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PULSE™ CSB MONITOR 34 kN and 43 kN Coated Steel Belts

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Pulse™ Advanced Diagnostics and Troubleshooting

This work and the information it contains (collectively referred to as ‘Work’) are the confidential property of the Otis Elevator Company (‘Otis’). This Work is delivered on the express condition that: it will be used or reproduced by Otis employees exclusively for, or on behalf of, Otis; it will not be disclosed, reproduced, or distributed by or to others, in whole or in part, without the prior written consent of Otis; and, it and any copies will be promptly returned to Otis upon demand or upon termination of employment.

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Pulse™ Advanced Diagnostics and Troubleshooting

1.

Introduction

Definition & Acronyms Pulse™—Resistance Based Inspection Monitor ANSI—American National Standards Institute (refers to ASME A17.1 / CSA B44 Safety Code for Elevators and Escalators) CSB—Coated Steel Belt EN—EN81-1 safety rules for the construction and installation of lifts, part 1 JHA—Job Hazard Analysis JIS—Japanese Industrial Standards (日本工業規格 Nippon Kōgyō Kikaku?) LED—Light Emitting Diode LOTO—Lock Out Tag Out REM—Remote Elevator Monitoring RSL—Remote Serial Link SVT—Service Tool SR—CSB Starting Resistance

Purpose This document will be used to provide System Integration Teams with component information about the start-up of the Pulse CSB monitoring system. The System Integration Team will use this information to provide system specific information for field mechanics.

Overview The Pulse™ CSB monitoring system is used to continuously monitor the condition of the steel cords inside the CSB. It will signal an alert or an alarm when the steel cords are damaged or worn, or when health of the monitor system is compromised. The Pulse™ controller could be connected to REM, which can provide the alert, alarm, and system health to local personnel.

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Pulse™ Advanced Diagnostics and Troubleshooting

Safety All jobsite work activity must be in full compliance with Otis World Wide Jobsite Safety Standards (WWJSSS). When carrying out this procedure particular consideration should be given to control of the elevator, LOTO, hoisting and rigging, ensuring public safety (signs and barriers), working in close proximity of unguarded rotating equipment (sheaves) and the wearing of appropriate personal protective equipment. It is required that field personnel conduct an appropriate JHA for the task at hand to familiarize themselves with the work task and environment.

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Pulse™ Advanced Diagnostics and Troubleshooting

Service Tool Port

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Pulse™ Advanced Diagnostics and Troubleshooting Manual Learn Operation using Service Tool (F-1-1-1)

The manual learn operation using the service tool is required when installing a Pulse unit for an elevator that has run more than one hundred thousand (100,000) times or for an elevator that has been in service more than one year. The manual operation enables the user to enter a CSB length (the length entered applies to all CSBs connected), and the CSB starting resistance is calculated: (CSB length (m)) * (cord resistance per meter) * (number of belt cords). 1. Connect service tool to PULSE service tool port. 2. Access the Start Resistance data entry (menu F-1-1) 3. Verify no learn operation is in progress 4. "Any Previous SRs Erased OK? (9=Y)" 5. Press 9 ONLY IF USER IS CERTAIN THAT PREVIOUS STARTING RESISTANCE VALUES MUST BE ERASED. 6. "Enter BeltLength 000.00 meters" 7. Enter belt length (meters) to within 100 mm. 8. "RBI Learn in progress . . .” 9. "Storing Data . . . . Then resetting . ." If the belt length entered is unacceptable, a message will appear: "Illegal SR press Clr to try again". Verify that the Pulse CSB Monitor is monitoring the CSBs, i.e., each CSB LED should be ON steady.

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Pulse™ Advanced Diagnostics and Troubleshooting Safety Code Data Entry using Service Tool (F-1-2)

The safety code data entry menu is used to select the proper coated steel belt retirement criteria for use with the EN-81-1 code, the ASME A17.1/CSB B44 code, or the JIS standards. 1. 2. 3. 4. 5. 6. 7. 8.

Connect service tool to PULSE service tool port. Access the Safety Code data entry (menu F-1-2) "Safety Code: 0=EN 1=ANSI 2=JIS" Enter either 0 or 1 or 2 "Set Parameters For CCCC? (9=Y)" (see note below) Enter 9 "Sfty Code = CCCC Press Enter..." (see note below) Press Enter to complete this operation.

