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KONE ECO3000™ Escalator

Installation Guide

© 2002 KONE Corporation AM-51.01.106

All rights reserved. E - 1 (C) 2002-06-17

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CONTRACT-SPECIFIC COMPONENTS

Installing step guards - standard balustrade E-2Installing step guards - extended balustrade E-4

Installing apex & deck guards E-5

Installing deck guards - ANSI E-8

Checking & adjusting automatic oiler (if equipped) E-10

Installing contact mat - EN 115 E-12

Installing intermediate (common center) deck E-14

Installing skirt brush guards (if equipped) E-15

Checking & adjusting auxiliary brake - EN 115 E-16

Checking & adjusting brake release &pad wear monitors (if equipped) - EN 115 E-18

Adjusting inverter E-19

Installing handrail lights - EN 115 E-20Installing skirt lights - EN 115 E-22

Installing skirt spot lights - EN 115 E-24

Checking access cover switches E-25



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- C o n t r a c t - s p e c i f i c c o m p o n e n t s


Installation Guide



Installing step guards - standard balustrade Complete the following to install step guards for a

standard balustrade.

1. Position step guard (1) with bottom lip of guard

underneath lower mounting bracket (2).

2. Insert upper mounting hardware (3), and tighten.

ä If height of step guard (1) must be

adjusted, adjust jam nuts (4).707-038 (6/2001)



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Installation Guide





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KONE ECO3000 ™ Escalator Installation Guide



Installing step guards - extended balustrade Step guards for extended balustrades are designed

to be adjustable. This adjustable design allows stepguards to be inserted at a narrow width into the pit,then, adjusted to the required width for installation.

Complete the following to install step guards for anescalator with extended balustrade.

1. Loosen adjusting wing nuts (1), adjust step

guard to a width narrow enough to fit into pit, andinsert step guard(2) in pit.

2. Adjust width of step guard, and position stepguard with bottom lip of guard underneath lower

mounting bracket (3).

3. Insert upper mounting hardware (4), and tighten.

ä If height of step guard (2) must be

adjusted, adjust jam nuts (5).707-176 (6/2001)



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Installing apex & deck guards

All apex (1) and deck (2) guards must be installed

prior to handover to Customer. Apex and deckguards are installed for the following basic escalator

arrangements.

ä A= Ceiling intersection apex guards are

required if distance between escalatorsand floor is less than 360 mm [14-1/8

inches].

ä B = Escalator truss intersection apexguards are required if distance betweenescalators is less than 360 mm [14-1/8

inches].

Refer to local governing Codes thatmay supersede dimensions (A, B)

described above.

Single escalator

Parallel escalators



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Criss-cross escalators

Scissored escalators



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Mounting apex guards on truss and ceiling

Installing apex guards & deck guards

Complete the following to install apex and deck

guards.

1. Position escalator intersection apex guard (1) at

intersection of escalators.

2. Mark location for mounting hardware (2) intotruss tube (3).

3. Remove apex guard, and drill and thread holesfor mounting hardware into underside of truss

tube.

4. Position apex guard, and mount with hardware.

5. Position and mount intersection apex guard (4)on ceiling.

6. Position and mount deck guard (5) on outer

deck.707-036 (12/99)



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Installing deck guards - ANSI Complete the following to install deck guards at the upper end and lower end of the escalator.

INSTALL DECK GUARDAT UPPER END

Install deck guard on horizontal deck 305 mm [12 in.]from end of deck.

1. Remove handrail from handrail guide at upper

end.

2. Locate position of mounting hole in deck 305

mm [12 in.] from end of deck (1) and 75 mm [2-15/16 in.] from glass (2).

3. Drill a 5.2 mm hole in deck, and tap for M6

mounting bolt (3).

4. Mount bottom panel holder (4) to deck (1) with

M6 mounting bolt (3). Tighten M6 mounting bolt(3) to secure panel holder (4).

