Mechanical and Electrical System Inspections
Once elevator installation is complete, the first step is a comprehensive inspection of the mechanical and electrical systems, similar to a full physical checkup for the elevator:
- Guide Rail Inspection: Ensure that verticality deviation is less than 5 millimeters and that the joints between guide rail sections are smooth.
- Door System Check: Confirm that the doors open and close smoothly and that clearances meet specification.
- Electrical Connections: Confirm that all wiring is correctly connected and that insulation resistance is within acceptable limits.
- Control System: Verify that all functional modules in the control cabinet are operating normally.
No-Load and Load Operation Tests
The elevator must be tested under a range of load conditions to verify the actual performance of the drive system:
- No-Load Test: Run the elevator between the top and bottom floors to check for smooth, stable operation.
- Half-Load Test: Apply approximately 50% of rated load to evaluate braking performance and confirm that the acceleration and deceleration curves are within normal ranges.
- Full-Load Test: Apply 100% of rated load to verify the drive system’s lifting capacity.
- Overload Test: Apply 110% of rated load to confirm that the overload protection device correctly triggers an alarm and prevents the doors from closing. A separate 125% static or dynamic traction test is also performed to verify the traction (friction) margin between the ropes and the sheave.
Verification of Safety Protection Functions
Every safety device on the elevator must be tested individually:
- Overspeed Governor Test: Simulate an overspeed condition to confirm that the governor trips promptly and engages the safety gear.
- Buffer Inspection: Confirm that the buffers are correctly positioned and can effectively absorb impact energy.
- Emergency Stop Test: Test the emergency stop buttons in the machine room, on the car top, in the pit, and inside the car to confirm they respond immediately.
- Emergency Power Test: Verify that emergency lighting and rescue functions operate correctly in the event of a power outage.
- Door System Test: Verify that door locks, door interlocks, and light curtains all function correctly; confirm that door opening and closing are synchronized and that anti-pinch (obstruction) protection works as intended.
- Brake Test: Verify that the brake engages reliably in the event of a power loss.
- Leveling Accuracy Test: Confirm that leveling error at each landing does not exceed ±10 millimeters.
- ARD (Automatic Rescue Device) Test: Simulate a mains power failure to verify that the ARD automatically activates, moving the car to the nearest landing to release passengers while maintaining cab lighting and communication.
- UCMP (Unintended Car Movement Protection) Test: Simulate unintended movement of the car with the doors open to verify that the UCMP system detects the movement and brings the car to a stop promptly.
- Emergency Communication Test: Verify that the in-car emergency intercom connects reliably to the monitoring center or control room and that communication is established without delay.
Car Interior Testing
To reduce on-site installation risk, Dazen pre-assembles key components — including the car, COP (Car Operating Panel), and LOP (Landing Operating Panel) — before shipment, and tests lighting, buttons, displays, and communication functions in the factory to confirm they all work correctly. This allows customers to complete on-site installation more efficiently.
Trial Run
Once installation, commissioning, and safety verification are complete, the elevator must undergo an extended trial run before being handed over for regular use, to confirm the long-term stability of the entire system. This includes:
- No fewer than 1,000 up-and-down runs
- Door opening and closing cycles
- Re-verification of leveling accuracy
- Noise level testing
- Vibration testing
- Testing of acceleration, deceleration, and jerk (rate of change of acceleration)
- Ride comfort assessment
Only once every one of these tests has been passed, and a complete test report has been compiled, can the elevator be certified safe for operation.