Description

1. Part-number breakdown

• SP = Switching Power
• 200 = 200 A continuous (150 % for 60 s)
• 27 = 27 VDC ±1 % (factory set; trim range 25-29 V)
  Built-in options: 3-phase 380 VAC input (±15%), PFC >0.98, hot-swap fan module, remote ON/OFF, RS-485 telemetry.

2. Safety first—lock-out & discharge Input terminals remain live even when the output is disabled. 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 The supply is 440 × 220 × 132 mm and weighs 11 kg. Use the four M6 mounting slots on a 10 mm steel back-plate; torque 18 N·m. Maintain 150 mm clearance above and below; every 10 °C rise halves electrolytic life. If the cabinet is <400 mm deep, mount vertically with input terminals down—this allows convection chimney. NYE supplies a free lifting handle (NY-HDL-SP200) and vibration pads (NY-VIB-SP200) to reduce structure-borne noise.
4. Wiring map (print and stick inside door) L1/L2/L3 IN: 10 mm², 600 V, 105 °C silicone, torque 4 N·m
   DC+/DC– OUT: 50 mm² copper bus-bar, torque 20 N·m
   PE: 6 mm² green/yellow to cabinet earth bar; leakage <3.5 mA
   Remote ON/OFF: 2-pin, 5 VDC or dry contact (J3)
   RS-485: J4, 9600-8-N-1, 3.3 V logic, 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 slows.
   Measure output: 27.00 V ±0.2 V no-load.
   Ripple: <100 mV pp (scope 20 MHz BW).
   Power factor: >0.98 @ 50% load.
   If fan does not start or ripple >150 mV, replace unit immediately.
6. Full-load heat run Connect 200 A resistive load bank for 2 h.
   Output voltage drop <0.3 V, temperature rise <35 °C at 25 °C ambient.
   Thermography: heat-sink <75 °C, toroid <80 °C, fan <55 °C.
   NYE includes a calibrated test report in every box—transfer values to the maintenance log.
7. 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 input spike)
   Poll every 30 s; fan speed <80 % or temperature >85 °C schedules replacement.
8. Temperature & lifetime model Electrolytic capacitors: 105 °C, 3 000 h rated; at 55 °C Arrhenius predicts 24 000 h.
   Fan: 40 kh @ 40 °C, doubles every 10 °C drop.
   Surge IGBT: 100 A peak, 1 000 surges @ 500 V before –3 dB.
   Translate to elevator duty: Light traffic (office, 8 h/day, 5 days/week) – capacitors ≈ 12 years, fan ≈ 18 years, full supply ≈ 10 years; inspect every 3 years. Medium traffic (mall, 12 h/day, 7 days/week) – capacitors ≈ 6 years, fan ≈ 8 years, full supply ≈ 5 years; inspect every 2 years. Heavy traffic (metro, 20 h/day) – capacitors ≈ 3 years, fan ≈ 4 years, full supply ≈ 3 years; inspect every 12 months.
9. Preventive inspection checklist Monthly: visual LED, listen for fan rattle. Quarterly: scope ripple; >150 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 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 DC+/DC– orientation. c) Remove four M6 bolts, slide old supply out. d) Offer new Nanjing Zhuye SP-200-27, torque foot bolts 18 N·m. e) Restore input, output, remote and fan cables, torque 20 N·m DC bus. f) Power up, verify 27.00 V, run 50 % load for 5 min. g) Log serial number and surge counter; 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 SP-200-27 saves 18 kg CO₂—enough to power the same elevator for two weeks.