed sensor rollers rotate. Make this
➤ The amber LED4 in the center of the check as the escalator just begins to move on start.
CPU board should go OFF. After escalator is up to speed the handrail speed
sensor LEDs will flicker too quickly to observe.
3. Stop the escalator and then start the escalator
in the UP direction. 3. Start escalator in the down direction and measure
the right handrail speed sensor frequency through
1 ➤ The amber LED4 in the center of the test points RHR and GND. The frequency should be
CPU board should illuminate. as follows:
LED 4 must go off when escalator is ✔ 17.8 hz ± 0.2 hz for 70 ft/min
started in down direction and LED4 ✔ 22.9 hz ± 0.2hz for 90 ft/min
must illuminate when escalator is
started in up direction. Both these ✔ 24.5 hz ± 0.3 hz for 100 ft/min
conditions must be true, otherwise, ✔ 30.6 hz ± 0.3 hz for 120 ft/min
2 follow corrective actions for fault ✔ 33.1 hz ± 0.3 hz for 130 ft/min
code 104.
✔ 33.9 hz ± 0.3 hz for 133 ft/min
4. Start escalator in the down direction and ✔ 35.1 hz ± 0.4 hz for 13 8ft/min
measure encoder frequency through test
points MS1 and GND. Make sure service tool 4. Start escalator in the down direction and measure
parameter Encoder Frequency is within 1% the left handrail speed sensor frequency through test
of the actual measured frequency. points LHR and GND. The frequency should be the
same as described for right handrail speed sensor.
3 5. Check that LEDs ENC_A and ENC_B flicker
90 degrees out of phase as the encoder is
rotated. Make this check as the escalator just
begins to move on start. After escalator is up
to speed the encoder LEDs will flicker too
quickly to observe.
48 PSM5-706 (10/98)
TM
Montgomery KONE
TM
49
Electrical System
Check operation of key start switch Check RUN mode operation of escalator
& inspect switches 1. Switch all inspect switches and construct switch to
Check operation of key start switch and inspect the RUN position.
switches. 2. Start escalator in the down direction. Hold the key
start switch in the start position until the alarm
For more information on checking sounds for one second.
operation of key start switch and inspect
switches, refer to Adjusting procedures/ 3. If the escalator fails to continue to run automatically,
Inspect mode, in this chapter. observe annunciator display for fault and follow the
fault code corrective actions for that fault.
1 4. Stop the escalator and repeat the same test in the

up direction.
5. Initial Start-up is complete.
703-E49 (7/97)
50 PSM5-706 (10/98)
TM
INSPECT MODE
The Inspect Mode allows the escalator to start and
run as long as the key start switch is held in a start
position. If the key start switch is released, the
escalator stops.The escalator will not achieve a
holding circuit.
Enter the Inspect Mode by either selecting the

slow speed mode (if escalator is equipped with the
pendant control option) or by switching one of the
inspect switches to the INSPECT position.
1
When the pendant control option is installed, the
pendant control disables both the upper and lower
key start switches. The lower Inspect switch, when
in the INSPECT position, disables the upper key
start switch. The upper Inspect switch, when in the
INSPECT position, disables the lower key start
switch. If both the upper and lower Inspect 2
switches are in the INSPECT position then both
key start switches are disabled.
When the Inspect Mode is entered, the CPU

sounds the alarm buzzer for two seconds.
3
Safety concerns
When switching to the inspect mode, if the alarm buzzer DOES NOT sound for
approximately two seconds then it is to be assumed that the Inspect Mode was NOT
entered.
Before starting the escalator, make sure that no one is in the machine or in a
position to be harmed if the escalator starts.
4
Each time the inspect mode is entered, verify the proper operation of Inspect Mode
as follows.
✔ Both upper and lower key start switches are disabled if pendant control
is used.
✔ The lower key start switch is disabled when the upper Inspect switch is 5
in the INSPECT position.
✔ The upper key start switch is disabled when the lower Inspect switch is
in the INSPECT position.
✔ When started, the escalator DOES NOT achieve a holding circuit.
Also, the escalator stops when the key start switch is released.
703-E50 (7/97)
Montgomery KONE
TM
51
Electrical System
SOFT START MOTOR CONTROL

The S-controller uses a soft start motor controller
for nearly all applications to reduce mechanical
shock to the escalator while starting. The soft start
motor controllers are located as follows
❏ Starter panel mount

