Kone ReSolve 200 User manual

KONE ReSolve 200
Installation Instruction
1 (258) AM-10.65.001
(D) 2013-04-17
© 2009 KONE Corporation
All rights reserved.
KONE ReSolve 200AM-10.65.001© 2009 KONE CorporationAll rights reserved.(D) 2013-04-17
KONE RESOLVE 200, 
SINGLE / FLEXIBLE MAN INSTALLATION INSTRUCTION
1067629.wmf

KONE ReSolve 200
Installation Instruction
2 (258) AM-10.65.001
(D) 2013-04-17
© 2009 KONE Corporation
All rights reserved.
Confidentiality Notice
This proprietary and confidential document is provided to you only for purposes of installing
and/or maintaining KONE products and it may not be used or its contents disclosed for any
other purpose without KONE's prior written permission. Neither this document nor its contents
may be copied or disclosed to third parties for any reason. KONE reserves the right to
prosecute any breach of this obligation.

Authorization Notice
This publication is for informational purposes only. All persons participating in the installation
and/or maintenance of KONE equipment and using these instructions must be qualified to
perform such work, are required to have received equipment specific training as specified by
KONE and must have KONE Corporation's authorization to install and maintain KONE
equipment.

DISCLAIMER OF WARRANTIES AND LIABILITIES
KONE reserves the right at any time to alter the product design, specifications and
procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT
IS TO BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED, AS
TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR
REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT.

KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION WITH THE
USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO
LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN
THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE
USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR
DISCLOSURE OF THIS DOCUMENT.

Trademark Notice
"KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE ECO3000 and all
other product names are trademarks or registered trademarks of KONE Corporation in
various countries."
Copyright Notice
Copyright © 2009 KONE Corporation
All rights reserved. No part of the contents of this document may be copied, reproduced or
transmitted in any form or by any means, or translated into another language or format, in
whole or part, without prior written permission of KONE Corporation.

KONE ReSolve 200
Installation Instruction
3 (258) AM-10.65.001
(D) 2013-04-17
© 2009 KONE Corporation
All rights reserved.
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special things about the method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
One fitter / two fitters working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
General safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conditions for safe operation of elevator control system . . . . . . . . . . . . . . . . . . . . . 14
Installation method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protecting work areas with safety fences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Public safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Determining need for car top balustrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pit access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safe access to all work areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SITE REQUIREMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ride comfort measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1 RECEIPT AND CONTROL OF MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 Checking of packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Transporting materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Unloading materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2PREPARATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Safety fences and signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Checking the power sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Checking safety gear operation and overspeed governor. . . . . . . . . . . . . . . . . . . . . 30
2.4 Checking overtravels and safety spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Marking the sling and car position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Measuring travelling cable loop length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Checking the car and counterweight balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Preparing the access for the travelling cables and the shaft bundle. . . . . . . . . . . . . 34
2.9 Installation of shaft lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 INSTALLING TRAVELLING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Installing travelling cable: Machinery below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Installing travelling cables: Machinery above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Dismantling old car equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

