Overload Sensors for Elevators
Elevate Safety. Ensure Precision. Prevent Overloading.
As urban infrastructure grows vertically, the safety and reliability of elevators become more critical than ever. One of the most essential components of a safe elevator system is accurate load monitoring. Overloading not only risks passenger safety but also leads to accelerated wear and tears, regulatory non-compliance, and unplanned downtimes.
Puretronics, a leading name in elevator electronics, offers a comprehensive range of Overload Sensors designed to deliver unmatched precision, seamless integration, and long-term performance across diverse elevator applications.
What Is an Overload Sensor?
An overload sensor is a compact, high-precision device installed within an elevator system to monitor the weight of its contents in real-time. These sensors detect when the load exceeds the permissible limit and communicate with the elevator controller to trigger safety mechanisms such as alarms, system halt, or load-reducing alerts.
Puretronics' overload sensors utilize intelligent wire rope sensing technology, ensuring highly accurate weight detection without compromising on installation simplicity or operational flexibility.
Why You Need an Overload Sensor in Your Elevator System
Elevator overloading is not just a mechanical issue—it’s a compliance risk and a safety hazard. Regulatory guidelines and safety codes in both residential and commercial real estate increasingly mandate load monitoring systems in elevators.
- Preventing elevator operation under unsafe load conditions
- Reducing mechanical stress on traction and braking systems
- Extending the lifespan of elevator components
- Helping meet ISO, EN-81, and local safety compliance standards
- Minimizing service costs and downtime due to overload-related faults
Key Advantages of Puretronics Overload Sensors
Puretronics is a leading Indian manufacturer of elevator safety and automation electronics. With decades of experience in embedded hardware and elevator system integration, we offer future-ready solutions that empower OEMs, AMC providers, and developers alike.
Fast Installation & Calibration
Our rope-type overload sensors can be installed and calibrated within 5 minutes. The universal clamp design makes them compatible with multiple rope diameters and elevator configurations—ideal for both new installations and modernization projects.
Integrated Display Interface
Our devices comes with a built-in digital display, offering real-time visibility of load values for technicians and service staff. This allows for quick diagnostics and accurate load threshold verification on the go.
Relay, Analog, and Digital Outputs
Support for relay logic, 0–10V analog output, and RS485 digital communication ensures compatibility with almost any elevator controller system—be it legacy or smart.
Compact, Durable & Maintenance-Free
Engineered for India’s tough elevator environments, our sensors are:
- Dust- and moisture-resistant
- Temperature stable
- Load-tolerant upto 200% Rated Capacity (RC)
Compact, Durable & Maintenance-Free
Features
| Feature | ARS Series | LXR Series | LPF Series |
|---|---|---|---|
| Application Type | Passenger | Passenger, Goods, Hospital, Car, Heavy-duty | Passenger, Goods, Hospital, Car, Heavy-duty |
| Mounting Type | Rope Mount | Rope Mount | Platform Mount |
| Load Capacity | Upto 999Kg | Upto 3000Kg | Upto 6400Kg |
| Integrated Display | Yes | Build in display at the controller | Build in display at the controller |
| Relay Output | Yes (Programmable) | Yes (Programmable) | Yes (Programmable) |
| Analog Output | NA | Yes | Yes |
| RS485 Communication | NA | Yes | Yes |
| Installation Time | Quick (5 min calibration) | Quick | Very Quick |
| Ideal For | Small to mid-capacity & retrofits | High-capacity new & retrofit systems | Space-constrained systems |
| Space Optimization | Moderate | High | High |
| Features | ARS Series | LXR Series | LPF Series |
|---|---|---|---|
| Mechanical | |||
| Related Load | 3500kg | 8000kg | 800kg/sensor |
| Safe Load | 150% RC | 150% RC | 150% RC |
| Ultimate Overload | 200% RC | 200% RC | 200% RC |
| Deflection at Overload | < 0.5 mm | < 0.5 mm | < 0.5 mm |
| Hysteresis | < 0.1% RC | < 0.1% RC | < 0.1% RC |
| Total Error | < 0.5% RC | < 0.5% RC | < 0.5% RC |
| Weight | Approx. 2kg | Approx. 4kg | 0.6 Kg / Sensor |
| Temperature Effect on Output | ±/-0.01% / °C | ±/-0.01% / °C | ±/-0.01% / °C |
| Temperature Effect on Zero | ±/-0.02% / RC | ±/-0.02% / RC | ±/-0.02% / RC |
| Operating Temperature | 10°C - 50°C | 10°C - 50°C | 10°C - 50°C |
| Measuring Range | 999 kg | 3000 kg | 6400 kg |
| Cable Length | 2 mtr / 5mtr | 7mtr | 5Mtr |
| Electrical | |||
| Power Supply | 24-48 VDC | 24-48 VDC | 24-48 VDC |
| Disabling Input | 24-VDC / 230-VAC | 24-VDC / 230-VAC | 24-VDC / 230-VAC |
| Relay | 250V 3A | 250V 3A | 250V 3A |
| Relay output (Configurable) | 2 | 3 | 3 |
| Nature of Relay Output (Configurable) | Active High, Active Low | Active High, Active Low | Active High, Active Low |
| Analog Output | 0-20mA, 4-20mA (Optional) | 0-20mA, 4-20mA (Optional) | 0-20mA, 4-20mA (Optional) |
| Voltage Output | 0 -10VDC | 0 -10VDC | 0 -10VDC |
| Communication | RS485 (Optional) | RS485 (Optional) | RS485 (Optional) |
Use Case Applications
Passenger Elevators
Ensure passenger safety and reduce service calls by preventing overloading with audible and visual alerts. The sensor actively monitors cabin load in real time and prevents the elevator from operating beyond its limit.
Hospital Elevators
With frequent transport of patients and heavy medical equipment, accurate load detection is crucial. The overload sensor avoids strain on elevator mechanisms while ensuring safe operation during critical emergencies.
Goods & Freight Elevators
In warehouses, factories, and logistics hubs, overload protection prevents accidents caused by equipment or pallet overloading. Our sensors automatically stop elevator movement when unsafe loads are detected.
Car Elevators
Especially in parking systems, basement lifts, and residential buildings, Puretronics overload sensors ensure vehicles are transported securely without exceeding the lift’s rated load.
Heavy-Duty Industrial Lifts
Engineered to handle intense weight fluctuations, our ARS series is ideal for industrial elevators that carry machinery and construction loads.
Who Uses Puretronics Overload Sensors?
We are trusted by:
- Elevator OEMs and cabin manufacturers
- Lift modernization contractors
- Facility management companies
- Industrial automation integrators
- Hospitals, hotels, real estate developers
With thousands of installations across India, Puretronics overload solutions have become the benchmark for safety and integration ease.