❏ External soft start mount
Starter panel mount

1
Whenever possible the Soft Start motor controller
is located on the starter panel in the controller.
Two types of Soft Starts that are used on the
starter panel are the Allen-Bradley STC and the
Telemecanique Modular Soft Start. Adjust both of
these soft starts in the following manner.
1. Set the Initial Torque potentiometer to the

2 minimum setting and set the Acceleration
Time potentiometer to the maximum setting.
2. Start the escalator in the down direction and
notice how the escalator starts. Stop the
escalator
3. If the escalator remained stalled for a period of
time while the motor was humming, increase
3 the Initial Torque potentiometer by 1/8 of a
turn. Repeat steps 2 and 3 until the escalator
begins to move (slowly) almost immediately
when starting.
4. After the Initial Torque potentiometer is
adjusted, adjust the Acceleration Time
potentiometer so that the escalator comes up
4 to speed within three seconds.
➤ When soft start adjustment is
complete the escalator should start
smoothly and come up to speed
within three seconds.
52 PSM5-706 (10/98)
TM
External soft start mount

When requirements are such that the soft start will
not fit on the starter panel, a soft start is mounted
external to the controller cabinet. One of the soft
starts that are used for this application is the
Nordic Soft Start Motor Controller. Adjust the
Nordic soft start in the following manner.
1. Remove fasteners (1) from cover (2), and

adjust the Line Limiter Voltage potentiometer
(3) to maximum value.
1
The Line Limiter Voltage
potentiometer should already be
permanently set to maximum value
from the factory.
2. Adjust PFC Voltage potentiometer (4) to

maximum value.
The PFC Voltage potentiometer 2

should already be permanently set to
maximum value from the factory.
3. Set the Initial Torque potentiometer (5) to the

minimum setting and set the Acceleration
Time potentiometer (6) to the maximum
setting.
4. Start the escalator in the down direction and
3
notice how the escalator starts. Stop the
escalator.
5. If the escalator remained stalled for a period of
time while the motor was humming, increase
the Initial Torque potentiometer (5) by 1/8 of a
turn. Repeat steps 4 and 5 until the escalator
begins to move (slowly) almost immediately 4
when starting.
6. After the Initial Torque potentiometer (5) is
adjusted, adjust the Acceleration Time
potentiometer (6) so that the escalator comes
up to speed within three seconds.
➤ When soft start adjustment is
complete the escalator should start 5
smoothly and come up to speed
within three seconds.
S704-023 (8/97)
Montgomery KONE
TM
53
Electrical System
Removing & replacing procedures

Complete the following removing and replacing procedures for:
■ Microswitch wiring ■ Key start switches

■ Access cover switches ■ Handrail inlet switches
■ Out-of-level step detector ■ Broken step-chain switches
■ Handrail speed sensor ■ Combplate impact device
■ Skirt switches ■ Step demarcation lamps
■ Emergency stop switches ■ Step out-of-position switch
■ Alarm switch ■ Step upthrust safety switch
S706-002 (8/97)
1 MICROSWITCH WIRING
Complete the following to remove and replace
microswitch wiring.
1. Loosen screws on bottom of switch cover, and

remove cover.
2. Loosen terminal screws, and remove wires.
2
3. Remove seal nut (1) and fittings (2) from
switch, and remove thread sealant from
threads of seal nut.
4. Pull wires from microswitch housing (3).
5. Place wires through fittings, and into
microswitch housing.
3 6. Check eyelet connections on wires. Replace
eyelets if necessary.
7. Place wires on common terminal and either the
NO (normally open) or NC (normally closed)
terminal. Whether the wires are placed on the
NO or NC terminal depends on the application
the switch is used for.
4 For more information on switch
applications, refer to contract-specific
Wiring Diagrams.
8. Tighten terminal screws.

9. Place thread sealant on seal nut threads.
10. Replace seal nut with fittings into microswitch,
5 and tighten seal nut.
73-H31 (5/94)
6
54 PSM5-706 (8/97)
TM
Wiring non-manual reset microswitch

2
Wiring manual reset microswitch (optional)
6
Montgomery KONE
TM
55
Electrical System
ACCESS COVER SWITCHES

access cover switches.
1. Remove microswitch mounting screws (1).

2. Remove microswitch (2) from switch bracket
(3).
3. Remove wires from old switch, and wire new
switch.
For more information on wiring a
microswitch, refer to Removing &
replacing/Wiring microswitches, in this
chapter.
4. Place switch on mounting bracket, and insert

1 mounting screws.
5. Adjust switch.
For more information on adjusting
access cover switches, refer to Adjusting
procedures/Access cover switches, in
this chapter.
2 6. Tighten microswitch mounting screws (1).

