Description

1. Part-number breakdown BG202-ES21C = 21 A continuous, 31 A for 60 s, 7.5 kW, built-in 2 A brake transistor, 24 VDC logic, IP20, –10 °C…+50 °C
   OT31C = 31 A continuous, 45 A for 60 s, 11 kW, same features, larger heat-sink
   Both share 300 × 220 × 90 mm footprint, common spare parts list, MTBF 80 kh @ 25 °C
2. Safety first—lock-out & discharge DC bus holds 540 V for up to 5 min after mains off. Lock the upstream breaker, hang a lock-out tag and wait for the red LED to extinguish. Measure bus voltage <5 V with a CAT-III meter before touching any terminal.
3. Mechanical mounting—keep it cool Snap onto 35 mm DIN rail; torque M4 screws 1.5 N·m if plate-mounted. Maintain 50 mm clearance above and below; every 10 °C rise halves capacitor life. NYE supplies a free DIN clip (NY-DIN-BG202) and 10 mm thermal pad (NY-PAD-BG202) for shallow headers.
4. Wiring map (print and stick inside door) L1/L2/L3 IN: 6 mm² (ES21C) or 10 mm² (OT31C), 600 V, 105 °C silicone, torque 2 N·m
   U/V/W OUT: same gauge to door motor, run in separate conduit from encoder cable
   DC+/DC–: 25 A brake resistor, min 100 Ω (ES21C) or 50 Ω (OT31C), 1 kW for 3 s (use NY-DBR-BG202)
   Encoder: 1024-ppr A/B/Z differential, shield grounded at inverter end only
   24 V & 0 V: 1.5 mm², 105 °C, torque 0.8 N·m
   RS-485: J6, 9600-8-N-1, 3.3 V logic, shield at MPU end only
5. Power-up & auto-tune Apply 24 VDC logic, then mains; green “PWR” LED steady, red “FLT” off.
   Key parameters (factory card shipped with every NYE unit): P0.00 = 3 (motor type: PM synchronous)
   P0.01 = 1 (control mode: closed-loop vector)
   P0.02 = 9.5 (motor rated current ES21C) or 14 (OT31C)
   P0.03 = 3000 (rated rpm @ 2.0 m/s door)
   P3.00 = 0 (run source: terminal)
   P3.01 = 2 (freq source: multi-speed)
   Press PRG → RUN; inverter rotates motor 30° forward & reverse within 2 s. If auto-tune fails with E05, swap any two motor phases and repeat.
6. Door-speed & torque tuning Capture actual speed with Otis Z-Term (free). Target: <5 mm overshoot, <3 mm crawl. Adjust: P5.01 (accel time 0→100 %) 0.4 s
   P5.02 (decel time 100→0 %) 0.3 s
   P5.05 (S-start) 25 %
   P5.06 (S-end) 20 %
   Save map to EEPROM (hold ENT 5 s). Green LED steady = burn-in complete.
7. Temperature & lifetime model Electrolytic capacitors: 105 °C, 5 000 h rated; at 50 °C Arrhenius predicts 40 000 h.
   Fan: 40 kh @ 40 °C, doubles every 10 °C drop.
   Opto-couplers: 50 kh @ 70 °C, double every 10 °C drop.
   Translate to door duty: Light traffic (office, 8 h/day, 5 days/week) – capacitors ≈ 18 years, fan ≈ 25 years, full inverter ≈ 15 years; inspect every 3 years. Medium traffic (mall, 12 h/day, 7 days/week) – capacitors ≈ 8 years, fan ≈ 10 years, full inverter ≈ 7 years; inspect every 2 years. Heavy traffic (metro, 20 h/day) – capacitors ≈ 4 years, fan ≈ 5 years, full inverter ≈ 4 years; inspect every 12 months.
8. Remote monitoring (optional) RS-485 registers:
   0x00 = output voltage (×100 mV)
   0x01 = output current (×100 mA)
   0x02 = temperature (°C)
   0x03 = fan speed (rpm)
   0x04 = surge counter (increments on >500 V spike)
   Poll every 30 s; fan speed <75 % or temperature >75 °C schedules replacement.
9. Preventive inspection checklist Monthly: visual PWR LED, listen for fan rattle. Quarterly: scope DC bus ripple; >100 mV pp indicates aged capacitors. Annually: megger U-V-W to PE >100 MΩ; <10 MΩ indicates carbon track. Bi-annually: torque test power terminals; vibration loosens them, causing arcing and fault F08.
10. Rapid swap (downtime < 8 min) a) Power down, lock-out, wait 5 min for bus <5 V.
    b) Photograph L1/L2/L3 and U/V/W orientation.
    c) Remove DIN clip, slide old inverter out.
    d) Insert new NYE BG202-ES21C/OT31C, snap onto rail.
    e) Restore power, motor, brake, encoder, RS-485, set DIP switches as photo.
    f) Power up, run auto-tune, verify 2.0 m/s door speed.
    g) Log serial number and date; return old unit for recycling.
11. Recycling & sustainability Nanjing Zhuye offers prepaid DHL labels inside every carton.
    Returned inverters are stripped: aluminium heat-sink remelted, copper bus-bars smelted, IGBT modules recovered for silver and gold.
    One recycled BG202-ES21C/OT31C saves 4.8 kg CO₂—enough to power the same door for a week.