Document: AAA29000AC_INSPG
Inspector’s Guide
Gen2 Machine Room-less Elevator System – the next generation of elevators
Revision 3/10/2008
"Copyright © 2006 Otis Elevator Company"
Gen2® Inspector’s Guide
Table of Contents
Gen2® Machine Room-less Elevator Guide for Inspectors.......... 2
Gen2 - Acceptance Tests ...................................................................... 2
Code Required Tests ............................................................................. 2
A. Power Opening of Doors – 8.10.2.2.1 (j) ................................................2
B. NTSD Test..............................................................................................2
C. ETSD Test ..............................................................................................2
D. Overload Test (capacity) ........................................................................3
E. Tripping Speed of Governor Using Tachometer .....................................3
F. Manual Reset of the Governor Overspeed Switch..................................4
G. Overspeed Tests....................................................................................5
H. Traction Test...........................................................................................5
I. Buffer Test ..............................................................................................5
J. Unintended Car Movement Protection....................................................5
K. Ascending Car Overspeed Protection ....................................................5
Coated-Steel Belt Inspection ................................................................ 6
Visual Inspection .................................................................................. 6
Coated-Steel Belt (CSB) Inspection Procedure using the Pulse™
System .................................................................................................. 11
Inspection Procedure Using Magnetic Flux Leakage Tool .............. 12
Other Tests & Procedures................................................................... 13
MRO – Manual Rescue Operation ...................................................... 13
Gen2 - Car Top Access Using Zoned Access .................................. 14
Governor Pull Through Force Test .................................................... 14
Brake Wear Inspection ........................................................................ 15
Copyright ©2006 Otis Elevator Company Page 1 of 16 Rev. 03/10/2008
Gen2® Inspector’s Guide
Gen2® Machine Room-less Elevator Guide for Inspectors
This guide is designed to assist local code inspectors with the examination of the
components associated with the Gen2 system. Otis is happy to provide training
for local inspectors on Gen2. If you are interested in this training or have any
questions please contact your local Otis office.
Gen2 - Acceptance Tests
All tests described in this section are intended to meet the requirements of ASME
A17.1-2000 & CSA B44-00. Refer to ASME A17.1-2000 & CSA B44-00 Section
8.10.2 – Acceptance Inspection and Tests of Electric Elevators for reference.
Code Required Tests
The ASME A17.1-2000 & CSA B44-00 safety codes for elevators require specific
tests to prove the effectiveness of the hardware and software safety devices as
used with static drive (microprocessor) systems.
A. Power Opening of Doors – 8.10.2.2.1 (j)
Power opening of doors checkout procedure consists of five parts.
1. Confirm that door can open only if elevator is in leveling zone.
2. Confirm that leveling zone extends not more than 75mm (3 in.) from
landing.
3. Confirm that Speed Check (SC) speed is set below 0.75 m/sec (150 fpm).
4. Confirm that elevator senses SC fault when set above threshold.
5. Confirm that door can open only if elevator speed is below SC speed.
B. NTSD Test
The NTSD test consists of two parts: NTSD Dynamic Test and NTSD Static
Test. The Dynamic test must be performed first.
B1. Dynamic Test
B2. Static Test
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.25.2 for reference.
C. ETSD Test
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.25.4 for reference.
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Gen2® Inspector’s Guide
D. Overload Test (capacity)
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.16.8 for reference.
E. Tripping Speed of Governor Using Tachometer
1. Turn Cartop Inspection Switch (CIS) to INSPECTION. Using Control
Room Inspection (CRI), position car top near floor level at top landing.
2. Access top of elevator*. Using top of car inspection, run elevator up to
reach governor.
3. Put top of car emergency stop switch in STOP position.
4. Attach nylon sling between crosshead and integrated machine and
bedplate structure before removing governor rope linkage.
5. Disconnect governor rope linkage from safety rod.
6. Hold tachometer on governor rope just as it exits through governor
mounting bracket.
7. Allow governor rope linkage to drop and slowly accelerate as it falls.
Listen for overspeed switch to click as it opens and immediately note
tachometer reading.
8. Pull governor rope linkage back up toward top of hoistway.
9. Repeat step 6.
10. Allow governor rope to accelerate down hoistway and note the speed at
which governor overspeed trips.
11. If governor rope does not accelerate rapidly enough to get valid readings,
attach a small weight to governor rope linkage.