5 Assemble top panel holder (5) to mounting

bracket (6), and loosely mount this assembly (5,6) to deck guard panel (7).

6. Position deck guard assembly (5, 6 ,7) in bottompanel holder (4).

7. Level the deck guard, and mark the location forthree mounting bolts (8) on handrail base (9).

8 Remove deck guard assembly (5, 6 ,7) from

bottom panel holder (4), and remove deck guardpanel (7) from top panel holder and mounting

bracket assembly (5, 6).

9. Drill a 4.5 mm hole through handrail guide andbase so that holes exit at the three locationspreviously marked.

10. Install top panel holder and mounting bracket

assembly (5, 6) on handrail base and guide

using mounting screws (8).11. Install deck guard panel (7) into bottom panel

holder (4) and top panel holder (5), and tighten.

INSTALL DECK GUARDAT LOWER END

Install deck guard on incline deck 1 meter [39-3/8 in.]above finished floor height.

1. Remove handrail from handrail guide at lower

end.

2. Locate position of mounting hole in deck 1 meter

[39-3/8 in.] above finished floor and 75 mm [2-15/16 in.] from glass (2).

3. Drill a 5.2 mm hole in deck (1), and tap for M6

mounting bolt (3).

4. Mount bottom panel holder (4) to deck (1) with

M6 mounting bolt (3). Tighten M6 mounting bolt(3) to secure panel holder (4).

5 Assemble top panel holder (5) to mounting

bracket (6), and loosely mount this assembly (5,6) to deck guard panel (7).

6. Position deck guard assembly (5, 6 ,7) in bottompanel holder (4).

7. Using a square, position deck guardperpendicular to the deck, and mark the location

for three mounting bolts (8) on handrail base (9).

8 Remove deck guard assembly (5, 6 ,7) frombottom panel holder (4), and remove deck guard

panel (7) from top panel holder and mountingbracket assembly (5, 6).

9. Drill a 4.5 mm hole through handrail guide andbase so that holes exit at the three locations

previously marked.

10. Install top panel holder and mounting bracket

assembly (5, 6) on handrail base and guideusing mounting screws (8).

11. Install deck guard panel (7) into bottom panel

holder (4) and top panel holder (5), and tighten.707-208 (5/2002)



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Installing common center deck guards - ANSI

Install common center deck guards in the same manner as described for standard deck guardswith the following exception.

ä Install lower end common center deck 305 mm [12 in.] from end of deck.

Do not install a common center deck at 1 meter [39-3/8 in.] above finishedfloor at lower end.

707-209 (5/2002)



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Setting pulse length & delay - EN 115

The pulse length and delay between pulses (for automatic oiler) are set by operational parameters inthe controller.

Pulse length (lubrication pump on time)

l Set operational parameter 19 (MINUTES) to 00.

l Set operational parameter 20 (SECONDS) to 02.

Delay between pulses (lubrication pump off time)

Delay between pulses is dependent on rise and whether the escalator is indoors or outdoors.

Values below are starting point values for an INDOOR escalator with a vertical rise

of 4.5 m. Parameters must be checked after first maintenance is completed andadjusted accordingly.

Values for escalators that are OUTDOORS and with different vertical rises may bedifferent.

l Set operational parameter 21 (HOURS) to 01.

l Set operational parameter 22 (MINUTES) to 10.

l Set operational parameter 23 (SECONDS) to 00.

707-183 (7/2001)

Checking & adjusting automatic oiler (if equipped) Complete the following to check and adjust automatic oiler.

1. Check brushes (1) for correct position at lubricating pointson step chain. Adjust brushes, if necessary.

2. Check oil level in reservoir (2). Fill with clean oil.

Make sure oil is absolutely clean when fillingautomatic oiler.

3. Check fitting connections for leakage. Tighten connections,if necessary.

4. Set pulse length and time delay between pulses.707-223 (5/2002)



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Installing contact mat - EN 115 Complete the following to install contact mats.