KONE ReSolve 200
Installation Instruction
4 (258) AM-10.65.001
(D) 2013-04-17
© 2009 KONE Corporation
All rights reserved.
3.4 Installing car top connection box and inspection drive unit. . . . . . . . . . . . . . . . . . . . 45
3.5 Routing cables to car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6 Connecting the travelling cable in the car top connection box . . . . . . . . . . . . . . . . . 47
3.7 Temporary wiring of car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.8 Fixing sensor unit to car roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9 Installing the wire hanger and limit switch in top of the shaft. . . . . . . . . . . . . . . . . . . 50
4 INSTALLING TOP SERVICE LIMIT RAMP (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Installing top service limit ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 DISMANTLING OLD MACHINE ROOM EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1 Marking the wires in the old control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Removing old equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 INSTALLATION AND WIRING OF MACHINERY / CONTROL PANEL . . . . . . . . . . . . . . . 59
6.1 Position the control panel according to the site survey . . . . . . . . . . . . . . . . . . . . . . . 60
6.2 Re-use / installation of trunking for travelling cable and elevator shaft wiring. . . . . . 63
6.3 Routing of wiring between controller panel and machinery. . . . . . . . . . . . . . . . . . . . 64
6.4 Snelis devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.5 Specific routing for V3F motor supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.6 Connecting the extension tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.7 Connecting travelling cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.8 Connecting machine room equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.9 Installing and connecting power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.10 Wiring other machine room equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7 COMMISSIONING FOR SERVICE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2 Preparations before turning the power on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.3 Reset button at KMI (KONE Maintenance Interface) . . . . . . . . . . . . . . . . . . . . . . . . 83
7.4 Example of setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.5 Checking of inverter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.6 Non-rotational autotuning of K1000 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.7 Driving the elevator for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.8 Preparation for driving the elevator on the car roof. . . . . . . . . . . . . . . . . . . . . . . . . . 90
8 INSTALLATION OF SHAFT LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.1 Installing elevator shaft lighting, if applicable (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.2 Installing elevator shaft lighting, if applicable (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9 REMOVING OLD ELEVATOR SHAFT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1 Removing of old levelling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2 Remove old limits and floor switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.3 Remove landing bands / support wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.4 Removing old travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

KONE ReSolve 200
Installation Instruction
5 (258) AM-10.65.001
(D) 2013-04-17
© 2009 KONE Corporation
All rights reserved.
10 INSTALLING THE HANGING WIRES AND POSITIONING MAGNETS . . . . . . . . . . . . . . 100
10.1 Hanging the wires at top of the shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.2 Fixing the wires in the pit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.3 Installing bottom service limit ramp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.4 Installing positioning magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
11 INSTALLATION OF SHAFT BUNDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
11.1 Installation of shaft bundle and trunking (serial, machinery above). . . . . . . . . . . . . .110
11.2 Installation of shaft bundle and trunking (serial, machinery below). . . . . . . . . . . . . .114
11.3 Installation of shaft bundle and trunking (parallel, machinery above) . . . . . . . . . . . .119
11.4 Installation of shaft bundle and trunking (parallel, machinery below) . . . . . . . . . . . 122
11.5 Finalising new elevator shaft lighting (if included). . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.6 Finalising the travelling cable installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11.7 Re-connecting travelling cables, if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
11.8 Taking the shaft bundle to the machine room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
11.9 Connecting shaft bundle (safety chain) in to the control panel . . . . . . . . . . . . . . . . 130
12 CONNECTING LANDING DOORS LOCKS AND BUTTONS . . . . . . . . . . . . . . . . . . . . . . 131
12.1 Positioning of the car. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12.2 Connection of landing door lock (serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
12.3 Wiring of landing call buttons (serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
12.4 Connection of landing door lock (parallel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
12.5 Wiring of indicators and optional landing devices (parallel) . . . . . . . . . . . . . . . . . . 144
12.6 Connecting shaft bundle (signalization) in to the control panel. . . . . . . . . . . . . . . . 154
13 REMOVING THE OLD SHAFT BUNDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
14 INSTALLATION AND WIRING OF ALL CAR EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . 156
14.1 Dismantling old car equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
14.2 Installation of door control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
14.3 Installation of parallel I/O box (only with parallel signalization) . . . . . . . . . . . . . . . . 160
14.4 Installation of ACU box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
14.5 Wiring of car top connection box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.6 Wiring of old car light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
14.7 Wiring of old car fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
14.8 Wiring of ADV door operator (Isola 96, Athena 96, Renova 96) . . . . . . . . . . . . . . . 164
14.9 Wiring of retiring ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
14.10 Wiring of door inverter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
14.11 Wiring of contactor control door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14.12 Wiring of Starlift door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
14.13 Wiring of ADF - ADX door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
14.14 Wiring of AMD door operator (Drive 1, 1.5 and 2). . . . . . . . . . . . . . . . . . . . . . . . . . 178
14.15 Wiring of DC2000 door control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
14.16 Wiring of KOF230V, C-type door control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
14.17 Wiring of ADT 3PH 125V door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

