TP48300B & TP48600B Maintenance Guide (V100R001 - 02)

TP48300B & TP48600B V100R001
Maintenance Guide
Issue Date Part Number
02 20121102
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and other Huawei trademarks are trademarks of Huawei Technologies Co., Ltd. All other trademarks and trade names mentioned in this document are the property of their respective holders.
Notice
The purchased products, services and features are stipulated by the contract made between Huawei and the customer. All or part of the products, services and features described in this document may not be within the purchase scope or the usage scope. Unless otherwise specified in the contract, all statements, information, and recommendations in this document are provided "AS IS" without warranties, guarantees or representations of any kind, either express or implied. The information in this document is subject to change without notice. Every effort has been made in the preparation of this document to ensure accuracy of the contents, but all statements, information, and recommendations in this document do not constitute the warranty of any kind, express or implied.
TP48300B & TP48600B Maintenance Guide
Contents
Contents
About This Document ..................................................................................................................... 1 1 Safety Information .....................................................................................................................1-1 2 Maintenance Preparation..........................................................................................................2-1 3 Routine Maintenance ................................................................................................................3-1 4 Troubleshooting .........................................................................................................................4-1 5 Common Component Faults ....................................................................................................5-1 6 Replacing Main Components ..................................................................................................6-1
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Figures
Figures
Figure 1-1 Wearing an ESD wrist strap .............................................................................................................. 1-3 Figure 4-1 Internal structure of the TP48600B ................................................................................................... 4-2 Figure 4-2 Internal structure of the TP48300B ................................................................................................... 4-3 Figure 4-3 Monitoring backplane ports .............................................................................................................. 4-4 Figure 4-4 DC surge protector ............................................................................................................................ 4-6 Figure 4-5 AC detection board ........................................................................................................................... 4-7 Figure 4-6 PSU Panel ......................................................................................................................................... 4-8 Figure 4-7 PMU01 panel .................................................................................................................................... 4-9 Figure 4-8 Checking alarm information ............................................................................................................. 4-9 Figure 4-9 AC detection cable connection (TP48300B on the left and TP48600B on the right) ..................... 4-17 Figure 4-10 Load detection cable connection ................................................................................................... 4-17 Figure 5-1 DC contactor ..................................................................................................................................... 5-2 Figure 6-1 Removing the old PSU ..................................................................................................................... 6-1 Figure 6-2 Installing the new PSU ..................................................................................................................... 6-1 Figure 6-3 Replacing the PMU........................................................................................................................... 6-2 Figure 6-4 Replacing the AC surge protector ..................................................................................................... 6-2 Figure 6-5 Installation position of the Power Monitoring Interface Board ........................................................ 6-3 Figure 6-6 Removing the fuse ............................................................................................................................ 6-3 Figure 6-7 Installing the fuse .............................................................................................................................. 6-4 Figure 6-8 Installation position of AC detection board ...................................................................................... 6-4
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Tables
Tables
Table 4-1 Description on ports of the monitoring backplane .............................................................................. 4-4 Table 4-2 Description on ports of the DC surge protector .................................................................................. 4-6 Table 4-3 Description on ports of the AC detection board.................................................................................. 4-7 Table 4-4 Description of the PSU indicators ...................................................................................................... 4-8 Table 4-5 Descriptions of the PMU01 panel ..................................................................................................... 4-10 Table 4-6 Common troubleshooting methods ................................................................................................... 4-10
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About This Document
About This Document

Overview
This guide describes the routine maintenance items and common troubleshooting methods. This guide is applicable to the TP48300B and TP48600B power systems.
Version
The following table lists the product version corresponding to this document. Product Name TP48600B TP48300B Version V100R001 V100R001
Intended Audience
This document is intended for:

