Kone Board 1O4 User manual

Product Instruction
Door Control Board:
Board 1Ø4® for PM/SSC
61111-149
(R3) 2000-08-31

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 2(R3) 2000-08-31
© 2000, 1992 KONE Inc.
Unpublished work. All rights reserved. No portion of this volume may be used or reproduced in any manner without
written permission from KONE Inc. — One KONE Ct; Moline, IL 61265
Due to our policy of continuing improvement, we reserve the right to alter design and specification without prior notice.
The right to make changes to product design and material use, without notice, is reserved. All hardware and software
referenced in this publication and/or used in conjunction with equipment described herein is the exclusive property of
KONE Inc. whether or not protected by U.S. and/or International Trademark, Copyright and/or Patent Laws.

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 3(R3) 2000-08-31
DOOR CONTROL BOARD:
Board 1Ø4® for PM/SSC
Equipment description 4
Features of door operators with Board 1Ø4®. . . . . . . . . . . . . . . . . . . . . 4
Input & output terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing door operator control Board 1Ø4® 6
Adjusting door operator control Board 1Ø4® 8
Measure current (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 9
Set potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjust door speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjust door closing force . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust nudge speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Set microswitch cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 4(R3) 2000-08-31
FEATURES OF DOOR
OPERATORS WITH BOARD 1Ø4®
Door operators with Board 1 Ø 4®control have
following operations and features:
❏Door control power
❏Current control
❏Speed & travel limits
❏Acceleration & deceleration
❏Troubleshooting & switch adjusting
❏Auxiliarypiloting
❏Other features
Door control power. Door operator control uses a
low voltage permanent magnet DC motor. DC motor
is powered by pulse width modulated power (high
speed switching - 20,000 Hz). Motor responds to
average voltage of high frequency pulses, and not
individualpulses.
Current control. Door operator control has a
current sensing circuit in both open and closed
directions to supply feedback to speed control
circuit. Current sensing circuit regulates door closing
force, and open/stall current caused by a hooked
interlock. Current sensing circuit also guarantees
that door operator control relay contacts do not
break or make when motor armature current is
present—helping to prevent damage to relay
contacts. Motor direction is controlled by reversing
armature connection using a conventional relay
system.
Speed & travel limits. Door operator control selects
speed and travel limits with cam operated
microswitches. These microswitches operate relays
tied into speed direction circuits.
Acceleration & deceleration. Door operator control
has an internal soft-start circuit which regulates
smooth acceleration and deceleration. Soft-start
circuit allows average motor voltage to change
gradually when speeds change. Board 1Ø4®
Equipment description
Solid state door operators with Board 1Ø4®are described as follows.
■Features of door operators with Board 1Ø4®
■Input & output terminals
149-001 (8/2000)
Troubleshooting & adjusting switches. Door
operator control has two small toggle switches
mounted on common circuit board. TEST/RUN
switch and
O-OFF-C switch are used to signal door opening or
closing from car top during troubleshooting and
adjusting; and to disconnect the door open and close
signals, and de-activate internal shutdown timer.
Auxiliary piloting. Door operator control also has a
Form “C” Open and a Form “C” Closed relay contact
for auxiliary piloting.
Other features. Additional items added to Solid
State door control.
➤Non-adjustable open current limit set at
5 amps.
➤Non-adjustable internal shutdown timer
removes power if doors do not open or
close within 20 to 30 seconds after a
direction signal is given. Shutdown
indicated by an illuminated LED 7.
F615-002 (3/97)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 5(R3) 2000-08-31
Input & Output Terminals
Required for door to operate
L1A to L2A 120VAC @ 500VA input. If one of
input lines is grounded, it should be
connected to L1A.
DO3 to L1A Open limit signal. A relay across
these terminals de-energizes when
open limit microswitch is actuated.
Relay is energized at all other times.
DO7 to L1A Signal to close. When a relay
contact across these terminals makes
up, doors should close.
DO10 to L1A Signal to open. When a relay
contact across these terminals makes
up, the doors should open.
DO17 to L1A Close limit signal. A relay across
these terminals de-energizes when
close limit microswitch is actuated.
Relay is energized at all other times.
Optional
DO3 to DO10 Auxiliary to “O” relay. A relay across
these terminals should be energized only
when doors are opening.
DO7 to DO17 Auxiliary to “C” relay. A relay across
these terminals should be energized only
when doors are closing.
DO4 to DO7 Reduced speed closing signal. When
doors have a signal to close, and a relay
contact across these terminals makes
up, door speed is controlled by “N”
potentiometer.
F NC NO Auxiliary C relay switching contact.
CDesignates a Form “C” contact on a 1-C
relay.
F NC NO Auxiliary O relay switching contact.
ODesignates a Form “C” contact on 1-O
relay.
DSD to SS Optional - Used on some projects for
load balancing or other customer
requirement.
F615-SI1 (3/97)
INPUT & OUTPUT TERMINALS
The PM/SSC door operator control requires an input
of single phase 115 VAC. When this power is
supplied by a transformer, the transformer must have
rating of at least 500 VA. Input and output terminal
signals are connected to TB1 (3).
149-002 (8/2000)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 6(R3) 2000-08-31
Installing door operator
control Board 1Ø4®
The following describes replacing a three or four
door control board with a single Door Control Board
1Ø4. Complete the following to install door operator
control Board 1Ø4®.
When replacing a four-board system, a
cable assembly (90527-022) must be
used. This cable replaces the wires on
the existing common board.
1. Turn OFF, lock-out, and tag mainline
disconnect.
2. Disconnect the two transformer primary wires
from the terminal strip on the common board.
High performance operators will have
two wires in each terminal. Keep two-
wire sets together so they can be
replaced correctly on the new door
control board. If the door operator is a
high performance operator, the J4
jumper must be in the high
performance position.
3. Unplug the molex connector.
➤This does not apply to four-board
systems.
4. Remove 45 VDC supply wires and motor wires
from power board.
Mark wires for correct polarity.
5. Remove wires connected to main terminal strip
on common board.
Label each wire to indicate which
terminal the wire will be connected to
later.
6. Remove common board.
7. Replace styrofoam spacer with anti-static
support spacer.
8. Install new Control Board 1Ø4®.
9. Connect wires previously removed from main
terminal strip to new control board using labels to
match each wire to correct terminal.
Door Control Board 1Ø4®does not
require terminals on wire leads.
10. Connect 45 VDC supply to terminals +45V and
GND of TB2.
➤Red wire is connected to +45V.
➤Black wire is connected to GND.
11. Connect motor wires to terminal A1 and A2 of
TB2.
Reverse motor wires position as
compared to original power board.
12. Plug molex connector into CN1.
Make sure wire number 1 of board
molex is plugged into pin 1 of molex
connector.
13. Connect transformer primary wires L2AX and
L1A terminals of TB3.
➤Multiple terminals are furnished for
connecting to HPM/SSC power
supplies.
149-003 (9/2000)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 7(R3) 2000-08-31