KONE ReSolve 200
Installation Instruction
6 (258) AM-10.65.001
(D) 2013-04-17
© 2009 KONE Corporation
All rights reserved.
14.18 Wiring of close command door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
14.19 Wiring of FIAM B/S door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
14.20 Wiring of Sabiem C door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
14.21 Wiring of ACC 230V door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
14.22 Wiring of general 24V electronic control door operator. . . . . . . . . . . . . . . . . . . . . . 197
14.23 Wiring of Selcom 1PH 220V automatic door operator. . . . . . . . . . . . . . . . . . . . . . . 199
14.24 Wiring of no car door, EMO N, AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
14.25 Wiring of BOF unit for non-automatic doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
14.26 Wiring of new COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
14.27 Wiring of old COP and display (if any, parallel I/O module). . . . . . . . . . . . . . . . . . . 204
14.28 Connection of ACU, if applicable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
14.29 Connection of KRM, KSS ReVive signalization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
14.30 Connection of KRM, parallel signalization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
14.31 Wiring of car extension door (CED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
15 FULL SPEED ADJUSTMENT / COMMISSIONING / SAFETY INSPECTIONS . . . . . . . . 210
15.1 Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
15.2 Selecting roll call type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
15.3 Selecting LWD type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
15.4 Shaft setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
15.5 Connecting FRD / FID (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
15.6 Adjusting motor no load current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
15.7 Checking creeping time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
15.8 Motor slip compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
15.9 Floor level adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
15.10 Final steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
15.11 External options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
15.12 Commissioning of the car door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
15.13 Check the parameters for door inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
15.14 Checking KCE board versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
15.15 Testing landing door locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
15.16 Testing safety contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
15.17 Measuring insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
15.18 Measuring earth continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
15.19 24 VDC ground fault test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
15.20 Testing operation of RCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
15.21 Speed measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
15.22 Current measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
15.23 Testing the final limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
15.24 Drive time supervision (DTS) test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
15.25 Buffer tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
15.26 Overspeed governor test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
15.27 Safety gear test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

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15.28 Ride comfort /Special V3F10 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
15.29 Setting the elevator to normal use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
15.30 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
16 HANDLING WASTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
17 HANDOVER TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
17.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
17.2 Handover form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
17.3 Autocontrol form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
17.4 Ride comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
17.5 Installation quality checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
18 APPROVALS AND VERSION HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
APPENDIX A. Changing the characteristics / V3F10 K1000 LED user interface . . . . . . . . . . . . 250
APPENDIX B. Control panel introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
APPENDIX C. Locking and unlocking Yaskawa parameter menus. . . . . . . . . . . . . . . . . . . . . . . 256
APPENDIX D. Estimating the mass of the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
APPENDIX E. Speed parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

KONE ReSolve 200
Installation Instruction
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© 2009 KONE Corporation
All rights reserved.
GENERAL
This installation method is designed to guarantee not only the working efficiency but also the
safety of the fitter and other people in the building.
This manual includes several variations for the elevator configuration, but on site is delivered
only the pages that suit the actual installation. The selected variation is depending on:
• Machine room position
• Drive type
• Door type
• Position of the limit switches (on the car or in the elevator shaft)
• Local options
Follow the method that is described in the documentation delivered on your site. Do not
make your own short cuts of the method. Do the installation in the same order as described in
the instruction that you get for each job.
Validity
This instruction is valid for installations of elevators with KCE electrification and V3F10 drive.
In case of alternatives in the described method, select the correct way according to the
location of the site.
Installation method
With this installation method, it is possible to:
• Identify easily the equipment in the packages. The material is grouped together according
to different phases and work places.
• Wire and connect easily, without the circuit diagram.
• Know the future phases of work and if necessary, to arrange the assistance of another
technician.
If there are several MMS packages, the best moments to install them are:
Phase MMS package
Phase 14: New car interior
New car door
New signalization in car
Phase 5: New machinery
Phase 12: New landing signalization