Technical engineers Maintenance engineers
Change History
Version 01 (2009-07-25) 02 (2010-04-21) 03 (2012-11-02) Change History Initial release. Secondly release. Port description is modified
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About This Document
Organization
1 Safety Information This chapter describes the safety precautions for the maintenance of the power system. 2 Maintenance Preparation Before performing the maintenance, you need to familiarize yourself with the conditions of the site and arrange for maintenance tools. 3 Routine Maintenance This chapter describes the routine maintenance tasks of the power system. 4 Troubleshooting This chapter describes the troubleshooting of the power system. 5 Common Component Faults This chapter describes the fault detection and handling methods of the components of the power system. The components include the PSU, fuse, circuit breaker, contactor, and monitoring backplane. 6 Replacing Main Components This chapter describes how to replace main components.
Conventions
Symbol Conventions
The symbols that may be found in this document are defined as follows. Symbol Description Indicates a hazard with a high level of risk that, if not avoided, will result in death or serious injury. Indicates a hazard with a medium or low level of risk which, if not avoided, could result in minor or moderate injury. Indicates a potentially hazardous situation that, if not avoided, could cause equipment damage, data loss, and performance degradation, or unexpected results. Indicates a tip that may help you solve a problem or save time. Provides additional information to emphasize or supplement important points of the main text.
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1 Safety Information
1
Safety Precautions
Safety Information
This chapter describes the safety precautions for the maintenance of the power system.
This section describes the safety precautions to be taken when you install, maintain, and operate the equipment provided by Huawei.
Before performing any operation, you should carefully read the instructions and precautions in this document to prevent accidents. The Danger, Caution, and Note items in this document do not cover all the safety precautions that must be followed. They only provide the general safety precautions for operations. Thus, the personnel in charge of installation and maintenance must be trained, be familiar with correct operating methods and safety precautions, and have associated working qualifications. You must comply with local safety regulations. Safety precautions described in this document are additional information and supplement local safety regulations. When operating on Huawei products and equipment, stick to the precautions and safety instructions. The safety precautions listed in this document does not cover the general safety precautions. Huawei is not liable for any accident owing to a violation of the general safety precautions and the safety regulations of design, production, and use. The personnel in charge of installation and maintenance must be trained and be familiar with correct operating methods and safety precautions.
Local Regulations and Standards

Comply with local safety regulations during the operations. Safety precautions described in this document are supplements to local safety regulations.
Grounding Requirements
This is only applied to the equipment for which the grounding is required.
The device (or system) must be connected permanently to the protection ground before an operation. The cross sectional area of protective ground conductor shall be at least.
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Never damage the grounding conductor. Never operate the equipment when the grounding conductor is not installed. The equipment should be grounded permanently. Before operating equipment, check the electrical connection of the equipment to ensure that the equipment is securely grounded.
Personnel Safety

Never operate equipment or cables in the case of a thunderstorm. To avoid electric shocks, never connect the safety extra-low voltage (SELV) circuit to the telecommunication network voltage (TNV) circuit. Before operating equipment, wear ESD working garments, ESD gloves, and ESD wrist strap. Remove conductive objects such as jewelry and watches to avoid electric shocks or burns. In case of a fire, evacuate from the building or the equipment area. Turn on the fire alarm bell or make an emergency call. Never enter the building on fire in any case.
Equipment Safety

Before the operation, ensure that the equipment is fixed on the floor or other solid objects, such as a wall or an installation rack. When the system is running, never block the air vent. When installing a panel, use tools to tighten the screws. After installation, remove the packing materials in the equipment area.
Electrical Safety
High Voltage
High-voltage power provides electricity for the equipment. A direct contact with the high-voltage power or indirect contact through damp objects may cause death. Improper high-voltage operations may result in accidents such as fire and electric shock.

The operations on high voltage and AC power supply facilities can be performed only by qualified personnel. When installing the AC cable, follow the local safety regulations and rules. When installing or operate the AC power supply facilities, follow the local safety regulations and rules. When operating the high voltage and AC power supply facilities, use special tools instead of common tools. When perform operations in a damp environment, ensure that water is kept off the device. If the cabinet is damp or wet, shut down the power supply immediately. Ground the equipment before powering on it. If the area which nearby power connector of the equipment is marked "leakage current", you must connect the grounding terminal of the equipment shell to the earth
Leakage Current

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before feeding AC input power to the equipment to avoid electric shocks caused by current leakage.
Power Cable