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 8(R3) 2000-08-31
Adjusting door operator control
Board 1Ø4®
Adjust door operator control Board 1Ø4®as follows.
■Measure current (optional)
■Set potentiometers
■Adjust door speeds
■Adjust door closing force
■Adjust nudge speed
■Set microswitch cams
Board 1Ø4®could be damaged if
adjustment instructions are not
followed carefully. If you cannot
complete any of procedures as
described, stop and request
assistance.
A604-017 (2/97)
Toggle switches
To adjust and service door control, use two toggle switches on door operator
control Board 1Ø4®— TEST-RUN switch and O-OFF-C switch.
➤TEST-RUN. TEST-RUN switch is normally in RUN position. When
TEST-RUN switch is in TEST position, it disconnects normal open
and close input signals from door control, and switches the O-OFF-
C toggle switch into the circuit.
➤O-OFF-C. O-OFF-C switch is normally in OFF (center) position.
OFF position does not indicate input power has been removed. It
only indicates no signal to open or close when TEST-RUN switch is
in TEST position.
A604-SI5 (2/97)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 9(R3) 2000-08-31
MEASURE CURRENT (OPTIONAL)
CAUTION: Do not install an ammeter in
power supply line.
Current measurements are not required to adjust
door operator control Board 1
Ø 4®. If necessary,
measure current as follows.
1. Connect a voltmeter to resistor R2 (.1 Ohm 5 watt
resistor) located between heat sinks Q2 and D2.
Viewing from TB1 side of control board,
right side of resistor R2 is (-) and left
side of resistor R2 is (+).
2. Set voltmeter to a low range — 1 volt or 2.5 volt.
3. Read measurement with following in mind.
➤1 volt on meter indicates 10 amps of
current.
➤.5 volt on meter indicates 5 amps of
current.
A604-018 (2/97)
SET POTENTIOMETERS
Make sure all potentiometers are set to ZERO,
except P8. Do not set potentiometer P8. It is factory-
set and sealed.
These multi-turn potentiometers
require 25 turns to traverse their
complete range.
A604-019 (3/97)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 10 (R3) 2000-08-31
TIP: If doors do not operate smoothly,
particularly on slower moving doors, it
may help to remove jumper J3. This
eliminates dynamic braking, and
allows a smoother transition between
speeds.
A604-SI6 (2/97)
ADJUST DOOR SPEEDS
1. Disconnect and tag-out power.
2. Remove door operator cover and close doors.
3. Set switches and potentiometer in following
positions.
●All speed control potentiometers - fully
counter-clockwise.
●C.C.L. potentiometer - Fully clockwise.
●TEST-RUN switch - TEST position.
●O-OFF-C switch - OFF (center)
position.
●Two position jumper J4 - just to right,
and slightly above, R01 relay.
(Standard position if one pair of wires
is present at TB3. High Performance if
two pairs of wires are present at TB3.)
4. Apply power. Toggle O-OFF-C switch to “O”
position. LED6 next to “PL” potentiometer
illuminates, indicating doors are in PL zone.
5. Turn “PL” potentiometer clockwise until doors
begin to open. When “PL” microswitch drops,
LED next to “PL” potentiometer goes out, and
LED next to “OF” potentiometer illuminates.
6. Turn “OF” potentiometer clockwise, just enough
to move doors through “OF” speed zone. When
“OSDL” microswitch drops, LED next to “OF”
potentiometer goes out, and LED next to “OS”
potentiometerilluminates.
7. Turn “OS” potentiometer, just enough to move
door through “OS” speed zone. When “OL” cam
activates “OL” microswitch, LED next to “OS”
potentiometer goes out. Doors should be fully
open.
8. Toggle O-OFF-C switch to C position. LED next
to “CF” potentiometer comes on.
9. Turn “CF” potentiometer clockwise until doors
begin to move. When “CSDL” microswitch is
dropped by its cam, LED next to “CF”
potentiometer goes out and LED next to “CS”
potentiometerilluminates.
10. Turn “CS” potentiometer clockwise until “CL”
microswitch is actuated by its CAM. LED next to
“CS” potentiometer goes out. Doors should open
and close at slow speed.
➤If doors do not fully open or close within
20 to 30 seconds, internal timer
removes motor power and LED 7 is lit.
➤If board senses over 5 amps, power
shuts down and LED 7 is lit.
11. Using speed zone potentiometer and CAM
settings, adjust door speeds for desired
performance. Green LED’s indicate which speed
control potentiometer is controlling door speed.
➤Increase door speed — turn
potentiometer clockwise
➤Decrease door speed — turn
potentiometer counterclockwise
Do not set potentiometer P8. It is
factory-set and sealed.
A604-020 (4/97)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 11 (R3) 2000-08-31
Board 1Ø4®