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Special things about the method
This work must not disturb the normal operations or elevator users in the building. The
working times must be agreed with the building owner carefully.
If the elevator is a member of an elevator group the operation of the existing group control
must be guaranteed during the works.
When the connections between the old group and/or the other elevators and this elevator are
disconnected, agree with the customer about the procedure and timing. Follow local rules.
In case the elevator is connected to external alarm systems (KONEXION), the forwarding of
alarms must be inhibited for the installation time.
Temporary connections for landing locks and service drive limit switch are needed.
To ensure public safety and your own safety, this method uses a special tool to connect the
old and new safety circuits in series by overconnecting the landing door locks.
Installation of shaft light can be done first if the elevator has a car inspection box.
Related documents
For more information, see:
•AM-01.03.001 Take 5 - Electrical safety when working on elevators
•AM-01.03.010 Safe working in elevator shaft and machine room areas
•AM-01.01.085 Planning guide and general instructions for low-rise elevator dismantling
•AM-12.20.005 KONE signalization system (KSS) installation
•AS-11.65.004 Replacement of V3F10 and V3F10CL drive module (V3F inverter unit)
•AS-10.60.001 Site reference guide for KONE MMS Resolve 10 and 20 electrification
•AS-10.65.006 Diagnostic guide for KONE ReSolve 200 commissioning
•AS-10.65.007 Fault finding instruction for KONE ReSolve 200
•AS-12.02.001 Instruction for handling electrostatic-discharge-sensitive-devices on site
•UM-10.65.001 User manual for KCE removable user interface
•UM-10.65.002 KONE Maintenance Interface, European Norm Version
•1374567 KCE parameter list
•958174D01 KCE fault code list
•773556D01 Door inverter instructions
•873805 V3F10/K7/K1000 Yaskawa drive parameter list
•878327 V3F10 fault codes
•834948 Tool for calculating V3F open loop parameters
•TC000034 KCE Electrification, Core learning guide
•TC000035 KONE ReSolve 200 Electrification Core Training Guide
•TC000036 V3F10 Drive Core Learning Guide
•TC000037 KCE Electrification, Special Technology
•TC000123 KCE KONE Maintenance Interface, Core learning guide

KONE ReSolve 200
Installation Instruction
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All rights reserved.
One fitter / two fitters working
The table below indicates in which phases of the installation two fitters are required and when
the installation can be undertaking by a single fitter.
This is indicated using symbols in the beginning of the chapters.
= One fitter working
= Two fitters working
Installation phases one / two fitter(s)
1Receipt and control of material (two fitters for transportation of
new material)
2Preparations OR
3Installing travelling cables
4Dismantling old machine room equipment
5Installing and wiring of machine room equipment
6Start-up
7Installing top service limit ramp
8Installing shaft lighting
9Removing old elevator shaft equipment
10 Installing hanging wires
11 Installing shaft bundle and positioning magnets
12 Connecting landing door locks and buttons
13 Removing old shaft bundle
14 Installing and wiring of car equipment
15 Installing floor level flags
16 Full speed adjustment / commissioning
17 Removing old equipment

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SAFETY
To ensure your safety and the safety of those around you, it is important that you read,
understand, and follow ALL the safety precautions relative to a particular task. In particular it
is important to read and understand any risk assessed method statements made at the time
of the safety survey.
Related safety instructions:
• AM-01.03.001, Use of fall prevention systems when working on elevators and escalators
Fall prevention planning is a mandatory requirement whenever either employees or the
general public are at risk of injury from falling during equipment installation, removal or
maintenance operations. Fall arrest systems must be used in accordance with local code
requirements when there is a risk of falling and it is not possible to remove the risk by
other means (e.g. balustrades). Use of harnesses must always be considered as a final
resort if it is impossible to remove the hazard by other means. Serious injury or death may
still be sustained after a fall wearing a harness in an enclosed space.
• AM-01.03.002, Take 5 - Electrical safety when working on elevators
• AM-01.03.003, Take 2 - Double security safety practice when using Tirak hoist for man-
riding purposes
Take 2 is the workplace protective practice of double-securing to prevent risk of falling
when using either a temporary platform or the elevator car for man riding when using the
Tirak hoist. The requirement to enforce this practice is part of KONE Safety policy. The
suitability of this method for a particular site requires inspection by a trained person. The
safety survey must be documented, completed and visible before hoist usage is allowed.
• AS-01.01.004, Take Care, End user safety focal points in elevator maintenance
• AM-01.03.009, General instructions for material handling, using transportation and lifting
equipment
• AM-01.03.010, Safe working in elevator shaft and machine room areas
• Site safety audit
Take time to familiarise yourself with the elevator. This is particularly important when working
on other manufacturer’s equipment where the level of training and information available may
vary and circuit diagrams are in an unfamiliar style.