12. Pull governor rope linkage back up toward top of hoistway. Reattach
governor rope linkage to safety rod.
13. Manually reset overspeed switch. (See step F below.)
14. Remove nylon sling between crosshead and machine structure.
15. Return top of car emergency stop switch to RUN position.
16. Using top of car inspection, run elevator down to egress car top.
17. Return Cartop Inspection Switch (CIS) to the NORMAL position.
18. Close hoistway doors
*Accessing the Car Top - When it is necessary to access the car top, the inspector should safely access the car top using a safe,
industry-accepted procedure. (For example, see NEII/Elevator World’s Elevator Industry Field Employees’ Safety Handbook.)
Copyright ©2006 Otis Elevator Company Page 3 of 16 Rev. 3/10/2008
Gen2® Inspector’s Guide
F. Manual Reset of the Governor Overspeed Switch*
1. Place controller on CRI for Control Room Inspection.
2. Place temporary jumper on the required terminals in the elevator controller
to bypass governor overspeed switch.
3. Run car on CRI to a spot in the hoistway where safe car top access is
possible.
4. Place service barricades. Open hoistway door.
5. Place top of car emergency stop switch to the STOP position. Place car
on car top inspection by turning the Car Top Inspection switch to
INSPECTION and turn on car top light.
6. Test and verify the top of car emergency stop switch, access the car top*
and test and verify the UP/DOWN commands.
7. Using top of car inspection ride car top up to access governor.
8. Remove top cover from governor.
9. Inspect governor for any visual damage.
10. Manually reset governor overspeed switch (Fig 1 and Fig 2).
Figure 1 Overspeed Switch in the Tripped Position
Figure 2 Overspeed Switch in the Reset or Normal Position
*Accessing the Car Top - When it is necessary to access the car top, the inspector should safely access the car top using a safe,
industry-accepted procedure. (For example, see NEII/Elevator World’s Elevator Industry Field Employees’ Safety Handbook.)
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Gen2® Inspector’s Guide
11. Re-install cover on governor.
12. Ride car down to the floor from where the cartop was accessed, open and
mechanically block the hoistway door, then egress car top.
13. Turn off car top light, place top of car inspection switch to the NORMAL
position and the car top stop switch to the RUN position.
14. Close hoistway door.
15. Place controller circuit breaker (CB1) to the off position.
16. Remove temporary jumper installed in step 2.
17. Place controller circuit breaker (CB1) to the ON position.
18. Run the car using CRI to confirm correct operation. Turn CRI key switch
back to NORMAL and ride car to verify performance.
G. Overspeed Tests
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.18 for reference.
H. Traction Test
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.24.2.3.2 for reference.
Note position of car when on fully compressed CWT or CAR buffer and watch
service panel board for car movement displayed on car direction LEDs while car
motion is commanded.
I. Buffer Test
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.22 for reference.
Note: No test is required for spring type buffers. This test applies to oil type
buffers only.
J. Unintended Car Movement Protection
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.19.2 for reference.
K. Ascending Car Overspeed Protection
Refer to ASME A17.1-2000 & CSA B44-00 Section 2.19.1 for reference.
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Gen2® Inspector’s Guide
Coated-Steel Belt Inspection
Visual Inspection*
Even though coated-steel belts are designed to last 2 to 3 times longer than
traditional elevator wire ropes, an annual visual inspection is recommended.
This procedure defines the technique for the visual inspection of coated-steel
belts. There are two main criteria for coated-steel belt replacements, evidence of
wire strand breakage or evidence of polyurethane degradation.
1. Using top of car inspection, run elevator from top of hoistway to bottom of
hoistway.
2. Stop as needed to inspect the coated-steel belts using the following
images for comparison and recommended action. (Note: these images
are of belts tested at our test facility and not from actual installations.)
3. Inspect coated-steel belts terminations, springs, fire clamps, nuts, cotter
pins and rod condition.
4. Egress car top.
5. Replace all coated-steel belts if any one in the set requires replacement.
*Accessing the Car Top - When it is necessary to access the car top, the inspector should safely access the car top using a safe,
industry-accepted procedure. (For example, see NEII/Elevator World’s Elevator Industry Field Employees’ Safety Handbook.)