1. Clean dust and grease from access frame (1).

2. Apply two strips of adhesive tape (2) side-by-side

to access frame.

3. Position contact mat (3) on top of adhesive tapelayer (2).

Make sure contact mat connectors (X2)

(X3) are positioned for connection tojunction box (4).

Make sure contact mat is flat and not

buckled. Any buckling of glass fibercable (contact mat) can cause damage

to the cable.

4. After determining contact mat (3) is in correctposition, glue contact mat to access frame.

5. Apply two strips of adhesive tape (5) side-by-sideto contact mat.

6. Position and glue stainless steel plates (6) to

adhesive tape layer (5).

Make sure stainless steel plates do nothave any sharp edges that could

damage contact mat.

7. Connect contact mat receiver (X2) andtransmitter (X3) cable connectors to junction box

(4).

Both connectors (X2) (X3) are labeledin the junction box.

ä The longer end of the cable is thereceiver connection (X2).

ä The shorter end of the cable is the

transmitter connection (X3).

707-177 (6/2001)



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Installing intermediate (common center) deck Complete the following to install intermediate deck.

1. Starting at lower end, insert intermediate deck(1) between outer deck trim (2).

ä If distance between trusses is greaterthan 250 mm [9-7/8 in.], insertintermediate deck sections (1) between

deck trim (2) and on top of intermediatedeck support brackets (3).

2. Insert intermediate deck sections up the incline

to make-up section (section next to upper end

intermediate deck section).ä Make sure intermediate deck joints are

smooth and that there are no gapsbetween deck sections. File or cut ends

if necessary to achieve a good fit.

3. Insert upper end intermediate deck section.

4. Measure, cut, fit, and install make-up section ofintermediate deck.

707-179 (6/2001)



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Installing skirt brush guards (if equipped)

Skirt brush guards (1) are mounted to a plastic (or

aluminum) profile (2) that is mounted to the skirt (3)with self-tapping screws (4). Complete the followingto install skirt brush guards.

1. Mount plastic profile (2) to skirt (3) with self-

tapping screws (4).

ä Horizontal end sections: position and

mount bottom of plastic profilebetween 25 mm and 50 mm [1 in. and2 in.] from step nose.

ä Incline sections: position and mount

bottom of plastic profile 25 mm [1 in.]

with a tolerance of +2 mm/-0 mm [+5/ 64in./-0 in.] from step nose.

2. Slide skirt brush guards (1) into profile (2).

3. Install end cap (5).707-178 (6/2001)



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Adjust brake wear reserve

Checking & adjusting auxiliary brake (1)

Checking & adjusting auxiliary brake - EN 115 Complete the following to check and adjust the brake.

n Check & adjust brake wear

n Check & adjust brake stopping distance

CHECK & ADJUST BRAKE WEAR

Adjust the brake wear reserve by adjusting the spacebetween brake-arm (1) and pin (2) to 2 mm [5/64 in.] as

follows.

1. Move hole in step band above the brake, turn main

power supply OFF, and engage step band lock.

2. Loosen lock-nut (3).

3. Adjust spacing to 2 mm [5/64 in.] at pin (2).

4. After adjusting to this dimension, lock pin (2) with nut

(3).

5. Check spacing again and readjust if necessary.

Never start an escalator withanyone on the step band.

073(3/97)



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CHECK & ADJUST BRAKESTOPPING DISTANCE

1. Check braking surfaces for oil and grease, andremove any impurities with degreasing agents.

2. Clear the step band of all personnel and tools,disengage step band lock, and turn main power

supply ON.

3. Start the escalator in the down direction, press

stop button, and measure the stopping distance.

ä Brake stopping distance for an open

loop brake with brake shoes should bebetween 200 mm and 380 mm. If

adjustment is needed, then the brakeshould be set to the nominal values.

Nominal values are 220 mm (0.4 m/s)and 270 mm (0.5 m/s).

