Field Manual

1.1 Module No.

Otis Equipment
506 NCE Escalator
Schindler Lifts Australia Otis Equipment
Copyright  506 NCE Escalator

Contents

1. Overview 3

2. Safety Switch Descriptions and Locations 4

3. Operation Panel, OP, & Fault Code Display 6

4. Machine Room/Maintenance Room – Upper Landing 8

4.1 Escalator Control Board (ECB) 9
4.2 Junction Box Upper Landing (JBUL) 11
4.3 Machine Components 12
4.4 Machine Brake Setup (Y1) 13
4.5 Broken Drive Chain Switch (BDC) 14
4.6 Handrail Entry Switches 14
4.7 Emergency Brake (Y2, EB1) 15
4.7.1 Emergency Brake Operation
4.7.2 Emergency Brake Set Up

5. Side Skirt Removal 18

6. Pit/Maintenance Room – Lower Landing 20

6.1 Inspection Panel 21
6.2 Tension Carriage Adjustment 21
6.3 Tension Carriage/Broken Step Chain Switch 21

7. Step Removal and Replacement 22

8. Common Faults & Fixes 24

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1. Overview

The Otis 506 NCE escalator is part of the Modular Control Systems
(MCS) product range of Elevators and Escalators using processor boards,
serial communications and the Otis Service Tool for diagnostics and set
up of the system.
Some important checks and adjustments specific to the 506 NCE
escalators should be made regularly to ensure the reliability of the
escalator.
These include Machine Brake adjustment and Emergency Brake
adjustment.

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2. Safety Switch Locations and Descriptions

Machine Room/Motor Room may be referred to as Maintenance Room

Upper Landing.
Pit/Lower Trap may be referred to as Maintenance Room Lower Landing.

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Location Switch Name Diagram Description

No. Label
1 Emergency Stop Buttons, S26(OP) Push Button, auto reset.
Upper & Lower Landing S25(OP1)
2 Handrail Entry Switches, S23, S24 Activated by faulty or loose
Upper Right & Left, Lower S21, S22 handrails, or a build up of
Right & Left foreign matter on handrails.
Auto reset.
3 Broken Step Chain Right & S14, S15 Broken or loose step chain,
Left (Tension Carriage) located in pit. Manual
Reset
4 Combplate Switches, Left S1, S2 Activated by foreign
Upper, Right Upper, Left S16, S17 objects caught in
Lower, Right Lower. combplates, located in
motor room and pit.
Auto reset
5 Broken Step/Axle, Upper & S10, S20 Located under steps/pallets
Lower 3 – 4 steps from top and
bottom landings, steps or
skirting must be removed to
reset.
6 Chain Wheel Contacts, Right S94, S95 Located under upper skirt
& Left panels.
Manual reset.
7 Non-Reversal Device B1, B1.1 Proximity sensors under
drive machine, input to
ECB, reset by SW1 on
ECB
8 Broken Drive Chain S28 Located in motor room.
(BDC) Manual reset
9 Governor Overspeed Switch S27 Located in motor room on
(OS) top of machine.
Manual reset.
10 Skirt Panel Switches, Upper S3, S4, Located behind skirt panels
Right & Left, Lower Right & S14, S15 near step entry points.
Left Auto reset.
11 Pit Stop Switch Q3 Located in pit.
Manual set & reset.
12 Emergency Brake Switch S53 Located in motor room near
(EB1/EB3) emergency brake. Detects
if Emergency Brake has
lifted.

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3. Operation Panel, OP, & Fault Code Display

Emergency
Stop Button,
Keyswitch,
S25, S26
KSU & KSD
Anti-clockwise
UP, clockwise
DOWN.

Display Panel

Fig. 4 Keyswitch &Display Panel, upper landing skirt

Display Code Fault Code Reference
EMERG.STOP S25/S26 Emergency Stop Button upper or lower
START ACC OPER landing
INSTRUCT
HANDRAIL ENTRY S21/S22 Handrail Entry switches right/left lower
START ACC OPER S23/S24 Handrail Entry switches right/left upper
INSTRUCT
OTIS GR3 F3 Safety Circuit Fuse (ECB F1)
S27 Governor Overspeed Switch
S28 Broken Drive Chain Switch
NRD Non Reversal Device
OTIS GR4 S1 Left Hand Comb
(Upper Landing S2 Right Hand Comb
switches) S3 Left Hand Skirt Panel
S4 Right Hand Skirt Panel
S10/S64 Broken Step or Pallet
S94 Right Hand Chain Wheel
S95 Left Hand Chain Wheel
OTIS GR5 S14 Right Hand Broken Step Chain
(Lower Landing S15 Left Hand Broken Step Chain
switches) S16 Left Hand Comb
S17 Right Hand Comb
S18 Right Hand Skirt Panel
S19 Left Hand Skirt Panel
S20/S65 Broken Step or Pallet
S45 Left Hand Broken Handrail
S46 Right Hand Broken Handrail
Q3 Stop Switch (Pit)
OTIS GR6 ASN Phase Device (low or reverse phase)
B2 Motor Thermal Device
S33 L/H Brake lifted contact
S34 R/H Brake lifted contact