Do not install or remove live power wires. Contact between a power cable and a conductor may cause electric sparks or arcs, thereby causing fire or eye injury. Switch off the power supply before installing or removing the power cables. Before connecting a power cable, ensure that labels of the power cable comply with the requirements of the actual installation. To ensure that the system runs safely, when a fuse blows, replace it with a fuse of the same type and specifications.
Fuse
Electrostatic Discharge
The static electricity generated by the human body may damage the electrostatic sensitive components on the circuit board, such as the large-scale integrated circuit (LSC).
The human body generates a static electromagnetic field in the following situations: movement of body, clothes friction, friction between shoes and the ground, and holding plastic in hand.The static electromagnetic field will not disappear unless being discharged. Before contacting the device, plug boards, circuit boards, and application specific integrated circuits (ASICs), wear a grounded ESD wrist strap. The ESD wrist strap can prevent the sensitive components from being damaged by the static electricity in the human body.
Figure 1-1 shows how to wear an ESD wrist strap. Figure 1-1 Wearing an ESD wrist strap
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2 Maintenance Preparation
2
Getting Familiar with the Site Arranging for Tools
Tool Multimeter
Maintenance Preparation
Before performing the maintenance, you need to familiarize yourself with the conditions of the site and arrange for maintenance tools.
Before performing maintenance, you need to familiarize yourself with the conditions of sites and the drawings and installation procedures of the power system.
Picture
Function Used for checking the electrical connections and electrical parameters Used for connecting cables and fastening screws Used for connecting cables and fastening screws Used for fastening bolts
Phillips screwdriver (M3, M6) Flat-head screwdriver (M3, M6) Socket wrench
Torque wrench
Used for fastening bolts
Adjustable wrench Hex key (M5) Crimping tool
Used for fastening bolts Used for fastening bolts Used for making wiring terminals
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2 Maintenance Preparation
Tool Diagonal pliers
Picture
Function Used for cutting cables
Wire stripper
Used for strip cables
Black PVC insulation tape
Used for insulation
Insulated handle
Used for installing and uninstalling fuses
Brush
Used for cleaning shells and panels, and painting Used for removing rust
Sand paper
Paint
Used for preventing rust
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3 Routine Maintenance
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Routine Maintenance
Maintenance Item Maintenance Task Check Item Voltage output Electricity
Routine Maintenance
This chapter describes the routine maintenance tasks of the power system.
Perform regular inspection of the power system at six-month intervals and solve the faults in time.
Check Method Multimeter
Handling Condition The voltage of the battery shutdown branch or load shutdown branch exceeds the configured range. Alarms are generated. The surface of the cabinet is damage or deformed.
Handling Method For the handling method, see Troubleshootin g.
Fault inspection Appearance
Indicator The paint and electroplated coating on the surface of the cabinet are intact.
Visual inspection Visual inspection
Repaint or repair the cabinet.
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Troubleshooting
This chapter describes the troubleshooting of the power system. Figure 4-1 shows internal structure of the power system.
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Figure 4-1 Internal structure of the TP48600B
(1) Load shutdown fuse (LLVD fuse) (5) Rectifier module (PSU) (9) Battery fuse
(2) BLVD MCB (6) N-type wiring terminal (10) Positive busbar of the DC output (14) LLVD switch
(3) Copper transfer bar (7) Grounding busbar of the cabinet (11) Power Monitoring Interface Board (under the cover plate) (15) LLVD MCB
(4) PMU (8) AC input MCB (12) AC surge protector
(13) BLVD switch
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Figure 4-2 Internal structure of the TP48300B
(1) Load shutdown fuse (LLVD fuse) (5) Rectifier module (PSU) (9) Battery fuse
(2) BLVD MCB (6) N-type wiring terminal (10) Positive busbar of the DC output (14) LLVD switch
(3) Copper transfer bar (7) Grounding busbar of the cabinet (11) Power Monitoring Interface Board (under the cover plate)
(4) PMU (8) AC input MCB (12) AC surge protector
(13) BLVD switch
Common Fault Handling Procedure

1. 2. 3. 4. Observe the fault indictors of each module and conduct initial fault location according to the indicators. Query the fault information by entering each monitoring module. Record the state of the indicators on module panels and monitor all fault information of the modules. Classify the faults (for example, DC, AC, module, battery, and monitoring faults).
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5. 6. 7. 8. 9.
Analyze fault causes according to fault types by referring to maintenance examples or maintenance tables. Troubleshoot the faults. Record the handling procedure and the data obtained in the handling process. Confirm that all faults are cleared by querying information once again. Fill in the handling results.
10. If faults persist, repeat the above mentioned procedure.
Introduction to the Monitoring Backplane