ä Visual check: escalator should stopwithin the length of one half to onestep.

Adjust brake stopping distance

If brake stopping distance must be adjusted,

complete the following.

1. Loosen groove nut (1).

2. Turn in adjusting ring (2) until pin (7) is flush with

adjusting ring (dimension x = 0 mm).

3. When the maximum brake setting is achieved,

lock adjusting ring (2) with groove nut (1).

4. Clear the step band of all personnel and tools,disengage step band lock, and turn main power

supply ON.

5. Start the escalator in the down direction, pressstop button, and measure the stopping distance.

ä If the minimum braking distance cannot

be achieved, reduce the brakingmoment (the pressure exerted by the

spring on the pin).

6. Carry out stopping distance checks with theescalator unloaded until the minimum stopping

distance is achieved.

ä If dimension X reaches 15.5 mm [5/8in.], the compression spring (8) is

completely relieved and the brakingmoment is equal to zero.

ä The smaller dimension X is, the greaterthe braking distance is, and the smaller

the braking moment.707-235 (6/2002)



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Checking & adjusting brake release & pad wear

monitors (if equipped) - EN 115 Complete the following to check and adjust brake

release and pad wear monitors.

Brake release monitor

1. With three steps removed, move hole in stepband to drive station area.

2. Turn main power supply OFF, and engage stepband lock.

3. Check gap between sensor (1) and pin (2).

ä Gap between sensor and pin formonitoring brake release must be 3.8

mm to 4 mm [9/64 in. to 5/32 in.] whenthe brake is applied.

4. If adjustment is necessary, loosen nut (3) andlock nut (4).

5. Adjust gap between sensor (1) and pin (2) to 3.8

mm to 4 mm [9/64 in. to 5/32 in.].

6. Secure sensor (1) with nut (3) and lock nut (4).

7. After securing the sensor, recheck the gap.

Readjust, if necessary to achieve a 3.8 mm to 4mm [9/64 in. to 5/32 in.] gap.

Pad wear monitor

1. Check gap between sensor (5) and pin (2).

ä Gap between sensor and pin for

monitoring brake lining wear must be2.8 mm to 3 mm [7/64 inch to 1/8 in.]

when the brake is applied.

2. If adjustment is necessary, loosen nut (6) andlock nut (7).

3. Adjust gap between sensor (5) and pin (2) to 2.8mm to 3 mm [7/64 inch to 1/8 in.].

4. Secure sensor (5) with nut (6) and lock nut (7).

5. After securing the sensor, recheck the gap.Readjust, if necessary to achieve a 2.8 mm to 3

mm [7/64 inch to 1/8 in.] gap.

After adjusting the brake release orbrake adjust monitors, check the

distance between brake shoe (8) andpin (9). If necessary, adjust brake

release distance.

For more information on adjusting brake,

refer to Step, Brake, Drive, & ChainMaintenance Module/Checking brake.

708-024 (11/2001)

Check & adjust brake release & adjust monitors

Never start an escalator withanyone on the step band.

073(3/97)



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Adjusting inverter Complete the following to adjust an inverter.

1. Set operational parameter 29 (normal running

time 103 and 102) to contract-specificparameter.

2. Set operational parameter 30 (normal runningtime 101 and 100) to contract-specific

parameter.

For more information on normal running

time, refer to contract-specific parameters.

3. Set operational parameter 31 (opposite runningtime) to a minimum of 10 seconds.

All other inverter operationalparameters are factory-set.

707-184 (8/2001)



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Installing handrail lights - EN 115 Complete the following to install handrail lights.

n Install handrail base & guide

n Install handrail lights

INSTALL HANDRAIL BASE &GUIDE

Handrail base sections are numbered (on adhesivelabels) in sequence of installation. Install handrail

base and guides starting at the bottom newel roller,installing in the sequence sections are numbered.