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Ensure you have adequate information to do the work and fully understand all the
possible effects of your actions.
- IF IN DOUBT - ASK.
Talk to your supervisor if you have any doubts about the working method or safety related
issues.
Any local variations to the method must be supported by a local method statement and risk
assessment.
Additional electrical safety measures:
• Use an approved multimeter (Fluke 179 or equivalent) on all circuits. Use fuse pullers to
change or remove fuses. NEVER use fingers, pliers or screwdrivers. Covers on exposed
electrical devices or wires MUST be installed to protect personnel from injury or shock.
• ALL landing doors, car and sling, connection boxes, switch boxes, transformer casings,
controller and tank must be verified for effective grounding to prevent shock to personnel
and to ensure that protective fuses operate (particularly where protection is provided using
residual current device (RCD)).
• When using a portable electric meter, DO NOT connect one wire and leave other wires
dangling loose.
• Before powering up a circuit, make sure that all is clear. This is necessary in order to
protect personnel from injury and to prevent damage to the equipment.
• Avoid accidental contact with equipment or conductors which are known to be live or are
NOT known to be de-energised. If it is necessary to work on equipment while it is hot,
extra care must be observed.
• TAKE TIME TO BE CAREFUL! Following safety precautions and using common sense
will prevent injury, mutilation, or death.
• During the safety survey the salesman/engineer will have made a detailed analysis of the
existing installation and will have detailed notes concerning which parts of the electrical
system need to be over-connected and which circuits must be isolated for the dismantling
operation, if the powered car system is to be used.

KONE ReSolve 200
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General safety
• Introduce yourself to site agent or person responsible for the building.
• Read the comments from the site safety survey.
• When working in buildings that are occupied, ensure therefore that your work cannot
cause a safety hazard to other people in the building.
• Place warning and information signs as required.
• Use barriers whenever necessary.
• Take care that the communication between fitters and between the fitters and other
building users is effective.
• When two or more persons are working on the same elevator, one person should be in
charge of control and access keys and safe and appropriate car movements. When the
car must be moved, the responsible person must inform the other(s) of the intended car
movements beforehand.
• Ensure that the main supply is locked and tagged.
• Report any defects or other dangerous conditions to your supervisor.
• Ensure that ALL DOORS (machine room, pit, access and inspection doors) are locked at
all times when unoccupied by authorised personnel.
• Cover any unused holes in the machine room floor with steel plates.
• Install temporary screens in common elevator shafts and machine rooms, where adjacent
elevators are running and there is no dividing screen.
• In machine rooms where adjacent elevators are running ensure that all work areas are
protected with barriers.
• Liaise with the building owner or his representative in cases where there are elevator
groups where adjacent elevators are running and passenger traffic in the lobby area may
interfere with your work. Ensure that all work areas are protected with barriers and that
access routes for other building users are safe. Refer to the site safety survey.
• If you suspect that hazardous materials are present, stop the work. Inform your supervisor
who will arrange for a specialist to check the installation. Disposal of hazardous material is
always a specialist’s job. Never attempt to do this yourself. Refer to the site safety survey.
• Hot work should be avoided wherever possible by applying tools and methods that do not
cause risk of fire. If hot work (disc cutting, flame cutting and so on) cannot be avoided,
local work procedures for the necessary routines and equipment shall be followed. Refer
to the site safety survey.