NOTE
All ports in this manual are protected by a security mechanism.
The monitoring backplane is a transfer board that implements the signal transmission between the PMU and the main equipment, and between the PMU and the sensors. Figure 4-3 shows the ports on the monitoring backplane PW31PMib VER.C BP.F. Figure 4-3 Monitoring backplane ports
Table 4-1 Description on ports of the monitoring backplane Port DC_SPD AC_SPD JTD1 JTD2 TEM_HUM VTEM2 VBTEM1 VBTEM2 J19 SIM1 SIM2 Description Fault alarm port for DC surge protector Fault alarm port for AC surge protector Standby input port 1 for Boolean value Standby input port 2 for Boolean value Port for humidity/temperature sensors Port for temperature sensor Port 1 for the temperature sensor of storage batteries Port 2 for the temperature sensor of storage batteries Port for controlling the powering on and powering off of batteries and loads Port 1 for voltage-type analog (0 V to 64 V) Port 2 for voltage-type analog (0 V to 64 V)
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Port WIRE SIM4 Authentication Center (AC) J18 J3 FUS1 FUS2 LAMP J15 BATF LOADF J16 J17 J1 J2 DB9 J11 J12
Description Port for Voltage-type analog (0 V to 64 V) to monitor the status of the DDF Port 4 for voltage-type analog (0 V to 5 V) AC detection port Port for connecting the negative poles of the batteries and the busbar Port for monitoring busbar voltage Port 1 for monitoring the disconnection of the battery fuse Port 2 for monitoring the disconnection of the battery fuse Port for cabinet lamp Port for monitoring the battery current Port for monitoring the fuse of the primary load shutdown Port for monitoring the fuse of the secondary load shutdown The RS485 port: the communication port between the PMU and the PSU The RS485 port: the communication port between the PMU and the PSU Backplane connector connected to the PMU signal port Backplane connector connected to the PMU power port MODEM communication port Port RS232/RS422: communication port between the PMU and the main equipment Commissioning port
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Introduction to the DC surge protector

Figure 4-4 DC surge protector
Table 4-2 Description on ports of the DC surge protector Port J1 J2 J3 J4 Description Port for connecting -48 V power supply Port for connecting the positive busbar of the DC output Port connecting to the ground Fault alarm port of the DC surge protector, connected to DC_SPD on the monitoring backplane
AC Detection Board
AC detection board detects the AC input voltage
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Figure 4-5 AC detection board
Table 4-3 Description on ports of the AC detection board Port J1 1 2 3 4 J2 J3 BAT Description Connected to phase N Connected to phase L1 Port for reporting the AC voltage, connected to the AC port on the monitoring backplane Port for detecting the AC input, similar to J1
Introduction to the PSU

PSU is a component that implements conversion from AC to DC. Figure 4-6 shows the panel.
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Figure 4-6 PSU Panel
(1) Power indicator
(2) Protection indicator
(3) Fault indicator
Table 4-4 Description of the PSU indicators Indicat or Indic ator Color Green Norm al Statu s On Abno rmal Statu s Off Exception Cause
Power indicato r Protecti on indicato r
The mains supply is faulty (no AC input, AC input overvoltage, or AC input undervoltage), or the rectifier module has no power output. There are preliminary temperature alarms. (Overtemperature power-off occurs when environment temperature exceeds 65 C.) The module is in sleep mode power-off. (Only the protection indicator is on and the module does not report any alarm.)
Yello w
Off
On
Fault indicato r
Red
Off
On
The module has no power output due to output overvoltage power-off, fan faults, overtemperature power-off, or the internal exceptions of the module. However, the fault indicator is not on if the unavailable power output is caused by mains supply fault which may be no AC input, AC input overvoltage, or AC input undervoltage.
Faults and Troubleshooting Methods

When critical faults occur in the power system, the red ALM indicator is on and alarms are generated on the PMU. Figure 4-7 shows the panel of the PMU. Table 4-5 lists the descriptions of the indicators and keys on the panel. Troubleshooting according to the alarm information. The procedures for checking the alarm information and for troubleshooting are shown in Figure 4-8 and Table 4-6 respectively. For detailed information about the PMU menu, see the corresponding Quick Installation Guide.
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Figure 4-7 PMU01 panel
Figure 4-8 Checking alarm information
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Table 4-5 Descriptions of the PMU01 panel Indicator/Key RUN green indicator Description The power system is working properly. RUN indicator blinks slowly when the PMU communicates with the main equipment. The power system is working properly. The RUN indicator is on when the PMU does not communicate with the main equipment. ALM red indicator When critical alarms are generated in the power system, the ALM indicator is on and the buzzer sounds. Before setting the PMU01 menu, press or to select options and set values. Press Enter to enter the main menu when the PMU is standby. On the main menu, press Enter to enter the submenu, and save the configuration by pressing Enter on the submenu. Press Cancel to cancel the operation and exit to the upper-level menu without saving the configuration.
or Enter
Cancel
NOTE After entering the menu, the LCD light of the PMU01 goes dark five minutes later if you do not press the button, and eight minutes later, the PMU goes back to standby monitoring mode if you do not press the button.
When the PMU is in standby mode, you can press and Enter to reduce the contrast and press and Enter to increase the contrast.
Table 4-6 Common troubleshooting methods Fault AC phase loss Fault Analysis