Note: the notation "CCCC" will be replaced by safety code "EN" or "ANSI" or "JIS" EN = EN81-1 ANSI = ASME A17.1/CSA B44 JIS = Japanese Industrial Standards

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Pulse™ Advanced Diagnostics and Troubleshooting View Status using Service Tool (F-2-1)

The view status menu is used to view operating characteristics of the Pulse system. 1. Connect service tool to PULSE service tool port. 2. Access the View Status menu (menu F-2-1) 3. "Mode=mmmmmmmmm S=nn nn nn nn nn" (see note 1 and note 2 below) 4. Press GO ON 5. "Mode=mmmmmmmmm A=aa aa aa aa aa" (see note 1 and note 3 below) 6. Press GO ON 7. "Mode=mmmmmmmmm a=al al al al al" (see note 1 and note 4 below) 8. Press GO ON 9. "Mode=mmmmmmmmm BoardFault = nn" (see note 1 and note 5 below) 10. Press GO ON 11. "Mode=mmmmmmmmm SftyCode = CCCC" (see note 1 and note 6 below) 12. Press GO ON 13. "Mode=mmmmmmmmm Temp = TT.TTT C" (see note 1 and note 7 below) Note 1: the notation "mmmmmmmmm" will be replaced by the current Pulse mode, i.e., either "Standby" or "Monitor" or "Learn" or "Calibrate". Note 2: the notation "nn" will be replaced by the belt status code "0" through "15" or by the notation " * * " . Coated steel belts 1 through 5 are shown from left to right. Belt Code Description Status Code CSB not detected: This is the default condition. Set this status condition 0 whenever no other per belt status or fault codes exist. Otherwise, it shall be cleared. All is well: This status shall be selected whenever the CSB is being monitored. 1 It shall be cleared whenever any other per belt fault occurs, with the exception of per belt faults 7, 11 and 12. 2,3,4 unused/spare 5 Alert: This status shall be selected whenever the retirement criteria analysis has declared the belt in “Alert” status. This fault can only be cleared manually by the operator.

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Pulse™ Advanced Diagnostics and Troubleshooting

Alarm: This status shall be selected whenever the retirement criteria analysis has declared the belt in “Alarm” status. This fault can only be cleared manually by the operator RSL Communication Failure: Declare this fault for all belts whenever the RSL 7 communication system is not disabled and has not achieved the “Command” state within 250ms. Otherwise, clear this fault for all belts. 8 unused/spare Data Archive Failure: Declare this fault whenever, during the Initialization Task, the 9 E2P copy of the starting resistance archive is structurally invalid or contains unusable Starting Resistances. It shall also be declared if, during “Monitor Mode” the E2P copy of the Starting Resistances is invalid. Clear this fault if these values have been validated during “Monitor Mode” or on CPU reset. Board Fault: Declare this fault for all belts whenever a board fault reportable to the 10 host controller is declared (refer to Board Level Fault Logging section below) including the case when unsuccessful in repairing a Flash archive on power up. Clear this fault for all belts when no reportable board faults exist. Signal an Alarm to the host controller if this fault is ever logged. Note that this is different from logging the per belt fault called “Alarm”. 11.12 unused/spare RBI System Overtemperature: Declare this fault whenever the measured 13 temperature is greater than or equal to 58°C. Clear this fault whenever the measured temperature is less than 55°C. This code is not ap plicable for ANSI applications. 14 unused/spare CSB System is in Standby: This status shall be selected for all belts whenever no 15 belts are being monitored. Otherwise it shall be cleared for all belts. CSB not being monitored ** 6

Note 3: the notation "aa" will be replaced by the alarm reason code "00" or "02" or "04" or "16" or "32" 00 = no alarm 02 = alarm caused by broken cords 04 = alarm caused by bad cords 16 = alarm caused by shorted cords 32 = alarm caused by promotion from alert to alarm, i.e., more than one belt in alert

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Pulse™ Advanced Diagnostics and Troubleshooting

