Abstract: This project report presents the successful modernization of a residential elevator equipped with a geared machine from an international brand using the INVT EC160A intelligent integrated drive. The solution improved ride quality, system stability, and operational consistency while retaining the existing machine. The results confirm that the EC160A drive provides a reliable and cost-effective solution for elevator modernization projects.
Keywords: EC160A, EC_CTB, One Elevator Machine & Encoder
Customer Background
The elevator is installed in a residential building and is equipped with a geared elevator machine from an international brand. The customer wanted to retain the existing machine while upgrading the drive system to improve ride comfort, reliability, and overall performance.
Previously, the elevator was operating with separate low-speed and high-speed windings, which resulted in noticeable performance differences between slow-speed and high-speed operation. These inconsistencies affected ride quality and passenger comfort. The customer required a stable and economic modernization solution without replacing the existing machine.
To address these requirements, the system was upgraded using the INVT EC160A drive with incremental encoder feedback, ensuring compatibility with the existing machine while delivering smooth, stable, and reliable operation suitable for residential use.
Challenges
Integration of the EC160A drive with an existing geared elevator machine from an international brand while retaining the original motor
Inconsistent ride quality due to separate low-speed and high-speed winding configuration
Achieving uniform performance across all operating speeds without mechanical modifications
Ensuring accurate speed feedback and stable control using an incremental encoder
Meeting residential ride comfort expectations with the existing electrical and mechanical setup
INVT Solutions
INVT provided the EC160A intelligent integrated drive as a reliable and cost-effective solution for modernizing the existing geared elevator system while retaining the original motor and mechanical components.
Key solution elements included:
Installation of the EC160A drive with incremental encoder feedback for precise speed control and stable operation
Selection and connection of the high-speed winding of the geared machine to eliminate performance differences between low-speed and high-speed operation
Optimization of motor parameters and vector control settings to achieve smooth acceleration, deceleration, and accurate levelling
Seamless integration with the existing elevator control and safety circuits without mechanical alterations
Fine-tuning of braking, ASR gains, and speed control parameters to meet residential ride comfort requirements
This solution ensured consistent ride quality, improved reliability, and enhanced overall elevator performance while minimizing installation effort and modernization cost.
The retrofitting system used:
EC160A-7R5-4(A) intelligent integrated drive – 1 unit
Incremental Encoder ISM3F-1024
Handheld operator EC-PAD
DC-03S display and calling boards – 13 units
Brake resistor – 60Ω / 2000W
System Commissioning
Incremental encoder installed and correctly wired
Motor parameters configured (7.5 kW, rated speed, frequency, voltage, and current)
Elevator speed profiles and floor data programmed into the EC160A drive
Brake timing, ASR gains, and UPS detection parameters adjusted
Trial runs conducted to verify smooth operation, accurate levelling, and stable control
Fig. Control Panel & & Motor
Fig. Motor Name plate & Encoder
Result
After installation and commissioning of the INVT EC160A drive with incremental encoder feedback, the elevator achieved stable and reliable operation with a significant improvement in ride quality.
By connecting the high-speed winding of the geared machine, the performance difference between low-speed and high-speed operation was completely eliminated. The elevator now operates with smooth acceleration, deceleration, and accurate levelling across all floors, meeting residential comfort standards.
Customer Feedback
Noticeable improvement in ride comfort and smoothness
Stable and consistent performance at both low and high speeds
Successful modernization without replacing the existing geared machine
Reduced maintenance concerns and improved long-term reliability
Increased confidence in adopting INVT solutions for future modernization projects
Conclusion
This case study demonstrates the effective modernization of a residential elevator using the INVT EC160A drive with incremental encoder feedback. By retaining the existing geared machine and optimizing the electrical configuration, consistent performance and improved ride comfort were achieved across all operating speeds. The solution offers a reliable and economical upgrade without mechanical replacement.
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