S76-F05 (7/95)
6
56 PSM5-706 (8/97)
TM
OUT-OF-LEVEL STEP DETECTOR

out-of-level step detectors.
1. Remove switch mounting screws (1) and seal

washers from switch bracket (2).
2. Remove switch (3) from bracket, and wire new
switch.
chapter.
3. Replace switch on bracket, and adjust.

For more information on adjusting out-of-
level step detectors, refer to Adjusting 1
procedures/Out-of-level step detectors,
in this chapter.
S76-F06 (7/95)
2
Cast step
5
Fabricated step
6
Montgomery KONE
TM
57
Electrical System
SKIRT SWITCHES
Complete the following procedures to remove and replace lower end skirt switches, lower curve skirt
switches, and upper end skirt switches.
Removing & replacing upper & lower

end skirt switches
The upper and lower end skirt switches (1) are set
against switch actuators (2). The actuator has a
pin which extends through an isolation hole (3)
drilled in the skirt (4). The actuator pin must not
extend more than 1/32 inch [0.8 mm] beyond the
face of the skirt.
1. Remove switch mounting screws (6)

connecting switch (1) to switch mounting
bracket (5).
1
2. Remove switch from switch mounting bracket,
and remove wiring.
3. To replace skirt switch, wire new switch, and
mount switch (1) to switch mounting bracket
(5).
2 replacing/Wiring microswitches, in this
chapter.
4. Adjust switch.
For more information on adjusting skirt
switches, refer to Adjusting procedures/
Skirt switches, in this chapter.
3 Removing & replacing lower curve

skirt switches
Lower curve skirts are set with the switch actuator
(5) touching the back side of the skirt (4).
1. Remove switch mounting screws (3)

connecting switch (1) to switch mounting
bracket (2).
4
2. Remove switch from switch mounting bracket,
and remove wiring.
3. To replace skirt switch, wire new switch, and
mount switch (1) to switch mounting bracket
(2).
5 replacing/Wiring microswitches, in this
chapter.
4. Adjust switch.
For more information on adjusting skirt
switches, refer to Adjusting procedures/
Skirt switches, in this chapter.
S76-F16 (8/95)
6
58 PSM5-706 (8/97)
TM
EMERGENCY STOP SWITCH ALARM SWITCH

Complete the following to remove and replace Complete the following to remove and replace alarm
emergency stop switches. switches.
1. Remove screws (1) from emergency stop 1. Remove screws (1) from emergency stop switch
switch cover plate (2). cover plate (2).
2. Remove emergency stop switch cover plate (2) 2. Remove cover plate (2) and emergency stop switch
and emergency stop switch assembly (3) from assembly (3) from switch box (4).
switch box (4).
3. Remove threaded hex nut (8) from switch assembly
3. Remove fastening nuts (9) connecting switch (3).
assembly (3) and cover plate (2), and remove
4. Remove drip shield (5), and alarm switch (6).
switch assembly.
5. Remove mounting screws (7) from alarm switch and
4. Mark and remove wires from switch assembly
drip shield.
(3).
5. Replace wires on new switch assembly, and
6. Cut wires and tag for identification. 1
tighten. 7. Splice new switch into wires.
6. Install switch assembly (3) onto cover plate (2), 8. Replace mounting screws (7) into alarm switch (6)
and tighten fasteners (9). and drip shield (5).
7. Position switch assembly and emergency 9. Replace drip shield (5) on switch assembly (3), and
cover plate in switch box (4). tighten threaded hex nut (8).
8. Replace and tighten cover plate fasteners (1). 10. Replace switch assembly (3) and cover plate (2) into 2
S76-F09 (7/95) switch box (4).
11. Replace stop cover plate screws (2), and tighten.
➤ If alarm switch actuator is too long after
installing, trim the necessary amount from
the actuator. The alarm should sound when
the cover is lifted, and deactivate when the
cover is down. 3
S76-F10 (7/95)
6
Montgomery KONE
TM
59
Electrical System
KEY START SWITCHES