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 12 (R3) 2000-08-31
ADJUST DOOR CLOSING FORCE
1. Toggle TEST-RUN switch to TEST position.
2. Stop doors at mid-point in closing direction by
toggling O-OFF-C switch to OFF position.
3. Turn CCL (close current limit) potentiometer fully
counter-clockwise until doors stall.
4. Turn CCL potentiometer clockwise until desired
door close operation is achieved. Door closing
force should be less than 30 pound maximum
allowed by Code.
5. To check door pressure, physically stall door at
midpoint in closing direction.
6. Place rubber end of a pressure gauge (1) on
edge of power-driven car door (3). Read pounds
of force (2) on gauge and record results.
7. Open and close doors with O-OFF-C switch
several times.
8. Physically stall doors again in closing direction
and re-check door closing force with pressure
gauge.
If door closing force CANNOT be kept
under 30 pounds, contact the door
factory.
A604-021 (9/2000)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 13 (R3) 2000-08-31
When all adjustments are complete,
place O-OFF-C switch in OFF position,
and TEST-RUN switch in RUN position.
Replace door operator cover.
A604-SI7 (2/97)
ADJUST NUDGE SPEED
1. Simulate a nudge signal by placing a jumper on
terminal strip TB-1 between L1A and DO4.
2. Set the TEST-RUN switch to TEST position.
3. Set O-OFF-C switch to C position. Doors should
close at nudge speed.
4. Turn the N potentiometer clockwise to desired
nudging speed.
5. Remove jumper between L1A and DO4 before
returning the TEST-RUN switch to RUN.
F615-010 (2/97)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 14 (R3) 2000-08-31
SET MICROSWITCH CAMS
PM/SSC door operator microswitch cams determine
where changes in door speed occur. Factory
settings are approximate. Set microswitch cams, if
necessary, per individual job requirements.
CL CAM actuates CL microswitch when doors
are in their desired fully closed position.
PL Initial opening CAM drops microswitch
when car door clutch has just engaged
both hoistway door rollers, but should not
drop microswitch if door interlock hangs
up.
OSDL CAM drops OSDL microswitch when
doors are approximately half open.
CSDL CAM drops CSDL microswitch when doors
are approximately 4 inches [10.2 mm] from
their fully closed position.
OL CAM actuates OL microswitch when doors
are in fully open position.
DSD (optional) CAM actuates DSD microswitch
when doors are approximately 4 to 6 inches
[10.2 to 15.2 mm] from fully closed position
when used with load balancing. CAM can
also be set for other customer
requirements.
F615-009 (2/97)

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 15 (R3) 2000-08-31
Door in closed position
Door in open position

Door Control Board: Board 1Ø4® for PM/SSC
Product Instruction
© 2000 KONE Inc. 61111-149
All rights reserved. 16 (R3) 2000-08-31
NOTES