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Conditions for safe operation of elevator control system
Installation conditions:
• It needs to be ensured by the selection of an appropriate place of controller and car roof
box that environmental influences like water, conductive dust and condensation don’t
have a negative impact to the safety circuit (KCEMSC, KCEFUI, KCECCG).
• It shall be ensured that all cabinet and enclosure doors and lids are closed when lift is put
in service.
24 Vdc system:
• Only 24Vdc power supplies approved by KONE shall be used in order to guarantee
electric safety and safety circuit reliable operation.
• In order to detect first ground fault of the safety circuit, the minus (-) of 24Vdc circuit shall
be connected protective earth (PE). Connection to protective earth is made with
connection of KCECPU PE terminal to control panel PE. The minus (-) of 24Vdc circuit
shall not be connected to PE in any other location of the system.
Safety contacts and related wiring:
• Only safety contacts in conformance with EN 81-1, clause 14.1.2.2 or switching elements
with at least the same safety level shall be connected to the safety inputs of the system.
Contacts shall be forcibly guided. Use of magnetically operated reed switches or similar is
forbidden.
• Safety contact wiring shall fulfill the requirements for short-circuit-proof. When safety
circuit wiring is installed in same conduit or trunking with other circuits, safety circuit
conductors shall be insulated for the highest nominal voltage present.
Installation method safety
Ensure that the safety of all lifting points has been verified in accordance with local
regulations.

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Personal protective equipment
Safety gloves, safety footwear, safety helmets, eye protection, dust masks, hearing protection
and fall protection equipment are supplied for your personal protection. USE THEM AS
REQUIRED.
Special precautions to limit injury in the event of a fall
Safety item
Safety harnesses and associated equipment. Refer to AM-01.03.001.
Dust mask, suitable for working with mineral wool insulation in landing doors.
First aid kit.
Eye protection.
Safety gloves.
Rubber gloves for protection when cleaning rails.
Hearing protection.
Safety helmet.
Work clothes / overalls.
Safety footwear with ankle protection.
WARNING
If the safety harness and its associated
equipment are not used correctly you may still
sustain severe injury or death during a fall.
Requirements
Always use the harness attached to an approved fixing point when there is a risk of falling
and you are working 1.8 m or more above a lower level. Refer to AM-01.03.001.
It is recommended that you attach the harness to a fixing point at least 2.0 m above the
working height.
Where this is not possible keep the lanyard AS SHORT AS POSSIBLE to minimize your
free fall. (Be aware of the effect of rope and harness stretch when estimating the likely drop
area and consider the risk from possibly dangerous striking points like guide rail brackets.)
If you are likely to fall down the side of the car you must try to minimize the free fall
distance to 300 mm or less.
If you have attached the harness to a guide rail bracket or other fixed point in the elevator
shaft you must ensure that there can not be any unwanted movement of the working
platform.
When your safety harness is not secured to a life line or other approved fixing point, ensure
that the lanyard does not cause a catching or tripping hazard.

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Protecting work areas with safety fences
Entrance protection must be:
• Lockable
• Openable without key from inside
• Imperforate or at minimum preventing contact with exposed components that can be a
safety risk.
Public safety
• Keep the working area closed to the public at all times.
• Keep the area outside the working area clean.
• Store materials in designated storage areas. Not on landings or in working area.
• In residential buildings keep to the agreed daily working schedules to avoid unnecessary
disturbance to residents.
• When transporting material into the elevator shaft, use additional safety fences or
guarding.
When not working at the
landing.
Closed landing door or
fence covering the whole
door opening.
Working on the car roof.
Closed landing door or car
atlanding andfenceclosing
the landing door area.
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Safety signs
The following safety signs are used in this instruction as highlights.
Determining need for car top balustrade
When working on car roof the need for car top balustrade must be determined.
When there is a risk of falling from height that can cause injury, car top balustrades/railings
must be fitted and raised before accessing or man riding on an elevator car top.
Possible differences between this instruction and local safety regulations must be
considered. Dimensions and rules in this instruction fulfil requirements set in EN 81-1. If local
requirements are at a higher level than described in this chapter, then they must be followed.
In case of conflict between requirements, follow the local legal requirements.
If working on old equipment where no balustrade exists then additional protective measures
must be taken as defined by risk assessment. Solutions may be based on use of temporary
portable balustrades/rails or fall restraint solutions. If fall arrest is used then special care must
be taken to define rescue measures, in case of fall.
Turn main
power OFF Lock and tag the switch Verify de- energization Push the stop button OFF Fall prevention measures