Handling Method 1. Check whether the AC input cable is correctly and securely connected. If not, correctly connect the cable. If the insulation layer is aged, replace the cable. 2. Check whether the AC input voltage is excessively low using a multimeter, and check whether the AC undervoltage (lower than 60 V AC) alarm is generated. If yes, check whether faults such as short-circuit or electric leakage exist on the AC input loop. If yes, replace the cable. 3. If the AC input is the mains supply, contact the mains supplier for troubleshooting. If the AC input is from the DG, check the DG by referring to the Diesel Generator User Manual.
AC input cable fault Main supply fault or diesel generator (also called DG) fault
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Fault AC power off
Fault Analysis

Handling Method 1. Check whether the AC input cable is correctly and securely connected. If not, correctly connect the cable. 2. Check whether the AC input is available. If not, check whether faults such as short-circuit or open circuit exist on the AC input loop. If the AC input loop is proper, contact the mains supplier for troubleshooting. If the AC input is from the D.G., check whether the D.G. is faulty by referring to the Diesel Generator User Manual. 3. If the AC input is available, check whether the AC detection cable is securely connected. Figure 4-9 shows the correct connection position of the AC detection cable. 4. If the AC detection cable is proper, replace the AC detection board. 5. If the power-off duration is short, supply DC power with batteries. If the power-off duration is long, switch to other power supply.
AC input cable fault Main supply fault or DG fault
AC overvoltage and undervoltage
Improper setting of PMU AC undervoltage or overvoltage threshold Main supply fault or DG fault Improper setting of PMU DC undervoltage or overvoltage threshold Main supply fault or DG fault
1. Check whether the AC undervoltage alarm threshold is properly set. If the threshold is excessively high or low, lower or raise the threshold according to the actual conditions. 2. If the AC input is the mains supply, contact the mains supplier for troubleshooting. If the AC input is from the DG, check the DG by referring to the Diesel Generator User Manual. 1. Check the alarm thresholds of the DC overvoltage and undervoltage. If the thresholds are not proper, reset the thresholds according to the actual conditions. 2. Turn off the AC input switches of all the rectifier modules when the storage batteries supply power properly. Then, turn on the switches one by one. If the system generates the overvoltage alarm when you turn on the switch of one module, you can infer that this module is overvoltaged. You need to replace the module. 1. Check whether PMU charging parameters are set according to actual conditions. If not, set the parameters properly. 2. Check whether the battery short-circuited or other faults. loop is
DC overvoltage and undervoltage
Charging overcurrent
Improper setting of PMU charging parameters Load loop or battery loop fault
3. Check whether batteries are faulty. If batteries are faulty, replace faulty batteries.
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Fault Load shutdown
Fault Analysis
Handling Method 1. Check whether the LLVD switch is set to OFF. If yes, set it to ON. 2. Check whether the load detection cable is securely connected. Figure 4-10 shows the installation position of the detection cable. If the cable is not connected securely, connect it correctly. 3. Check whether the load MCB is turned off or the fuse protection is disconnected. Checking method: Check the position of the handle on the MCB. If the MCB is turned off, turn on the MCB. Measure the voltage at the fuse ends using the multimeter. If the voltage is close to 0 V, the fuse is proper. Otherwise, replace the fuse. 4. Check whether the contactor is faulty and whether it can be connected or disconnected. If the contactor is faulty, replace it. 5. Check whether the load shutdown voltage from PMU is set excessively high. If it is set excessively high, set it according to the actual situation. 6. Check whether the load power is higher than the configured rectifier module power. If yes, add a rectifier module and set the PSU number in PMU. Then, set the corresponding MCB of the added rectifier module to ON. If the load power exceeds the maximum supported power of the system, lower the load power.
Load fuse fault or MCB OFF LLVD switch OFF Contactor fault Excessively high setting of PMU load shutdown voltage Output undervoltage due to greater load power than configured rectifier module power
Battery shutdown
Improper setting of PMU battery parameters BLVD switch OFF Contactor fault
1. Check whether the BLVD is set to OFF. If yes, set it to ON. 2. Check whether the mains supply is off or the voltage of batteries is lower than the Battery Shutdown Voltage. 3. Check whether permission is set. the battery shutdown
4. Check whether the battery cables or the connectors are faulty. Replace the cables or connectors if they are faulty. 5. Check whether the contactor is faulty and whether it can be connected or disconnected. If the contactor is faulty, replace it.
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Fault Battery loop failure
Fault Analysis