Components must be positionedprecisely in the order in which they are

numbered, otherwise they might not fittogether properly.

1. Attach first numbered handrail base section (1)

to clips (2) located on inner panel.

ä Clips (2) for attaching handrail base

sections are factory-installed on top ofinner panel.

ä Handrail base must project towardsouter deck side of balustrade.

2. Position next section of handrail base (3) on topof inner panels.

3. Insert splice plate (4) between handrail base

section (1) and handrail base section (3). Securehandrail base sections together with screws,

washer, lock washer, and nuts.

Use factory-drilled holes for fasteninghardware.

4. Install remaining handrail base sections in the

same manner.

5. Position handrail guide (5) on top of handrailbase sections in the order guide sections arenumbered.

6. Insert threaded mounting plate (6) into handrail

base channel, and align with mounting screw (7).Attach handrail guide (5) to handrail base withscrew (7) and threaded plate (6).

Do not tighten securely at this time.

7. After all handrail guide sections are installed,

check all joints for alignment and sharp edges.Align sections, and remove any sharp edges

found.

Sharp edges at handrail guide jointsand misaligned handrail guides can

cause damage to handrail.

8. Make sure all handrail guides are aligned, andtighten mounting screws (7) securely.

INSTALL HANDRAIL LIGHTS

1. Starting at lower end, determine location of lamp

brackets (8) for lower end curve lamp (9).

ä Center of lamp brackets (8) should be

located 100 mm [4 in.] from end oflamp (9).

2. Snap lamp brackets (8) into center ridge (10) ofhandrail base at these locations.

3. Clip lower end curve lamp (2) into lamp brackets

(8).

4. Install fixture ends (11) on both ends of lamp (9).

5. Install ballast (12) and starter (13).

6. Locate position of first incline lamp (14) and lamp

brackets (8).

ä End of incline lamp (14) should be

located a minimum of 100 mm [4 in.]from end of lower curve lamp (9).

ä Center of lamp brackets (8) should belocated 100 mm [4 in.] from end oflamp (14).

7. Install fixture ends (11) on both ends of lamp

(14).

8. Install ballast (12) and starter (13).

9. Install remaining lamps, lamp brackets, lampfixtures, ballasts, and lamps in the samemanner.

10. Clip lens (15) into position on handrail base (1).

11. Install lens brackets (16) at each end of thebalustrade with screw (17).

707-180 (6/2001)



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Installing skirt lights - EN 115 Skirt light fixtures are numbered (on adhesive labels)

in sequence of installation. Install skirt lights startingat the lower end, installing in the sequence fixtures

are numbered. Complete the following to install skirtlights.

Components must be positioned

precisely in the order in which they arenumbered, otherwise they might not fit

together properly.

1. Position skirt light fixture (1) on top of skirt (2),and mount with screws (3) in factory-drilled

holes.

2. Position lens (4) on skirt light fixture (1).

3. Insert inner deck (5) into deck trim (6) and over

lens (4).

4. Align mounting holes and attach inner deck (5) to

lens (4) and skirt light fixture (1) with screw (7).

5. Install remaining skirt light fixtures in the samemanner.

707-181 (6/2001)



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Installing skirt spot lights - EN 115 The skirt spot light has the option of 18 mm x 100

mm fixture. Complete the following to installskirt spot lights.

1. Position skirt spot light fixture (1) at skirt

cutout (2).

2. Fasten fixture to skirt with mountinghardware (3).

707-182 (6/2002)

18 mm x 100 mm



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Checking access cover switches

Complete the following to check access cover

switches.

1. Remove access cover.

2. Place straight edge (1) across access frame,next to access cover switch (2).

3. Make sure actuator wand (3) is above bottomedge of straight edge (1).

707-186 (8/2001)



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NOTES

ins-man-4

Documents

apex guards deck guards

deck guard panel

mount deck guard

mounting apex guards

end of deck

deck guards ansicomplete

incline deck

horizontal deck