Description
KONE Elevator KDL16R Inverter KM968094G03 Brief introduction
| Brand | Original |
| Model | KONE Elevator KDL16R Inverter |
| Goods No. | KM968094G03 |
| MOQ | 1 |
| Warranty Time | 1 year |
| Certificates | ISO9001 |
| Brand | KONE |
KONE Elevator KDL16R Inverter KM968094G03 – Setup, Servicing & Replacement Guide
Nanjing Zhuye Elevator Parts – OEM stock, global shipping, 24/7 support
Nanjing Zhuye Elevator Parts – OEM stock, global shipping, 24/7 support
The KM968094G03 is the 4 kW, 400 V-class vector inverter that powers every KONE KDL16R® and KDL32R® gearless machine up to 1,600 kg and 2.5 m/s. Encased in an IP55 aluminium housing, the unit converts DC-bus energy into variable-frequency, sensor-less torque with an efficiency above 98 % while meeting SIL-3 safety and IEC 61800-3 EMC requirements. A single shorted IGBT or a dusty heat-sink can raise the temperature sensor and force an immediate “65” shutdown. Nanjing Zhuye Elevator Parts keeps hundreds of factory-tested KM968094G03 inverters in Rotterdam and Nanjing so you can restore full-speed operation the same shift. Below is an 800-word field manual that explains correct usage, on-car commissioning and the replacement cycle that keeps your elevators energy-efficient, whisper-quiet and code-compliant.
1. What the KM968094G03 does
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4 kW continuous, 150 % overload 60 s, 200 % 2 s
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Sensor-less vector control, 0 Hz → 150 Hz, ±0.01 % speed accuracy
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Integrated DC choke, brake chopper and 3 % input harmonic filter
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Dual CAN channels (K-CAN & Car-CAN) plus RS-485 for weight sensor
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IP55 cast-aluminium frame, built-in heat-sink, fan 24 Vdc 0.35 A
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UL/CE certified to EN 81-20/50 and CSA B44.1 for 15-year design life
2. Tools to carry
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KM968094G03 inverter (Nanjing Zhuye part #KN-INV-KM968094G03-4kW) on pallet
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4 mm, 5 mm, 6 mm Allen keys, 10 mm & 13 mm sockets
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Torque wrench (10–50 N·m) and 1,000 Vdc multimeter
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KONE E-Link Service Tool (EEST) laptop with KDL16R licence
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RJ-45 to M12 adapter, USB-to-CAN dongle
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IR thermometer and vibration pen
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Lock-out / tag-out kit
3. Installation – 60 minutes with two technicians
Safety: place the car on top-of-travel buffers, engage mechanical brake and lock-out main supply.
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Photograph every power and signal connector – note DC+, DC-, U/V/W, K-CAN, Car-CAN, brake resistor.
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Support the inverter with a sling; remove four M6 flange bolts and lower to pallet.
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Check the heat-sink for dust – compressed-air clean if <2 mm fin gap.
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Mount new KM968094G03; torque bolts to 25 N·m.
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Re-connect all plugs; apply KONE-supplied conductive grease on DC bus.
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Power up – STATUS LED blinks green 3 times then solid; K-CAN LED flashes every 100 ms.
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Launch EEST → Drive → Auto-Tune; rotate sheave by hand until resistance and inductance are stored.
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Run 3 full-speed cycles; verify current <8 A and dT <40 K.
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Record serial number, date and tune values in CMMS.
4. Functional test – prove it to the controller
a) No-load current: 2.8 A ±0.2 A per phase at 50 Hz.
b) Speed accuracy: ±0.01 % from 0.1 m/s to rated speed.
c) Encoder drift: <0.5 mm at every floor after 10 cycles.
d) Temperature: heat-sink <70 °C after 30 min run.
e) Export EEST report and attach PDF to site file.
b) Speed accuracy: ±0.01 % from 0.1 m/s to rated speed.
c) Encoder drift: <0.5 mm at every floor after 10 cycles.
d) Temperature: heat-sink <70 °C after 30 min run.
e) Export EEST report and attach PDF to site file.
5. Preventive maintenance schedule
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Monthly – visual sweep for dust, fan noise or swollen DC-bus capacitors.
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Quarterly – measure heat-sink temperature <65 °C with IR gun.
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Annually – scope PWM outputs; shoot-through spikes must be <50 V.
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Every two years – replace the 470 µF, 450 V capacitor – ESR doubles every 5 years.
6. Replacement cycle – duty and temperature decide
KONE specification: 15 years. Nanjing Zhuye analytics refine this:
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Light duty (<150 starts/day, office): 18 years
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Standard duty (150–400 starts, residential): 15 years
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Heavy duty (>400 starts, hospital, mall): 12 years
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High ambient (>40 °C, rooftop MRL): 10 years – capacitor life halves every 10 °C rise.
Replace immediately if:
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STATUS LED red steady – IGBT desaturation or over-temperature
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DC bus droops below 550 V under load – capacitor ESR too high
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Burn mark around IGBT terminals – heat-sink paste dried out
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Vibration >4.5 mm/s – fan bearing failure imminent
7. Eco-disposal & warranty
Return the old inverter on the supplied pallet; Nanjing Zhuye recovers aluminium, copper and gold and issues a €50 recycling credit. Every KM968094G03 ships with a 24-month replacement warranty, extendable to 60 months when you join our annual capacitor-replacement program.
8. Why buy from Nanjing Zhuye Elevator Parts
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220 units in stock, Rotterdam & Nanjing, flashed with latest firmware
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Factory-sealed KONE packaging with hologram and calibration sheet – no grey-market clones
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QR code on nameplate links to wiring diagram and 5-minute tuning video
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24/7 technical hotline staffed by ex-KONE drive engineers
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Bundle pricing: buy 2 inverters and get a free heat-sink cleaning kit plus freight credit
9. Bottom line
A failed inverter is the fastest way to a trapped-passenger call. Keep a genuine, pre-flashed KM968094G03 on standby, swap it in 60 minutes, and your KDL16R drives will deliver energy-efficient, whisper-quiet rides for the full 15-year design life. Order today from Nanjing Zhuye Elevator Parts – the fastest route from “drive fault” to “perfect ride.”
