Dual Plunger Retrofit Brake Kit

Titan’s offering prioritizes elevator safety and reliability.

submitted by Titan

Field service teams frequently encounter aging or underperforming single plunger-designed brake systems that demand attention. Titan’s Dual Plunger Retrofit Brake Kit — a purpose-built solution designed to meet current safety expectations and make the lives of elevator professionals easier — was designed with this in mind.

Why the Dual Plunger Kit Was Developed

The inspiration for the Dual Plunger Retrofit Brake Kit grew directly from feedback from the large installation base of Titan’s line of geared traction machines in and around the NYC metro area. The issue was the reliance of the machine on a single plunger to actuate the main brake. While the design philosophy had been a hallmark of many well-performing legacy machines, there was an inherent challenge associated with a design that lacks mechanical redundancy. Recognizing this need, Titan’s engineering team set out to design a brake retrofit solution that would not only meet code requirements but also enhance safety while addressing downtime concerns for the upgrade. The Dual Plunger Kit was developed to:

• Deliver redundant, consistent, braking power utilizing dual plungers and solenoids
• In gearless applications, provide ascending car overspeed (ACO) and unintended car movement protection (UCMP)
• Improve safety and redundancy, giving mechanics and building owners confidence in their equipment
• Simplify retrofit installation without requiring extensive machine modifications
• Extend service life with heavy-duty, precision-engineered components.

The result is a kit that combines the robustness mechanics want with the reliability consultants and property managers demand, all while exceeding all safety factors and meeting new code requirements. 

What the Kit Includes

The Dual Plunger Retrofit Brake Kit is a complete, field-ready package that contains model-specific components. Kits always include:

• Dual plungers and solenoids, certified to meet code and matched to the machine’s force requirements
• Mounting hardware and retrofit bracketry engineered to align seamlessly with existing machine models
• Dual high-quality micro switches to deliver brake status signals for controller integration
• Precision-machined components for maximum performance
• Installation instructions and support resources created with mechanics in mind, minimizing downtime and guesswork For ACO and UCMP applications, kits may include some or all of the following components:
• High-friction, long-wear brake shoes for reliable stopping power
• Replacement mounting and adjustment hardware
• Replacement brake arms and compression springs

Everything ships as a turnkey solution including manuals and expert technical support one phone call away so field teams can focus on the install instead of chasing parts or fabricating workarounds.

Field Response and Industry Recognition

The first Dual Plunger Kit was introduced and installed on Titan I geared traction machines in 2021. Since then, hundreds of units have been installed and continue to operate reliably throughout the Northeastern U.S. on Titan I and Titan II machines.

In September 2024, Titan introduced the newest expansion of the kit to include Westinghouse gearless machines at the National Association of Elevator Contractors convention in Atlantic City, New Jersey. The new variant, WBK-157, is designed, certified and tested on Westinghouse model 157(A) machines. Recent installations confirm the downtime for the machines undergoing the upgrade is a fraction of the time associated with installing competing products. Earlier in 2025 at the International Association of Elevator Consultants (IAEC) convention in New Orleans, veteran consultants praised the engineering behind the design. At the IAEC event, Carlos Escobar and Pete McIntosh unveiled development plans that expanded the product offering to include nearly all legacy equipment — both geared and gearless — that currently employ the single plunger design that spurred the product’s initial development. Attendees pointed out the clean construction, straightforward retrofit process and long-term benefits for safety and performance.

Since then, customer response has been overwhelmingly positive. Independent service contractors see the kit as a time-saving upgrade that adds value to their maintenance contracts. Consultants appreciate the code compliance and long-term safety benefits. And building owners, especially those with high-traffic facilities, welcome the confidence of knowing their elevators are equipped with a modern, codecompliant and reliable primary and emergency braking solutions.

Who Uses It

The Titan Dual Plunger Retrofit Brake Kit has become a go-to solution across several key segments of the elevator industry. These include:

• Elevator contractors looking for a trusted retrofit kit that installs quickly and performs reliably
• Elevator consultants seeking modern code-compliant braking solutions for modernization projects and safety upgrades, particularly when legacy equipment is well maintained and suitable for retention
• Building owners and property managers who need confidence that their equipment is both code-compliant and dependable
• Mechanics in the field who want a brake system that’s not only safe but also designed to make their job easier From commercial high-rises to residential buildings, the Dual Plunger Kit is proving its versatility and reliability.

Why the Market Needs This

Single-plunger systems, while still common, have an inherent single point of failure. A failure or binding of that single plunger could likely result in, at best, increased downtime and brake adjustments, or at worst, catastrophic damage to property or loss of life. With the Dual Plunger Retrofit Brake Kit, Titan believes it has delivered a smarter, safer and more efficient option that directly addresses these concerns.

In a field where every second of downtime costs money and every safety risk carries liability, this kit provides a critical upgrade that keeps elevators moving — and passengers safe.

Key Benefits at a Glance

• Enhanced safety with dual plungers for redundant reliable braking
• Ease of installation with retrofit-friendly components
• Durability with highest quality electrical and mechanical components
• Positive industry reception from consultants, contractors and owners
• Peace of mind for mechanics, operators and passengers

Looking Ahead 

The Dual Plunger Retrofit Brake Kit’s design and functionality is demonstrative of Titan’s company ethos. These kits are a testament to the company philosophy: “We build strong, we build heavy, we cut no corners and we DO NOT compromise on safety.”

As one consultant put it after seeing the product in action: “This is exactly the type of thoughtful, field-driven solution our industry needs. It takes what’s been frustrating mechanics for years and turns it into a straightforward, reliable fix.”

With growing adoption across North America and recognition from industry leaders, the Titan Dual Plunger line of retrofit brake kits is poised to become the standard for retaining reliable and well-maintained traction machines in modernization projects and safety upgrades in the years ahead. landing.hyperion-solutions.com/titan