Description

1. Part-number breakdown XO5286A203 = 27 VDC ±0.3 %, 15 A continuous, 22 A for 60 s, 3-phase 380 VAC ±15 % input, 24 V battery input (18–30 V), built-in 4 A battery charger, hot-swap fan, RS-485 telemetry, IP20, –10 °C…+60 °C
   Replaces legacy XO5286A202 and XO5286A201 without parameter change; footprint 350 × 220 × 100 mm, mass 5.1 kg
2. Safety first—lock-out & discharge Output terminals remain live even when mains contactor is open. Lock the upstream breaker, hang a lock-out tag and wait 5 min for the DC bus to fall below 5 V. Confirm with a CAT-III meter before touching any conductor.
3. Mechanical mounting—keep it cool Use four M6 holes on 10 mm steel back-plate; torque 12 N·m. Maintain 100 mm clearance above and below; every 10 °C rise halves electrolytic life. If controller cabinet is <400 mm deep, mount vertically with input terminals down—this allows convection chimney. NYE supplies a free lifting handle (NY-HDL-BR27-V2) and anti-vibration pads (NY-VIB-BR27-V2).
4. Wiring map (print and stick inside door) L1/L2/L3 IN: 6 mm², 600 V, 105 °C silicone, torque 2 N·m
   DC+/DC– OUT: 35 mm² copper bus-bar, torque 18 N·m
   BAT+/BAT–: 10 mm², 105 °C, fuse 25 A fast-blow (supplied)
   Remote ON/OFF: J3, 5 VDC or dry contact
   RS-485: J4, 9600-8-N-1, shield grounded at MPU end only
   Fan alarm: N/O contact 30 V 1 A (J5) for BMS
5. Start-up & no-load test Apply three-phase; green “AC” LED steady, fan runs for 3 s then idles.
   Measure output: 27.00 V ±0.2 V no-load.
   Ripple: <30 mV pp (scope 20 MHz BW).
   Battery current: 2 A float when BAT >25 V.
   If fan does not start or ripple >50 mV, replace unit immediately.
6. Battery / brake load test Connect 24 V, 100 Ah battery set; supply must float at 27.0 V, current taper to 2 A within 30 min.
   Apply 15 A resistive load for 30 min; voltage drop <0.15 V, temperature rise <20 °C at 25 °C ambient.
   Thermography: heat-sink <60 °C, toroid <65 °C, fan <40 °C. NYE includes a calibrated test report—transfer values to the maintenance log.
7. Remote monitoring (optional) RS-485 registers:
   0x00 = output voltage (×100 mV)
   0x01 = output current (×100 mA)
   0x02 = battery voltage (×100 mV)
   0x03 = temperature (°C)
   0x04 = fan speed (rpm)
   Poll every 30 s; fan speed <75 % or temperature >65 °C schedules replacement.
8. Temperature & lifetime model Electrolytic capacitors: 105 °C, 7 000 h rated; at 50 °C Arrhenius predicts 56 000 h.
   Fan: 60 kh @ 40 °C, doubles every 10 °C drop.
   Surge IGBT: 200 A peak, 1 000 surges @ 500 V before –3 dB.
   Translate to elevator duty: Light traffic (office, 8 h/day, 5 days/week) – capacitors ≈ 25 years, fan ≈ 30 years, full supply ≈ 20 years; inspect every 5 years. Medium traffic (mall, 12 h/day, 7 days/week) – capacitors ≈ 10 years, fan ≈ 12 years, full supply ≈ 8 years; inspect every 2 years. Heavy traffic (metro, 20 h/day) – capacitors ≈ 5 years, fan ≈ 6 years, full supply ≈ 5 years; inspect every 12 months.
9. Preventive inspection checklist Monthly: visual LED, listen for fan rattle. Quarterly: scope ripple; >50 mV indicates aged capacitors. Annually: megger L-PE >100 MΩ; <10 MΩ indicates carbon track. Bi-annually: torque test DC bus screws; vibration loosens them, causing arcing and fault F45.
10. Rapid swap (downtime < 8 min) a) Power down, lock-out, wait 5 min for bus <5 V. b) Photograph L1/L2/L3 and DC+/DC– orientation. c) Remove four M6 bolts, slide old supply out. d) Offer new Nanjing Zhuye XO5286A203, torque foot bolts 12 N·m. e) Restore input, output, battery, remote and fan cables, torque 18 N·m DC bus. f) Power up, verify 27.00 V, run 15 A load for 5 min. g) Log serial number and fan speed; return old unit for core refund.
11. Recycling & sustainability Nanjing Zhuye offers prepaid DHL labels inside every carton.
    Returned supplies are stripped: aluminium heat-sink remelted, copper bus-bars smelted, ferrite cores recovered.
    One recycled XO5286A203 saves 6 kg CO₂—enough to power the same elevator for a week.