Handling Method 1. Check whether cables of the battery loop or connectors are faulty. Replace the cables or connectors if they are faulty. 2. Check whether the contactor is faulty and whether it can be connected or disconnected. If the contactor is faulty, replace it. 3. Check whether batteries are faulty. If batteries are faulty, replace faulty batteries.
Battery loop fault Contactor fault Battery fault
Ambient overtemperat ure or undertempera ture alarm threshold
Improper setting of PMU temperature alarm parameters Overtemperature or undertemperature in the shelter with the temperature sensor Temperature sensor fault
1. Check whether PMU temperature alarm thresholds are set according to local conditions. If not, set the thresholds accordingly. 2. Check whether the temperature control device in the shelter is faulty. If the temperature control device is faulty, repair it. The alarm is automatically cleared when the temperature in the shelter is adjusted to the proper range. 3. If the alarm persists when the temperature is proper, check whether the temperature sensor is faulty. 1. Check whether the sensor signal cable is securely connected to the Power Monitoring Interface Board. If the connection is not secure, connect the signal cable again or replace the signal cable. 2. If the cable is not faulty, replace the temperature sensor. 3. If the alarm persists after the temperature sensor is replaced, replace the Power Monitoring Interface Board.
Ambient temperature sensor failure Battery sensor failure
Poor contact Temperature sensor fault Power Monitoring Interface Board fault
Ambient overhumidity or underhumidit y alarm
Improper setting of PMU humidity alarm parameters Overhumidity or underhumidity in the shelter with the humidity sensor Humidity sensor fault
1. Check whether PMU humidity alarm thresholds are set according to local conditions. If not, set the thresholds accordingly. 2. Check whether the floor of the shelter is seepy. If the floor is seepy, dry the floor using dry cotton cloth or other dehumidifiers. 3. If the alarm persists when the humidity is proper, check whether the humidity sensor is faulty.
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Fault Humidity sensor failure
Fault Analysis