Note 4: the notation "al" will be replaced by the alert reason code "00" or "02" or "02" or "03" 00 = no alert 01 = alert due to belt wear 02 = alert due to belt shorts 03 = alert due to both belt wear and belt shorts Note 5: the notation "nn" will be replaced by the board fault code "0" through "31". Board Reportable To Retained Code Description Fault Host through Code Controller CPU reset No board faults exist: This is the all is well 0 NO NO indication. Task Backlog: Declare this fault whenever the 1 NO NO MainTaskTimer is non-zero after decrementing it when initiating the 50ms task. Otherwise, clear this fault. ADC Result Late: Declare this fault when the 2 NO NO measurement process is in progress and it is time to process the ADC result. Otherwise, clear this fault. 3 NO NO Short Task Frequency: Declare this fault when the 50ms task is executed in less than 45ms (90%) from the last time it executed. Otherwise, clear this fault. Long Task Duty: Declare this fault when the 4 NO NO 50ms task takes longer than 45ms (90%) to complete. Otherwise, clear this fault. Debug Queue Full: Declare this fault whenever 5 NO NO the debug serial communications transmission queue has overflowed. Otherwise, clear this fault. 6 NO NO Idle Too Long: Declare this fault whenever the Idle task exceeds 5ms (10%). Otherwise, clear this fault. Retire Check Fail: Declare this fault whenever 7 YES as a YES “Board Fault” the starting resistance or calibration data is in failure when in the Monitor Mode. This fault can only be cleared manually by the operator.

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9

YES as a “Board Fault” YES as an “Alarm”

10

NO

11

NO

12

NO

13

NO

14

YES as a “Board Fault” YES as an “Alarm”

15

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Pulse™ Advanced Diagnostics and Troubleshooting

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8

PULSE™ CSB MONITOR

NO Belt History Fail: Declare this fault whenever the area of non-volatile memory used to memorized faults that are to be retained through a power cycle has been erased. Otherwise, clear this fault on power on reset or via the manual interface when clearing all fault history. NO E2P Avg Data Update Failure: Declare this fault whenever the EEPROM (E2P) portion of the periodic process to update the filtered resistance readings in the Flash and E2P has not completed when it is time to run it again. Otherwise, whenever the E2P portion of this process is initiated, clear this fault. NO Flash Busy When Erasing: Declare this fault when the MSC1210 Data Flash is busy when a Flash Erase operation needs to be initiated. Otherwise, clear this fault upon CPU reset only. Note that a Flash Erase operation should not release the CPU after being initiated, until it has completed. Therefore, the Flash should normally never be busy upon initiating this operation. NO Flash Busy When Writing: Declare this fault when the MSC1210 Data Flash is busy when a Flash Write operation needs to be initiated. Otherwise, clear this fault on CPU reset only. Note that a Flash Write operation should not release the CPU after being initiated, until it has completed. Therefore, the Flash should normally never be busy upon initiating this operation. NO Flash Write Fail: Declare this fault when, at the end of an MSC1210 Flash Write cycle, the data read back from the programmed location, does not match the data written during the write operation. Otherwise, clear this fault on CPU reset only. NO Service Tool Queue Full: Declare this fault whenever the Service Tool serial communications transmission queue has overflowed. Otherwise, clear this fault. Data Flash Fix Failure: Declare this fault when, during power up NO initialization, the Data Flash has failed to align to a valid EEPROM copy of the Starting Resistance data archive. NO SR Archive Repair Failed: The process that repairs the EEPROM Data Archive during Monitor mode has been unsuccessful in repairing the EEPROM copy of the Starting Resistance Archive. Signal an Alarm to the host controller if this fault is ever logged. Note that this is different from logging the per belt fault called “Alarm”.