key start switches.
1. With key removed from key start switch, 5. Install plastic washers (5), metal washer (4), lock nut
remove mounting screws (1) from key start (3) on barrel of key switch.
cover plate (2). 6. Wire switch, and insert switch assembly and cover
2. Remove cover plate and switch assembly from plate into frontplate and switch box.
frontplate and switch box, and disconnect 7. Mount cover plate to frontplate with mounting
wiring. Tag wiring for identification purposes. screws (1).
3. Remove lock nut (3), metal washer (4), and 8. Replace access covers, and turn mainline
plastic washer (5) from barrel of key switch, disconnect ON.
and remove cover plate (2).
9. Insert switch into key slot. Turn key in both
4. Position two rubber washers (6) over barrel of directions to make sure unit is operating correctly.
1 key switch, and insert new switch into cover Also, make sure key returns to center position after
plate. releasing the key, and key can only be removed
from key slot when in the center position.
Make sure arrow on key hole is
S76-F11 (7/95)
pointing up.
6
60 PSM5-706 (8/97)
TM
HANDRAIL INLET SWITCHES

handrail inlet switches.

4. Remove end inner deck to gain access to
handrail inlet switch (1) behind frontplate (2).
5. Remove switch mounting screws (3) from
microswitch (1) and mounting plate (4).
6. Remove microswitch, and remove wires.
7. Wire new switch and insert switch on mounting
plate.
1
For more information on wiring
microswitches, refer to section titled:
Microswitch Wiring.
8. Position handrail inlet switch to actuate when

inlet doors (5) are opened.
9. Insert switch mounting screws, and tighten. 2
10. Replace inner deck and access cover.
S704-018 (5/97)
BROKEN STEP-CHAIN SWITCH

Complete the following to remove and replace 3
broken step-chain switches.
1. Remove screws (1) mounting switch (2) to

bracket (3).
2. Remove old microswitch, remove wires, and
wire new microswitch.
3. If bracket (3) must be replaced, remove nuts 4
(4) and screws (5) connecting the bracket and
lower reversing station support angle (6).
4. Remove old bracket, and replace with new
bracket.
5. Replace screws (5) and nuts (4) into bracket
(3) and lower reversing station support angle
(6). 5
6. Adjust microswitch (2) to actuator (7).
For more information on adjusting the
microswitch, refer to Adjusting
procedures/Broken step-chain switch, in
this chapter.
73-H42 (5/94)
6
Montgomery KONE
TM
61
Electrical System
COMBPLATE IMPACT DEVICE

combplate impact device.
Removing combplate impact device 6. Insert first set screw (12) into wedge and tighten
1. Remove M10 bearing bolt (14), wedge until set screw is flush with inside edge of wedge.
assembly (11). 7. Bolt pre-assembled wedge assemblies to combplate
2. Remove microswitch (7) and switch mounting supports. Do not tighten at this time.
plate (8) from combplate support arm. 8. Place combplate nose section on combplate
3. Remove rear bearing (13) and trip arm (4) from supports and slide it back on dowel pin. Make sure
combplate nose section (5). o-ring is in slot of nose section.
➤ The nose section should be able to slide all
the way back until it is touching tail section
1 Replacing combplate impact device of combplate. If it does not, make sure
dowel pin has been hammered into tail
1. Hammer dowel pin (1) onto hole in center of
section far enough.
beveled edge of combplate tail section (2), and
place o-ring on end of dowel. 9. Position combplate nose section with .20 inch [5.1
mm] gap between nose and tail sections.
2. Mount rear bearings (3) and trip arms (4) on
combplate nose section (5). 10. Tighten down bearing roller (13) to combplate nose
section through the eyebolt (9) using M10 bearing
2 3. Turn 1/4 inch adjustment screw (6) all the way
bolt (14).
into trip arm.
11. Make sure wedges are square and in contact with
4. Mount microswitch (7) on mounting bracket bearing roller, and there is .20 inch [5.1 mm] gap
(8), and install switch assembly onto between the nose and tail sections. Then, tighten
combplate supports. wedges down.
5. Pre-assemble eyebolts (9) and springs (10) to 12. Tighten spring washer stack down to a height of 1-1/
wedges (11). Do not tighten at this time. 8 inch [25.58 mm] as an initial setting.
3 ➤ The 28 belleville springs must be in a For information on setting combplate impact
series-parallel configuration (as device trip distance and trip load, refer to
shown in the graphic) with two Adjusting procedures/Combplate impact device
springs parallel to each other and all in this chapter.
springs in series to each other. The S76-F14 (7/95)
end springs are open and face out.
6
62 PSM5-706 (8/97)
TM
6
Montgomery KONE
TM
63
Electrical System
STEP DEMARCATION LAMPS

