Kone elevator control/power electronics panel teardown

This is a Kone Elevator control and power electronics panel dated around 1999-2000 according to stickers and test marks. It does not appear to have had a user interface, unless that was connected to the RS232 port.

The front reveals a control board with a -12 VDC, GND and +12 VDC power supply at the top, used primarily for the gate drive of the IGBT module and rest of the logic runs on +5 VDC.

The controllers heart is the Intel N80C196KC20 microcontroller, known as the “80196” family of microcontrollers, it was discontinued by Intel in 2007 without any newer replacement parts available. It is a 16-bit 20 MHz microcontroller which have two ST M27C1000 8x 256 KB EEPROMs connected. One with the main program and the other is marked in the PCB to have a test program. To store data while the controller is powered off there is a ST M48Z35Y ZEROPOWERRAM which is 256 KB of SRAM, besides the SRAM module there is a voltage sense and switching circuitry along with a lithium battery in the package.

There is a large pin-header for connecting a flat cable with all peripheral circuits like buttons, level indicators, sensors and safety monitoring devices. There is a funny, yet a little freightening, push button switch on the board that says “Full power”, along with other texts that refer to “Offset test”, “Record out” or “Test program”

To control the phase angles of the motor there are three TLC 8-bit DACs which get their digital signal from the microcontroller and delivers a variable phase angle signal to the IGBT driver board.

The heart of the power electronics is a 3 phase Eupec BSM50GD120 IGBT module which is rated for 50 Ampere at 1200 VDC. The DC bus filtering is two RIFA 1000 uF / 350 VDC electrolytic capacitors. The output from the drive goes through 3 ring core inductors before going to the motor connection terminals.

Mains input goes through a 3 phase filter before it goes to IXYS 3 phase rectifier and brake chopper module protected with MOVs. There is a separate brake module that dumps energy from the motor to two power resistors.

There is two heavy shielded cables going off the PCB with a DC+ and brake engage wires to the large mechanical brake on the lift itself to lock it into place when not moving.

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