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16

YES as an “Alarm”

NO

17

YES as an “Alarm”

NO

18, 19 20

NO

NO

YES as a “Board Fault” YES as a “Board Fault” YES as a “Board Fault” YES as a “Board Fault” YES as a “Board Fault”

NO

21

22

23

24

2531

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NO

Invalid EEPROM SR Archive: The EEPROM Starting Resistance Data Archive has been detected as invalid during power up validation. Signal an Alarm to the host controller if this fault is ever logged. Note that this is different from logging the per belt fault called “Alarm”. Invalid Starting Resistance Values: The EEPROM Starting Resistance Data Archive has been detected as valid during power up validation, however the resistance values are unacceptable. Signal an Alarm to the host controller if this fault is ever logged. Note that this is different from logging the per belt fault called “Alarm”. unused/spare Measurement System Failure: The measurement system has been determined unhealthy because the checking resistor measurement is out of tolerance (+/-2.5%). Current Source Failure: The current source portion of the measurement system is unhealthy.

NO

Trim Register Failure: Factory set trim register values (by TI) in the MSC1210 configuration register area are blank and the Vref and/or Analog Brownout functions may not work properly.

NO

HCR setting mismatch: Either HCR0 or HCR1 are not set consistent with the RBI application expectations.

YES Configuration Data Failure: The both data flash areas containing both copies of the configuration parameters are corrupt or have been erased and therefore, the defaults for the EN safety code have been loaded. To rectify this, the safety code must be re-selected via the service tool and then faults must be manually cleared. unused/spare

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Pulse™ Advanced Diagnostics and Troubleshooting

Note 6: the notation "CCCC" will be replaced by safety code "EN" or "ANSI" or "JIS" EN = EN81-1 ANSI = ASME A17.1/CSA B44 JIS = Japanese Industrial Standards Note 7: the notation "TT.TTT C" will be replaced by the temperature sensor reading in degrees Celsius.

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Pulse™ Advanced Diagnostics and Troubleshooting View Starting Resistance Values using Service Tool (F-2-2)

The view starting resistances menu is used to determine the starting resistance values of coated steel belts connected to a Pulse unit. These starting resistances are determined during the learn operation. 1. 2. 3. 4. 5.

Connect service tool to PULSE service tool port. Access the Safety Code data entry (menu F-2-2) "Enter the Belt# to View (1-5)" Enter a valid belt number either 1 or 2 or 3 or 4 or 5 "Bn= ###.### Ohms (SR) Belt = " (see note 1 and note 2 below)

Note 1: the notation "n" will be the belt number "1" or "2" or "3" or "4" or "5" Note 2: the notation "###.### Ohms" will be replaced by the resistance value in ohms (Ω) for the selected belt calculated by Pulse during the learn operation

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Pulse™ Advanced Diagnostics and Troubleshooting

6. View Current CSB Resistance Values using Service Tool (F-2-3) The view current CSB resistances menu is used to determine the current resistance values of coated steel belts connected to a Pulse unit. These resistances are determined during the most recent measurement cycle. 1. 2. 3. 4. 5.

Connect service tool to PULSE service tool port. Access the Safety Code data entry (menu F-2-3) "Enter the Belt# to View (1-5)" Enter a valid belt number either 1 or 2 or 3 or 4 or 5 "Bn= ###.### Ohms Belt = " (see note 1 and note 2 below)

Note 1: the notation "n" will be the belt number "1" or "2" or "3" or "4" or "5" Note 2: the notation "###.### Ohms" will be replaced by the resistance value in ohms (Ω) for the selected belt calculated by Pulse during the most recent measurement cycle

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PULSE™ CSB MONITOR 34 kN and 43 kN Coated Steel Belts

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Pulse™ Advanced Diagnostics and Troubleshooting View Percent of Starting Resistance using Service Tool (F-2-4)

The view percent of starting resistance menu is used to determine the percentage ratio of a coated steel belt's latest filtered resistance reading to its starting resistance. 1. 2. 3. 4. 5.

Connect service tool to PULSE service tool port. Access the Safety Code data entry (menu F-2-4) "Enter the Belt# to View (1-5)" Enter a valid belt number either 1 or 2 or 3 or 4 or 5 "Bn= ###.### Belt = " (see note 1 and note 2 below)

Note 1: the notation "n" will be the belt number "1" or "2" or "3" or "4" or "5" Note 2: the notation "###.###" will be replaced by the percentage ratio of the latest filtered resistance reading to its starting resistance for the selected belt

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Pulse™ Advanced Diagnostics and Troubleshooting Automatic Learn Operation using Service Tool (F-3-1)