Step demarcation lamps must be
replaced every 10,000 hours of
operation. Failure of ballasts and
starters could occur if step
demarcation lamps are not replaced
when burned out.
1. Barricade both ends of the escalator, and

remove access cover.
2. Remove three steps and position hole in step
band above step demarcation light (1) in lower
end.
1 4. Remove fasteners (2) connecting lens (3) to
step demarcation light assembly (1), and
remove lens.
5. Remove old lamp (4) from assembly and
replace with new lamp.
6. Replace lens and fasteners.
7. Replace steps and access covers, remove
2 barricades, and turn mainline disconnect ON.
S704-019 (5/97)
6
64 PSM5-706 (8/97)
TM
STEP OUT-OF-POSITION SWITCHES

Complete the following procedures for removing
and replacing the step out-of-position switch.
The spring coil switches are manually

reset by pushing button on bottom of
microswitch.

4. Remove switch mounting screws (1) from
switch (2) and switch bracket (3) at lower end.
5. Wire new switch, and install on mounting
bracket.
1
chapter.
Upper end missing step detector
6. Replace switch mounting screws and tighten.
7. Replace the upper end microswitch in the 2
same manner as the lower end microswitch.
73-H35 (5/94)
Lower end missing step detector
6
Montgomery KONE
TM
65
Electrical System
STEP UPTHRUST SAFETY

SWITCHES
step upthrust safety switches.
1. Mark position of switch mounting bracket (1) 5. To replace step upthrust switch, wire new switch,
to lip track (2). and mount switch (4) to switch mounting bracket (1).
2. Loosen switch mounting bracket (1), and slide For more information on wiring a microswitch,
mounting bracket downhill to gain access to refer to Removing & replacing/Wiring
switch mounting screws (3). microswitches, in this chapter.
3. Loosen switch mounting screws (3), and 6. Adjust switch.

remove switch (4). For more information on adjusting upthrust
4. Remove switch from switch mounting bracket, switches, refer to Adjusting procedures/Step
upthrust safety switches in this chapter.
1 and remove wiring.
S76-F17 (8/95)
6
66 PSM5-706 (8/97)
TM
NOTES
6
Montgomery KONE
TM
67
Electrical System
Alphabetical index
A D
Access cover switches DIP Switch SW 3 Settings 28
adjusting procedures 35
equipment operation 18 E
removing & replacing procedures 56 Electrical system
Adjusting procedures equipment operation 5
access cover switches 35 removing & replacing procedures 54
brake controller board 28 adjusting procedures 28
broken step-chain switch 37 annunciator boards 12
combplate impact device 31 block diagram 4
controller - initial start-up 40 controller 6
missing step detector 38 encoder 22
out-of-level step detector 36 handrail speed sensor 23
skirt switches 34 junction boxes 10
soft start motor control 52 safety switches 14
step out-of-position switch 30 safety testing procedures 25
step upthrust safety switches 39 step demarcation lights 22
Alarm switch Emergency stop switches
equipment operation 20 equipment operation 20
removing & replacing procedures 59 removing & replacing procedures 59
Annunciator display, description 9 safety testing procedures 26
Annunciator PC board 42 Encoder, description 22
Encoder feedback, check 48
B Equipment operation
Brake controller board access cover switch 18
adjusting procedures 28 alarm switch 20
check brake release 47 annunciator boards 12
checking 43 brake controller board 8
equipment operation 8 brake temperature switch 21
Brake temperature switch, description 21 broken step-chain switches 20
Broken step-chain switch combplate impact device 16
adjusting procedures 37 controller 6
equipment operation 20 controller annunciator display 9
removing & replacing procedures 61 emergency stop switches 20
encoder 22
C handrail inlet switch 15
Comb lights, description 24 handrail speed sensor 23
Combplate impact device junction boxes 10
adjusting procedures 31 key start switch 21
equipment operation 16 missing step detector 15
removing & replacing procedures 62 out-of-level step detectors 19
5 Controller pit stop switch 18
brake controller board 8 safety switches 14
equipment operation 6 skirt switches 17
initial start-up 40 step demarcation lights 22
safety testing procedures 25 step upthrust safety switches 17
CPU board, main controller 6, 44
68 PSM5-706 (8/97)
TM
H key start switches 60