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Display Code Reference

OTIS B25 Missing Step/Pallet upper landing
OTIS B26 Missing Step/Pallet lower landing
OTIS S05 Floorplate upper landing
OTIS S06 Floorplate lower landing
OTIS B2 Motor Temperature contact
OTIS J Phase Reversal
OTIS NRD Non-reversal device – ECB
OTIS E12 Up & Down at same time – logic error ECB
OTIS E11 No Up or Down while running – logic error ECB
OTIS E14 KSU (Keyswitch Up) or KSD (Keyswitch Down) while on INS
OTIS E15 KSU signal & D relay or KSD & U relay
OTIS E16 Power fail 24V (VRS)
OTIS E17 KSU/D longer than 10 seconds
OTIS E18 Handrail slip right
OTIS E19 Handrail slip left
OTIS E20 Right Handrail slip LOCKED fault – too many slip errors
OTIS E21 Left Handrail slip LOCKED fault – too many slip errors
OTIS E22 No run signal within 2 seconds of KSU or KSD
OTIS S53 Emergency brake switch
OTIS E26/E27 No Up/No Down – Check ECB on board relays.

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4. Machine Room/Maintenance Room – Upper Landing

Fig 4.1 Upper landing trapdoor removed Fig. 4.2 Machine Room Guarding

Fig. 4.3 Machine Room Equipment, Trap door removed.

Governor switch,
under flywheel

Emergency
Brake Solenoid
Broken
Drive Machine Drive Chain
Switch

RSFF input Board, NRD Machine Brake,

RS4R input/output Controller, & Brake
ECB Switches
Boards Switches

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4.1 Escalator Control Board (ECB)

P5 P4 P6
P2
P1

3 4 5 6
1 2

P15
7 8 9
P6

11

10
12 13
P14
P8

P9

P12 P10

Fig. 4.4 Escalator Control Board, removed from controller box

Table 4.1 ECB Component Descriptions

No. Name Description
1 REL1 – Ready Energises with Up or Down relays when running
2 REL2 – Up Up direction relay
3 REL3 – Down Down direction relay
4 REL4 – Check Checks Up, Down, Ready, NRD1, NRD2, EOK and
K1 & K2 have dropped before running
5 REL5 – NRD1 Non Reversal Device 1 OK
6 REL6 – NRD2 Non Reversal Device 2 OK
7 REL7 – YD Star-Delta relay – in for delta operation
8 REL8 – EOK Electronics OK – in if all boards are OK
9 REL9 – GO Controls K1 & K2, main motor contactors
10 SW1 – NRD Resets electronically locked failures by the ECB, i.e.
Reset NRD failure & Handrail Slip Errors
11 LED’s 4 – 7 Either on, off or blinking – refer to table 6.2
12 LED 8 – RSL Blinking – Remote Serial Link communications OK
13 LED 9 – VLC On – ECB 5Volt Supply OK

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Table 4.2 ECB Plug Connectors

No. Description
P1 Safety Circuit/Up & Down start inputs
P2 ‘CHECK’ & main contactor inputs
P3 NRD1/NRD2 & Timer contacts
P4 Motor speed monitoring – B1 (NRD1 sensor)
P5 Motor speed monitoring – B1.1 (NRD 2 sensor)
P6 Motor temperature monitoring – B2
P7 Handrail speed monitoring/key switch monitor etc.
P8 Remote Serial Link
P9 Contactor monitoring
P10 415vac & 240vac input & neutral
P12 Service Tool port
P14 ECB power supply
P15 230vac input/output and relay drivers

Table 4.3 ECB LED’s 4 – 7

LED No. Name State Failure

(LED 4 OFF) (LED’s 5, 6 & 7 change function if LED 4
ON)
4 Failure off Off indicates no failures
5 Operating on Maintenance operation
Mode off Normal operation
6 Up Blink Up Keyswitch input active, Up contactor
(K1) not active.
on Up contactor, K1, active
7 Down Blink Down Keyswitch input active, Down
contactor (K2) not active.
on Down contactor, K2, active

