INVT EC160A Elevator Drive Retrofit for Gearless Elevator System Modernization Project in India

Abstract: This project report presents the successful retrofitting of a One Elevator gearless motor in India using the INVT EC160A elevator intelligent integrated machine. The solution offered improved system stability, compatibility with One Elevator’s synchronous motor, and simplified commissioning. Results proved that EC160A provides high performance, reliability, and cost-effective modernization.

Keywords: EC160A, EC-MB, EC_CTB, One Elevator Machine & Encoder

Customer Background

The customer in India owned a gearless elevator (1.75m/s,12-person capacity, 23 floors, 22kW synchronous motor, 415V supply) that was out of service due to maintenance and parts availability issues. They required an alternative modernization solution that could restore reliable operation, ensure smooth commissioning under Indian site conditions, and extend the system’s operational life.

Challenges

• One Elevator’s closed system prevented the use of third-party spares.

• Elevator downtime due to failed AMC and no cost-effective repair options.

• Need for compatibility with synchronous motor and original encoder system.

• Ensuring reliable operation and smooth commissioning under Indian site conditions.

INVT Solutions

INVT provided the EC160A integrated machine as a replacement for One Elevator’s proprietary system. Key features included:

• Integrated controller + inverter design for compact and efficient installation.

• High-performance vector control with encoder feedback for synchronous motors.

• Dual communication options (serial & parallel).

• Remote monitoring and debugging via TCP/IP module.

• ARD function allowing UPS-based emergency evacuation to the nearest floor.

The retrofitting system used:

• EC160A-030-4(A) intelligent integrated machine (1 unit).

• Encoder RI54 4096/0130X01.

• Handheld operator EC-PAD.

• DC-03S display and calling boards (24 units).

• Brake resistors (20Ω/12000W).

• EC-MB used for external commissioning and monitoring.

System Commissioning

• Encoder installed and correctly wired.

• Motor parameters configured (30kW, rated speed & frequency, voltage & current values).

• Elevator speed and floor data programmed into EC160A.

• Brake timing, ASR gains, and UPS detection set.

• Trial runs confirmed smooth operation, accurate levelling, and stable control.

Fig. Control Panel & Junction box

Fig. Motor & Name plate

Result

The retrofitted elevator achieved stable operation, precise speed regulation, and reliable emergency rescue capability. The system reduced dependence on One Elevator spare parts and ensured long-term maintainability.

Customer Feedback

• Smooth elevator performance after retrofitting.

• Significant cost savings compared to One Elevator’s AMC.

• Confidence in INVT technology for future modernization projects.

Conclusion

The project proved that INVT EC160A intelligent integrated machines can fully replace One Elevator gearless elevator systems, breaking service monopolies and offering cost-effective modernization. The solution not only restored elevator operation but also opened opportunities for wider adoption of EC160A in the elevator market.