Description

• Nominal 48 V DC traction bus, 20 A continuous, 120 A peak brake-lift current
• 4 × 12 V 22 Ah maintenance-free AGM batteries, hot-swap tray, five-year calendar life
• IGBT H-bridge with regenerative protection, efficiency > 92 %, audible noise < 45 dB
• Dual-channel safety chain: independent brake relay + motor contactor, both SIL 3 rated
• Automatic, semi-auto and manual modes selectable from the 3.5-inch colour HMI
• Built-in self-test every 24 h; records battery impedance, charge cycles and fault log
• IP54 wall-mount cabinet, 450 × 350 × 200 mm, 28 kg total weight, key-lockable
• Operating temperature −10 °C to +45 °C, humidity 5–95 % non-condensing
• Compatible with Otis Gen2®, Gen2® Life, Gen2® Switch, 3200 and 4200 gearless machines

1. Mains failure is detected within 200 ms; cabinet beeps once to confirm board wake-up.
2. Controller checks door zone: if car is within ±150 mm of landing, brake opens and doors unlock immediately.
3. If car is between floors, brake lifts, inverter supplies 48 V at 15 Hz to motor, car creeps to nearest level.
4. When door zone sensor confirms arrival, brake re-applies, doors open, internal emergency light stays on.
5. After 10 min of inactivity the system shuts down to preserve battery, keeping only the HMI alive for diagnostics.
6. Once mains is restored the charger resumes, topping batteries to 100 % in < 8 h and clearing the evacuation fault.

• Insert key, open cabinet, press “MANUAL” soft-button.
• Use ▲ ▼ arrows to jog car at 0.1 m/s; release button and brake sets instantly.
• HMI displays real-time battery voltage, current and estimated run time—useful when multiple trips are required during commissioning.

1. De-energise main supply; lock-out/tag-out breaker.
2. Fix cabinet to wall with four M10 expansion anchors; minimum 100 mm clearance top and bottom for ventilation.
3. Run 16 mm² supply cables from controller isolation contactor to terminals L+/L− inside cabinet; fit Otis-supplied ferrite bead to reduce EMI.
4. Connect brake wires to B+/B−, motor wires to U/V/W through the provided grommets; torque to 2 Nm.
5. Plug battery tray; green “READY” LED must illuminate within 5 s.
6. Close door, switch on mains, verify charger voltage 54.6 V ± 0.3 V on HMI.
7. Initiate functional test: press and hold “TEST” for 3 s; car should move to nearest floor and open doors on battery power alone.
8. Record test date, battery internal resistance and technician signature in the logbook.

• Visual inspection every 6 months: look for case bulging, terminal corrosion or electrolyte odour.
• Automatic impedance test every 24 h; replace battery set if impedance > 18 mΩ per 12 V block or if capacity < 70 % of nominal.
• Calendar replacement every 5 years regardless of cycle count—high shaft temperatures accelerate sulphation.
• Full load test annually: disconnect mains, allow car to run evacuation cycle twice; battery must maintain > 46 V under 20 A load.
• Replace entire battery tray (Otis part 71386845) rather than individual cells to maintain factory balance and warranty.

• HMI displays “Brake transistor fault” or “Contactor welded” – replace power board immediately.
• Cabinet fan seized – swap 24 V DC fan (80 mm) to prevent thermal ageing of IGBTs.
• Terminal block carbonised after lightning strike – inspect and replace cabinet if any trace of arcing.

1. Never mix old and new batteries; unmatched impedance causes early failure.
2. Keep cabinet key in the machine-room lock-box—technicians can’t help passengers if they can’t open the door.
3. After any battery replacement, run the full automatic test twice and clear the “Battery low” fault from the controller.
4. Log all tests digitally; our free QR-code sticker links to a cloud form that time-stamps every entry for auditors.
5. Stock a spare C-DQ48VD power board (part 71386844) on high-traffic sites; at 0.8 kg it eliminates 24-hour waits.