LED No. Name State Failure

(LED 4 ON)
4 Failure on Fault auto reset by Keyswitch
blink Manual reset fault – ECB Electrically
Locked, reset switch/ECB Reset SW1
5 Safety circuit off Safety Chain contacts at RSFF input OK
on Safety Chain contact at RSFF open
6 ECB off No failure on ECB
on ECB failure
7 RSR4 contacts off RSR4 inputs OK
on RSR4 inputs faulty

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4.2 Junction Box Upper Landing (JBUL)

Fig. 4.5 Junction Box, RSFF & RS4R Boards

Terminal
Block

Remote
Station Fault
Finder Board, Remote
Station Relay
RSFF
Boards, RS4R

Circuit Breaker
for Step Lighting,
Demarcation
Lights

Emergency Brake
Contactors, KO2 &
KO2.1

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4.3 Machine Components

Motor Terminals, connected in

a sealant and not serviceable

Machine cover
Switch/Handwheel Contact
(S73),
Fig. 4.6 Machine

Hole to reset Governor Switch. Lift

Machine Brake & manually turn
flywheel to align hole with switch.

Wiring to
Governor Switch

Machine cover switch/Handwheel

Contact (S73), in Safety Circuit
Fig. 4.7 Machine with cover removed

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4.4 Machine Brake Setup (Y1)

Brake Springs, &

Tension adjustment
Nuts.

Brake Lift
Adjustment

Figure 4.8 Machine Brake

• Machine Brake adjustment may be adjusted with the escalator

running in the down direction with no load.
• For escalator running speed of 0.5 m/sec, slide should be between
0.2 metres and 1.0 metre.
• For escalator running speed of 0.75 m/sec, slide should be between
0.35 metres and 1.5 metres.
• If too much tension is put on brake it may not fully lift. If so
increase brake lift and re-tension brake springs.

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4.5 Broken Drive Chain Switch (S28, BDC)

Switch activated by
plunger if guide
moves in downward
direction

Bolts to adjust height

and center of switch
guide to center of
chain

4.6 Handrail Entry Switches (S23, S24-Upper/S21, S22-Lower)

Ensure 3mm gap

Minimum for entire
length of handrail.

Ensure plastic cover is

clipped in flush with
metal surround.

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4.7 Emergency Brake (Y2, EB1)

The Emergency Brake will engage if any of the following conditions
occur; Governor Overspeed Switch, Broken Drive Chain Switch, blown
Safety Circuit Fuse or power failure. The Escalator then must be run UP
direction to reset the Brake.

Main Drive Shaft

Emergency Brake
Disc
Emergency
Brake Shoe

Brake Shoe Latch

(not visible, Engages
Solenoid Latch Arm) Solenoid
Latch Arm

Emergency Brake
Solenoid, Y2

4.7.1 Emergency Brake operation:

• When escalator main circuit breaker is switched on, provided the
Governor Overspeed switch (OS), Broken Drive Chain Contact
(BDC) and NRD Timers (K063 – K066) are correct, K02 and
K02.1 will energise, hence energising the Solenoid, Y2.
• Although the solenoid has energised, the Emergency Brake will not
set until the escalator is run in the UP direction.
• Due to Emergency Brake Switch, S53, the escalator will be
prevented from running in the down direction.
• As the escalator is run in the up direction, arms located on the
Drive Shaft Disc disengage the Brake Shoe.
• The Emergency Brake Arm then latches the Brake Shoe in the
down position, keeping it disengaged from the disc.
• If the Emergency Brake does not deactivate and latch in the down
position, the escalator will stop after 5 seconds.
• The Emergency Brake Switch, S53, is activated by the Brake arm
allowing the escalator to be run in the down direction.

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Emergency Brake Beam

Brake Disc Adjustment
Bolt
Upper Shoe
Stop Bracket
Brake Beam
Emergency Brake (hinged at the
Shoe in engaged bottom)
position

Emergency Brake
Solenoid, Y2

4.7.2 Emergency Brake Setup

• Turn Main Circuit Breaker off so that Emergency Brake engages.
• Check that the Solenoid has de-energised, solenoid arm has
lowered and brake shoe has released and engaged the Drive Shaft
Brake Disc (the shoe is spring loaded).
• Emergency Brake Switch (EBS) arm should be in the up position.
A bracket on the brake shoe positions the switch arm.

Fig 4.8 Solenoid energised, arm lifted Fig 4.9 Solenoid De-energised, arm dropped

• Loosen the lock nuts at the top of the Brake Beam.

• Switch on the main circuit breaker. KO2 & KO2.1 contactors
energise, the solenoid should energise, lifting the arm 20mm –
25mm.
• Warning! If arm lifts too high, brake shoe latch may break when
brake resets. Careful adjustment of arm is necessary.

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Emergency Brake Setup (cont.)

Push down here

with large
screwdiver.