Copyright ©2006 Otis Elevator Company Page 6 of 16 Rev. 3/10/2008
Gen2® Inspector’s Guide
EXAMPLES SHOWN ARE THE RESULT OF OTIS’ COMPREHENSIVE TESTING. THE COATED-
STEEL BELTS SHOWN ARE THE END RESULT OF OUR TESTING PROCEDURES AT THE OTIS
TEST TOWER AND ARE NOT FROM ACTUAL INSTALLATIONS.
Example of Good Coated-Steel Belt
Appearance: Smooth uniformed surface, no rouging (rust). No nicks or wear
spots on polyurethane coating.
Action: None
Example of Polished Coated-Steel Belt
Appearance: Shiny, polished areas on polyurethane, but no cords exposed.
Action: Monitor for any change to a condition which would require replacing
belts
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Gen2® Inspector’s Guide
Example of Cord Imprints – Severe Wear
Wear marks, visual signs
of cord imprints from
exterior.
Appearance: Visual evidence from exterior of cord imprints.
Action: Replacement of coated-steel belts.
Example of Exposed Wires
Steel cords
breaking through
polyurethane.
Appearance: Evidence of steel cords breaking through polyurethane.
Action: Replacement of coated-steel belts.
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Gen2® Inspector’s Guide
Example of Exposed Wires
Wire strands
breaking through.
Appearance: Evidence of wire strands breaking through polyurethane.
Action: Replacement of coated-steel belts.
Example of Exposed Wires (Enlarged)
Appearance: Evidence of steel strands breaking through polyurethane.
Action: Replacement of coated-steel belts.
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Gen2® Inspector’s Guide
Example of Cut Belt
Cut marks in plastic
Appearance: Cut marks in polyurethane coating.
Action: Replacement of coated-steel belts.
Example of Severe Rouging
Rouge (rust) deposits
Appearance: Steel belts show rust rouging caused by extreme number of
cycles, wear and environment.
Action: Plan for replacement of coated-steel belts
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Gen2® Inspector’s Guide
Coated-Steel Belt (CSB) Inspection Procedure using the Pulse™
System
Pulse is the Otis commercial solution to CSB inspection. It monitors the
condition of the steel cords inside the CSB continuously and signals the car
controller of the CSB status. The CSB status is communicated as an alert or an
alarm. When in ALARM the elevator will go out of service immediately after
allowing passengers to exit. If the system has REM installed, alerts, alarms, and
system health is reported to local personnel.
Copyright ©2006 Otis Elevator Company Page 11 of 16 Rev. 3/10/2008
Gen2® Inspector’s Guide
Inspection Procedure Using Magnetic Flux Leakage Tool
Otis recommends inspection using the Magnetic Flux Leakage Tool after the first
5 years of operation and annually each year thereafter.
Procedure A:
1. Access car top at top landing.*
2. Run car up to floor level, and mount the device to the 1st coated-steel belt.
3. Read the display.
If tool reads READY, proceed to next step.
If tool display alternates between SERVICE and READY, the tool is
defective. You need to replace the tool before you can proceed.
4. Depress the yellow “START” button on tool.
5. Run car through entire hoistway. Display will read “_ _ _ Sequence @
1hz”
6. Depress the yellow “START” button on tool.
7. Read the display
If the tool reads COATED-STEEL BELTS OK, proceed to next step
If the tool reads COATED-STEEL BELTS WORN, go to Procedure B
If the tool reads COATED-STEEL BELTS BAD, go to Procedure C
8. Move the sensor head to second coated-steel belt.
9. Repeat steps 2 – 7 for all coated-steel belts.
Procedure B:
(Followed when – COATED-STEEL BELTS WORN is displayed during step 7 of
Inspection Procedure using Magnetic Flux Leakage Tool)
1. Power down the device. Repeat test procedure A for the same belt.
2. If display still reads COATED-STEEL BELTS WORN replace all coated-
steel belts within 6 months.
Procedure C*:
(Followed when – COATED-STEEL BELTS BAD is displayed during step 7 of
Inspection Procedure using Magnetic Flux Leakage Tool)
*Accessing the Car Top - When it is necessary to access the car top, the inspector should safely access the car top using a safe,
industry-accepted procedure. (For example, see NEII/Elevator World’s Elevator Industry Field Employees’ Safety Handbook.)