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Pit access
See AM-01.03.010, Safe working in elevator shaft and machine room areas.
Safe access to all work areas
See AM-01.03.010, Safe working in elevator shaft and machine room areas.
Step Action Note
1Measure the distances between the car
wall and the elevator shaft wall.
If the gap is less than 300 mm the
balustrade is not needed.
NOTE!For hydraulic elevators, prevent
upwards movement before working
on car roof by disconnecting the up
direction solenoid.
2If the gap is 100 mm to 299 mm, fix the
kick plate.
3If the gap is 300 mm to 850 mm, use at
least 0.7 m high balustrade.
4If the gap is larger than 850 mm, use a
1.1 m high balustrade.
If the clearance between thebalustrade
top bar and the lowest obstruction in
the headroom when the counterweight
is on the buffer or when the cylinder is
fully extended (hydraulic elevators)
would be less than 300 mm,
temporarily increase the height of
counterweight buffer or use props.
5If the landing doors have been
removed, the gap on the landing side
may exceed 300 mm.
In that case, install an extra detachable
handrail (provided locally) to the
balustrade on the landing side.
Refer to site survey if available.
6If it is not possible to use a balustrade,
fall arrest equipment must be available.
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SITE REQUIREMENTS AND TOOLS
Site requirements
Familiarise yourself with the data that is collected earlier from this elevator site. Read the
order form for the positions and critical dimensions of the elevator (machine room, car roof
and elevator shaft equipment).
In addition to the normal survey made when the quotation is prepared a site safety audit is
essential before any work can commence.
• Machine room and car roof layout documents must be available.
• Transportation of equipment to the machine room must be planned. Transportation routes,
transportation loadings and lifting point loadings must be planned.
• Suitable secure material storage areas must be agreed with building owner, adjacent to
the elevator shaft.
• Clear and unobstructed access routes must be defined.
• Suitable provision for disposal of waste materials must be available, according to local
requirements.
• Adequate lighting, temporary or permanent, must be installed.
• Lifting points must be correctly positioned in the machine room and marked with the safe
working loads.
• All building work must be planned and agreed with the building owner.
• All required electrical work, for example new main supply, must be done.
• Installation of shaft light can be done first if the elevator has a car inspection box.
WARNING
Ensure that the car and counterweight are balanced to 50%.

KONE ReSolve 200
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Tools
• Normal hand tools
• 2x PERI adjustable multi prop 250. See APPENDIX D., Estimating the mass of the
counterweight.
• 2x Pit prop fixing
• Two chains for securing the car according to mass
of car + 200 kg.
• Manual chain hoist for lifting of control panel to the
machine room (200 kg capacity).
• Multimeter (Fluke 179 or equivalent) and long
insulated test probes (minimum length 100 mm)
• Electrostatic Discharge (ESD) kit, KM857505
• RUD eye bolts (optional)
• Working stool / scaffolds
• Insulation resistance meter
• Handheld tachometer
• Electric drill
• Portable crane
• Extension tool KM796238G10050 for landing
doors
• Pull rope, minimum length = Elevator shaft height + 5 m.
• KONE MiniConsole
NOTE! These tools can be used in several KCE installations, store them for later use.
• Group of parts, cabinet trolley adapt
KM5002834R01 including:
• lifting handles KM796643H51
(see 6.1.1, Transporting and hoisting
the control panel)
• stair-climber wheels and frame
KM50012010G01
• Extension tool KM796238G10050
(see 6.6, Connecting the extension tool)
• Installation tool, plug
KM796239G10070
(see 6.6, Connecting the extension tool)
• Shaft light installation tool
KM796237G10300
(see 8, Installation of shaft lighting)
• 24V DC ground fault test wire
KM796185G10100
• Magnet installation tool (optional)
KM50086979G01
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