The automated learn operation using the LEARN switch can be performed successfully only one time. It is intended to be used for a new Pulse unit installed on an elevator with new coated steel belts. After the learn operation is successfully completed, all subsequent learn operations (if required) must be performed using the service tool. This feature prevents the inadvertent re-learning of belt resistance. Important note: performing a subsequent learn operation after completing one successful learn operation will cause the earlier data to be erased and replaced with the new data. THEREFORE, DO NOT PERFORM A SUBSEQUENT LEARN OPERATION TO CORRECT A FAULT ON AN ELEVATOR THAT HAS BEEN PLACED INTO SERVICE! The automatic learn operation using the service tool cannot be used for an elevator that has run more than one hundred thousand (100,000) times or for an elevator that has been in service more than one year. Instead, follow the procedure for the manual learn operation using the service tool. The automatic learn operation is used for an elevator when the entire set of coated steel belts is replaced with a set of new coated steel belts. 1. Connect service tool to PULSE service tool port. 2. Access the Start Resistance Auto Learn (menu F-3-1) 3. Verify no learn operation is in progress 4. "Are new Belts Installed? (9=Y)" 5. Press 9 ONLY IF USER IS CERTAIN THAT THE COATED STEEL BELTS HAVE NO SIGNIFICANT WEAR AND THAT A NEW LEARN OPERATION IS REQUIRED. 6. "Any Previous SRs Erased OK? (9=Y)" 7. Press 9 ONLY IF USER IS CERTAIN THAT PREVIOUS STARTING RESISTANCE VALUES MUST BE ERASED. 8. "RBI System now in Learn Mode . . ." 9. "RBI Learn in progress" 10. "Storing Data . . . Then resetting . ." Verify that the Pulse CSB Monitor is monitoring the CSBs, i.e., each CSB LED should be ON steady.

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Pulse™ Advanced Diagnostics and Troubleshooting

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9.

CSB LED Status CSB LEDs

Each CSB LED displays a number of status conditions. However, to simplify the display, the specific cause of any alarm or alert condition must be determined using the service tool. LED

Status Condition OFF steady belt is not being monitored ON steady belt is being monitored high speed flashing (50 ms ON, 50 ms OFF) SR learn process, med speed flashing (250 msON, 250 ms OFF) alarm condition or monitor system failure low speed flashing (1 sec ON, 1 sec OFF) alert condition There are several possible causes, each with a specific fault code, for an alert or an alarm.

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Pulse™ Advanced Diagnostics and Troubleshooting

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10.

Reset Operation

LEARN switch

Press LEARN switch three times within five seconds to reset alarm and alert conditions. Note: the RESET switch is not used to reset faults; it is used to configure and install software on the printed circuit board. If condition(s) that caused the fault persist, the fault will reappear after the next measurement cycle (60 seconds).

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Troubleshooting Procedures

Installation step

What can go wrong

How to fix it

Cut belt slightly shorter to allow new end of belt to fit into connector Screw head strips Replace screw or connector Screw threads strip Not problematic Plastic strips Not problematic Cut belt slightly shorter to Shorting connection not made create new belt end for making improved connection Screw falls down the hoistway Replace screw or connector Cut belt slightly shorter to Belt does not fit into allow new end of belt to fit into connector connector Screw head strips Replace screw or connector Screw threads strip Not problematic Plastic strips Not problematic Cut belt slightly shorter to Shorting connection not made create new belt end for making improved connection Cut belt slightly shorter to Piercing connection not made create new belt end for making improved connection Screw falls down the hoistway Replace screw or connector Connector will not fit into Replace connector Pulse housing Belt does not fit into connector

Install shorting connector

Install monitor connector

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Pulse™ Advanced Diagnostics and Troubleshooting

No electrical continuity

Perform learn run

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Failed learn run due to belt resistance not being within 10% of other belts Failed learn run due to improper number of belts Failed learn run due to a prior successful learn run having been performed

Check coupler connections by checking resistance between screw heads of outermost screws of monitor connector Remove monitor connectors from Pulse housing and check resistance between screw heads of outermost screws of monitor connector Verify correct number of belts connected for installation Perform subsequent automatic learn run using service tool (F-3-1)

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