Handrail inlet switch out-of-level step detectors 57
equipment operation 15 skirt switches 58
removing & replacing procedures 61 step demarcation lamps 64
Handrail speed sensor step out-of-position switches 65
check feedback 48 step upthrust safety switches 66
equipment operation 23 RUN mode 44, 50
High voltage junction box, description 10
S
I Safety circuit strings 12
Inspect mode 46, 51 Safety concerns 5
Safety relays, controller 6, 12
J Safety switches
Junction boxes, description 10 access cover switch 18, 35, 56
alarm switch 20, 59
K brake temperature switch, description 21
broken step-chain switch 20, 37, 61
Key start switches
combplate impact device 16, 31, 62
equipment operation 21
emergency stop switch 20, 59
removing & replacing procedures 60
handrail inlet switch 15, 61
safety testing procedures 26
key start switch 21, 60
L missing step detector 15, 38
out-of-level step detector 19, 36, 57
LEDs pit stop switch, description 18
annunciator boards 42 skirt switches 17, 34, 58
brake control board 43 step out-of-position switch 30, 65
Lower annunciator board, description 12 step upthrust safety switch 17, 39, 66
Lower junction box, description 11 Safety testing procedures 25
M Service guide 70
Skirt switches
Microswitch, wiring 54 adjusting procedures 34
Missing step detector equipment operation 17
adjusting procedures 38 removing & replacing procedures 58
equipment operation 15 safety testing procedures 27
O Soft start motor control 52
Step demarcation lights
Out-of-level step detector equipment operation 22
adjusting procedures 36 removing & replacing procedures 64
equipment operation 19 safety testing procedures 27
removing & replacing procedures 57 Step out-of-position switch
adjusting procedures 30
P equipment operation 21
PC boards removing & replacing procedures 65
annunciator boards 12 Step upthrust safety switch
brake controller board 8 adjusting 39
main controller CPU board 6 equipment operation 17
Pit stop switch, description 18 removing & replacing procedures 66
Switches. See Safety switches
R
T 5
Relays, safety, controller 6, 12
Removing & replacing procedures Tables
access cover switches 56 Brake Controller Board LED Indications 29
alarm switch 59 Service Guide 70
broken step-chain switches 61
combplate impact device 62 U
emergency stop switches 59 Upper annunciator board, description 12
handrail inlet switches 61 Upper junction box, description 10
Montgomery KONE
TM
69
Electrical System
Service guide
SERVICE GUIDE
electrical system with S-controller
Equipment Frequency Procedure
EACH SERVICE
Emergency stop switch, alarm E Lift plastic cover and make sure alarm buzzer sounds. Check
switch, and alarm buzzer operation of emergency stop switch.
Handrail inlet switches & access E Check operation of all handrail inlet switches and access cover
cover switches switches.
Skirt switches E Check operation of all skirt switches.
Key start switches & inspect E Check operation of all key start switches and inspect switches. Key
switches start switches should be able to start escalator in either direction.
The key start switches should spring return to center. The inspect
switches should be able to put the escalator in the run mode or the
inspect mode as well as disable opposite end start switch.
Brake E Burnish brake 3 times. Press brake burnish button in controller while
escalator is running. Allow all brakes to burnish once, then repeat
process two more times.
Check brakes for noise. If noise exists, readjust brake board(s). If
noise persists replace brake.
Step demarcation lights E Replace burned out lamps. Make sure step demarcation lights at the
upper and lower ends are operating. Failure of starter and ballast
can occur if burned out lamps are not replaced.
Handrail speed sensor E Check error log for 5% handrail speed sensor errors (#109 & #110).
If error exists, determine cause of handrail slippage, and correct
problem.
Electrical system E Check error log for any errors that are recorded. Determine if any
action is required. For more information, refer to escalator
diagnostics.
TRI-ANNUALLY (every four months)

All safety switches T Actuate every safety switch. Every safety switch must shut the
escalator down and show proper indication of shut down on the
annunciator.
Combplate impact device T Check operation of combplate impact device switches.
Broken step chain switch T Check operation of broken step-chain switches.
ANNUALLY
Step demarcation lights Every 10,000 Replace all step demarcation lamps, regardless if they are burned
hrs of operation out or not. This will help ensure long life of ballasts and starters.
E = Each service T = Tri-annually (every 4 months) S = Semi-annually A = Annually
6 S704-T02 (5/97)
70 PSM5-706 (8/97)
TM
NOTES
Montgomery KONE
TM
71

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What safety procedures are outlined for testing and maintaining the electrical system?

E-SERIES HR Escalator with S-controller

Service Support Guide

components of the Electrical System of an E-SERIES HRTM escalator with

a S-controller. This service support guide also provides Field Personnel

2 with information on safety testing procedures, adjusting procedures, and

removing and replacing procedures.

2. Safety testing procedures 25

4. Removing & replacing procedures 54