• Run escalator UP to disengage Brake Shoe. If it fails to latch, stop

the escalator using the Emergency Stop button. Using a large
screwdriver push down from the top of the Brake Shoe until it
latches.
• Ensure Brake shoe is centered on Disc. Move Brake Beam towards
Disc using adjusting bolts.
• Engage Emergency Brake by switching off Main Circuit Breaker.
• Brake Shoe should be 20mm clear of Upper Shoe Stop Bracket
when engaged correctly.
• Switch on escalator and run in UP direction to disengage
Emergency Brake. Re-do procedure if necessary.
• Tighten adjusting bolts when correctly adjusted.

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5. Switches Accessible Under Skirt Panels

5.1 Combplate
switch

5.2 Skirt Panel

Switch

5.3 Chain
Wheel Switch

5.4 Broken
Step/Step Sag
Switch (Most
models have arm
to reset without
removing steps)

Fig. 5.1 Side Skirt removed, upper landing

5.1 Combplate Switch (S1, S2-Upper/S16, S17-Lower)

1 – 1.5mm
gap to switch
roller
Combplate
switch location

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5.2 Skirt Panel Switch (S3, S4-Upper/S18, S19-Lower)

1mm gap to
switch

Skirt Panel Covers of these switches

Skirt Panel are hinged at back, unclip
bracket Switch location
to see wiring connections

5.3 Chain Wheel Switch (S94, S95)

5.4 Broken Step/Step Sag Switch (S20)

Arm connected to Step Sag

bracket. Allows switch to be
reset by removing skirt
rather than steps.

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6. Pit/Maintenance Room – Lower Landing

Fig. 6 Lower Trap open with guarding erected

Tension
carriage/Broken Step
Chain Switches, (S14 &
S15)

Tension Carriage
Adjustment Springs

Stop Switch
Maintenance Room, Inspection Panel
(Q3) Socket, (X6)

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6.1 Inspection Panel

STOP Button

Remove Blind Plug UP Button DOWN Button

and insert
inspection Panel
socket

6.2 Tension Carriage Adjustment

Left Side Right Side

Spring length Spring Length

102mm +/- 2mm 102mm +/- 2mm

6.3 Tension Carriage/Broken Step Chain Switches (S14, S15)

Switch should
be centered 1-
1.5mm clear of
bracket

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7. Step Removal and Replacement

Step Removal Keys

Step release clips

Step guard wing nuts.

Fig. 7 Lower Trap, with Step Guard removed

1. Ensure escalator is on inspection control and Emergency Stop

Button in and inspection panel plugged in. (Refer to section 6.1)
2. Remove step guard by loosening wing nuts.
3. Nudge escalator so that Step Release Keys are accessible, and cut
out for Step Roller is clear. (Refer to Figure 7.3)
4. Using Step Release Keys, undo clips and slide towards middle of
step, then pull step from track by moving step roller towards cut
out in track. (Refer to Figure 7.1)
5. Using inspection panel nudge escalator to access next step and
repeat procedure.
6. Step replacement is reversal of this procedure; ensuring step clips
are properly re-engaged.

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Clip in
released
position Step Key used
to release clip

Figure7.1 Step Key inserted into Step Release Clip

Figure 7.2 Top of step released

Next step positioned

so that cut out is
clear Cut out for Step
Roller to remove step

Figure 7.3 Step unclipped, showing cut out for removal

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8. Common Faults & Fixes

• The most common fault with the escalator control board is the on-
board Siemens relays. Replacement of this board requires re-
installation of the software parameters by use of the Service Tool.
• Another common fault is the ‘Wago’ type connector block contacts
to the ECB becoming high resistance.
• Intermittently stopping with Handrail Entry errors. Switches
too close to handrail, ensure Handrail Entry plastic casing is
clipped into metal surround properly and handrails are free of
debris.
• Escalator will not run in down direction but will run in up
direction. Check Emergency brake setup and Emergency brake
Switch position.
• Escalator intermittently tripping Main Circuit Breaker.
1. Check Machine Brake adjustment, ensure it lifting fully.
2. Check step Demarcation Lighting circuit breaker, possible short
circuit in wiring, it may have rubbed on the handrail if not secured
properly.
• Escalator will not start, showing E15/E17/E22 on display.
1. Check auxiliary contacts on K1, K2, K3 and K4 contactors
located behind ECB Board in controller.
2. Check Operation Panel wiring behind skirt paneling is secured
and not worn on handrail.
3. Check operation of ECB on board relays, replace ECB if
necessary.
• Escalator will not start, showing GR3 or F3 on display. Check
ECB fuse, F1, check Remote Station Fault Finder Boards (RSFF)
are O.K, i.e. GL1 LED is flashing, if not check wiring, if O.K.
replace RSFF Board.

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