Copyright ©2006 Otis Elevator Company Page 12 of 16 Rev. 3/10/2008
Gen2® Inspector’s Guide
1. Power down the device, repeat test Procedure A for the same belt
2. Read the display.
If the tool reads COATED-STEEL BELTS OK, repeat Procedure A one
additional time
If the tool reads COATED-STEEL BELTS WORN, go to Procedure B.
If the tool reads COATED-STEEL BELTS BAD, power down and remove
the inspection tool. Ride car down and exit at top landing.
3. Power down and “lock and tag out” the elevator. Coated-steel belts must
be changed before returning the car to service.
Other Tests & Procedures
MRO – Manual Rescue Operation
Only properly trained, authorized and qualified personnel should perform Manual
Rescue Operation.
1. Remove power to elevator, lock out, tag out, test, and verify.
2. Verify that all hoistway and car doors are closed completely.
3. Set CB2 circuit breaker to the OFF position.
4. Ensure CB1 circuit breaker is in the ON position.
5. Insert the Manual Rescue key (UTE) in the Manual Rescue Enable
keyswitch (BRB2) on controller under the service panel board.
UTE should not be left in the BRB2 keyswitch or stored in the
controller.
6. Turn the BRB2 to the ENABLED position and then depress the BRB1
button located at the bottom of the service panel board. Elevator should
move in short pulses in the direction of system overbalance.
7. Direction and movement of elevator will be displayed on the service panel
board LEDs. Car position will be on the service panel board display when
car motion stops. The DZ light on the service panel board will illuminate
when the car is in the door zone ±3 in. (±76 mm).
8. Elevator should automatically stop at the next door zone if constant
pressure is maintained on BRB1 and the BRB2.
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Gen2® Inspector’s Guide
9. Release the BRB1 button and release the BRB2.
10. Test and verify that elevator can move to next landing by turning the BRB2
keyswitch to the ENABLED position again and then depress the BRB1
button. Elevator should move in short pulses in the direction of imbalance
to the next door zone and stop.
11. When testing is complete, remove the UTE Key from the BRB2 keyswitch.
Gen2 - Car Top Access Using Zoned Access*
1. Call elevator to the top landing.
2. Using the inspection keyswitch in the car operating panel place elevator
on INSPECTION.
3. Place a barricade in front of the hoistway door.
4. Move the elevator down using the zoned access keyswitch located
adjacent to the doorjamb to a height where the car top can be accessed
safely.
5. Turn on car top work light.
6. Place the car top stop switch to the STOP position and the car top
inspection switch to the INSPECTION position.
7. Access car top and assume a safe position.
8. Test and verify performance of the top of car run station buttons and
features.
9. Close hoistway door and move elevator using car top inspection station
buttons.
Governor Pull through Force Test
1. Set up Klein grip, dynamometer (or torque multiplier), and lever hoist to
pull against safety hitch and through governor sheave.
2. Trip governor by holding fly weights to the overspeed sheave locked
position.
3. Pull governor rope down with lever hoist until ropes slides through sheave.
4. Observe measurement on dynamometer or torque multiplier when rope
first starts to slide over governor sheave.
*Accessing the Car Top - When it is necessary to access the car top, the inspector should safely access the car top using a safe,
industry-accepted procedure. (For example, see NEII/Elevator World’s Elevator Industry Field Employees’ Safety Handbook.)
Copyright ©2006 Otis Elevator Company Page 14 of 16 Rev. 3/10/2008
Gen2® Inspector’s Guide
Brake Wear Inspection
1. Access the brake.
2. Measure between the brake armature and magnet housing using a 0.025''
or 0.635 mm feeler gauge.
3. A new brake will have an air gap of 0.21mm to 0.5mm.
4. An air gap of > 0.60mm or 0.024 inches requires brake replacement.
Figure 3 Gen2 Brake Details
Revision Date Comments Author
8/6/07 Changed line 2 pg. 17 from measure RDS
between pad and magnet to measure
between brake armature and magnet
8/6/07 New Gen2 LOGO RDS
10/9/07 Changed action in Visual Belt Inspection, RDS
polished belt to; Monitor for any change
to a condition which would require
replacing belts
3/10/08 Changed Page Footers to contain : RDS
"Copyright © 2006 Otis Elevator
Company" instead of unpublished
work
Copyright ©2006 Otis Elevator Company Page 15 of 16 Rev. 3/10/2008