Handling Method 1. Check whether the sensor signal cable is securely connected to the Power Monitoring Interface Board. If the connection is not secure, connect the signal cable again or replace the signal cable. 2. If the cable is not faulty, replace the humidity sensor. 3. If the alarm persists after the humidity sensor is replaced, replace the Power Monitoring Interface Board.
Poor contact Humidity sensor fault Power Monitoring Interface Board fault
Battery overtemperat ure or undertempera ture alarm
Battery cabin overtemperature Improper setting of PMU battery temperature alarm parameters Battery charging overcurrent Temperature sensor fault
1. Check whether PMU battery temperature alarm thresholds are properly set. If not, set the thresholds accordingly. 2. Check whether the temperature in the battery room is excessively high. If yes, the alarm can be cleared when the temperature is lowered. 3. Check the charging current. If the current is excessively strong, switch equalized charging to floating charging and check whether the charging current is weakened. If the charging current is still excessively strong, adjust the current suppression to reduce the charging current. If the preceding steps do not work, replace the faulty battery. 1. The alarm is cleared after the cabinet door is closed. 2. If the alarm persists after the cabinet door is closed, check whether the door status sensor is faulty. 3. If the door status sensor is not faulty, replace the Power Monitoring Interface Board.
Door control alarm
Opened cabinet door Door status sensor fault
Water immersion alarm
Shelter water accumulation Water sensor fault
1. Check whether the floor of the shelter is seepy. If the floor is seepy, dry the floor using dry cotton cloth or other dehumidifiers. 2. If the alarm persists after the water accumulation is removed, check whether the water sensor is faulty. 3. If the water sensor is not faulty, replace the Power Monitoring Interface Board.
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Smoke alarm
Smoke in the shelter Smoke sensor fault
1. Check whether the smoke exists in the shelter caused by fire. If there is fire, extinguish the fire and ventilate the shelter. 2. If the alarm persists when there is no smoke, check whether the smoke sensor is faulty. 3. If the water sensor is not faulty, replace the Power Monitoring Interface Board.
Module fault
Poor contact of the rectifier module Rectifier module fault
1. Check whether the ALM indicator (red) on the panel of the rectifier module blinks. If yes, you can infer that the rectifier module is faulty. Replace the rectifier module. 2. Disconnect AC input to the rectifier module and restart the rectifier module later on. If the alarm persists, replace the rectifier module.
Module shutdown Module protection
Input overvoltage or undervoltage of the rectifier module Rectifier module fault
1. Check whether the mains voltage is over the AC overvoltage protect point (300 V) of the rectifier module or below the AC undervoltage protect point (85 V). For the power supply network with long-time overvoltage or undervoltage, negotiate with the maintenance personnel of the electricity department to improve the power supply network. 2. If the alarm persists when the input voltage of the rectifier module is proper, check whether the rectifier module is proper. If it is faulty, replace it.
Failure of communicati on between rectifier module and PMU
Signal cable connection fault of the rectifier module Rectifier module out of position Poor contact of the rectifier module Rectifier module fault Power Monitoring Interface Board fault
1. Check whether the rectifier module is in position or whether it is in poor contact. If the rectifier module is inserted in an incorrect position, insert it correctly. If it is in poor contact, remove and then insert it. 2. Check whether the communication cables between the rectifier module and the Power Monitoring Interface Board is correctly and securely connected. If the connection is proper, restart the rectifier module. 3. If the alarm persists, replace the rectifier module. 4. If the alarm is not cleared after the rectifier module is replaced, replace the Power Monitoring Interface Board.
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DG fault
DG signal cable fault Improper setting of the PMU DG fault
1. Check whether the signal cable of the DG is correctly and securely connected. If not, connect the signal cable correctly. 2. Check whether the start permission of the DG in the PMU is set to NO and whether the diesel generator is started manually. If the permission is set to NO and the DG is started manually, this is normal. The alarm is cleared after the DG is shut down. 3. Check whether the DG is faulty by referring to the User Guide delivered with the DG.
Disconnectio n of the load fuse
Fuse fault Load MCB OFF
1. Check whether the load MCB is set to OFF. If yes, set it to ON. 2. If the alarm persists when the MCB is set to ON, check the load fuse. 3. Check whether the load fuse is damaged. Checking method: Measure the voltage at both ends of the fuse by using a multimeter. If the voltage is close to 0 V, the fuse is proper. Otherwise, the fuse is damaged. You need to replace the fuse. 4. If the alarm persists after replacing the fuse, check whether the new fuse is damaged. If the new fuse is damaged or the MCB is automatically set to OFF after you set it to ON, check whether the load branch is overloaded or short-circuited. You need to check and rectify the load loop fault. If the new fuse is not damaged, you can infer that the alarm loop is faulty. Replace the PMU.
AC surge protector fault
AC surge protector fault Power Monitoring Interface Board fault
1. Check the observation window on the AC surge protector. If the color of the window is red, replace the surge protector. If the color is not red, you can infer that the alarm loop is faulty. Replace the PMU. 2. If the alarm persists after the PMU is replaced, replace the Power Monitoring Interface Board.
DC surge protector fault
DC surge protector fault
1.
Replace the DC surge protector.
2. Replace the PMU. If the alarm persists after the PMU is replaced, replace the Power Monitoring Interface Board.
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4 Troubleshooting
Because the NMS management requires setting of the storage battery capacity, do not connect the system power module and the BBU with an Ethernet cable or RJ45 communication cable unless the customer requires in-band NMS management of the system power module. If you rectify the corresponding faults, the active alarms in the PMU is automatically cleared and saved in history alarm information. The battery and load shutdown branch fuses are called load fuses for short. Disconnect the corresponding fuse loop before replacing a fuse. Otherwise, this operation may cause human injury. After the PMU is replaced, you need to set parameters again. For details, see the Quick Installation Guide. The PMU and rectifier module are hot-swappable. Take anti-static measures when replacing the Power Monitoring Interface Board. For example, wear ESD gloves.
Figure 4-9 AC detection cable connection (TP48300B on the left and TP48600B on the right)
Figure 4-10 Load detection cable connection
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5 Common Component Faults
5
Varistor Gas Discharge Tube
Common Component Faults
This chapter describes the fault detection and handling methods of the components of the power system. The components include the PSU, fuse, circuit breaker, contactor, and monitoring backplane.
Checking method of the varistor: If the exterior of the varistor is burnt or not intact, you can infer that the varistor is damaged.
Check the resistance at both ends of the gas discharge tube. The normal resistance is infinite. If the gas discharge tube is damaged, the resistance is small.
Surge Protector
Watch the observation window of the surge protector. If the window turns red, it indicates that the surge protector is damaged. Replace the damaged surge protector. If the window or indicator remains green, it indicates that the surge protector works normally.
Fuse
Check whether the voltages at the input end and the output end of the fuse are the same. If the voltages at the two ends are not the same, it indicates that the fuse is damaged.
Circuit Breaker
Checking method of the circuit breaker: The circuit breaker fault is usually caused by overcurrent or short circuit. Check whether the circuit breaker switch is between ON and OFF. If yes, switch the circuit breaker to OFF and then to ON to clear the fault. If this method does not work, you can infer that the circuit breaker is damaged.
DC Contactor
Checking method of the DC contactor:
When there is no voltage at the control poles of the contactor, check whether the input and output poles of the contactor are proper by using the multimeter. For example, the contactor of the TP48300/A is an always-off-type contactor as shown in Figure 5-1.
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When there is no voltage at control poles 1 and 2 but measuring shows that the input and output poles 3 and 4 are disconnected, it indicates that the contactor is faulty.
When there is voltage at the control poles of the contactor, check whether the input and output poles of the contactor are proper by using the multimeter. For example, the contactor of the TP48300/A is an always-off-type contactor as shown in Figure 5-1. When there is voltage at control poles 1 and 2 but measuring shows that the input and output poles 3 and 4 are connected, it indicates that the contactor is faulty.
Figure 5-1 DC contactor
PSU
The PSU is faulty when one of the following occurs:
The RUN indicator of the PSU is on but the ALM indicator is off when there is no communication between the PSU and the PMU and the input AC voltage is around 220 V. The output of the rectifier is normal. The PMU can perform equalized charge, float charge, and current control of the PSU when the communication cable of the PSU is correctly connected and communication is established between the PSU and the PMU.
PMU
The common PMU faults are as follows:

The PMU is faulty, for example, when one of the following occurs: breakdown, startup failure, LCD display failure, and keyboard operation failure. The PMU does not generate an alarm when a fault occurs in the system. The PMU generates an alarm when the system runs normally (false alarm). Communication disruption occurs when the PMU monitors the subordinate equipment. The PMU fails to control and monitor all the modules when these modules work normally and communication cables are correctly connected. The PMU fails to monitor and control AC distribution and DC distribution when AC distribution and DC distribution are normal and communication cables are correctly connected. PMU parameter setting fails and operation information cannot be checked through the PMU.
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AC Detection Board
The AC detection board PW31ACDA is taken as an example to the procedure of checking an AC detection board. 1. 2. Remove the cover plate of the power subrack and the protection board of the AC detection board using a screwdriver. First, set the multimeter to the AC mode and measure the A-phase AC input at port J1 (pin 1 and pin 4) of the board. Second, remove the cable connected to port J2 and wrap the connector with ESD tape, and then measure the small AC signal sent to the monitoring backplane at port J2 (pin 1 and pin 5 from the right). Calculate according to the formula: AAC small signal = AAC input x 510/400 K. For example, if the measured AAC input at port J1 is 220 V, then the measured AAC small signal should be about 280 mV. If the AC signal is incorrect, it indicates that the AC detection board is damaged.
DC Surge Protector
The DC surge protector WD22DLPB is taken as an example to show the procedure of checking a DC surge protector. 1. 2. 3. Set the AC circuit breaker to OFF to disconnect the battery loop. Remove the rear plate of the cabinet and find the DC surge protector. Set the multimeter to the diode mode and measure the two pins of port J4 to check whether there is short-circuit. If there is short-circuit, it indicates that the DC surge protector is faulty. (The DC surge protector can be removed from the cabinet to facilitate the process of measuring. The removal procedure is as follows: Attach labels to the cables connected to the DC surge protector and then remove the cables. Unscrew the screws on the DC surge protector using a Phillips screwdriver, and then remove the DC surge protector.) Further locate the fault if repair of the DC surge protector is needed. Check whether the protection tubes F1, F2, and F3 are disconnected. If F1 is disconnected, check whether varistors RV1 and RV2 are short-circuited. It indicates that the varistors are damaged if they are short-circuited. If F2 is disconnected, check whether varistors RV3 and RV4 are short-circuited. If F3 is disconnected, check whether varistors RV5 and RV6 are short-circuited. Check the varistors after replacing the damaged ones. Reinstall the DC surge protector when the faults are cleared.
4.
Monitoring Backplane
The monitoring backplane PW31PMib is taken as an example to show the procedure of checking a monitoring backplane. The main functions of the PW31PMib are surge protection and signal transfer. A PW31PMib becomes faulty because of lightning or short-circuit in most cases. Ensure that all connectors on the board are correctly and securely installed. Check a faulty PW31PMib from the following aspects:
A. Check whether the busbar voltage input is proper. First, check whether the busbar voltage is proper. If the busbar voltage is improper, clear the busbar voltage fault. If the busbar voltage is proper, remove the connector from port J3 and measure the voltage between pin 1 and pin 4 of the connector. If the voltage between the two pins is not the same as the busbar voltage, it indicates that the input cable of the J3 is faulty; if the voltage between the two pins is the same as the busbar voltage, connect the connector to J3 and then remove the CPMU01 to check whether
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there is voltage output at power supply port J2 of the backplane. Checking method: connect a metal wire to one pin in the middle and another metal wire to one pin at the side of port J2, and then measure the voltage between the two wires. Ensure that the two wires do not touch each other or touch the cabinet shell. If there is no voltage output at port J2, remove the CPMU01, and then remove the backplane. Check whether the copper sheet of the PCB is burnt at both sides of the backplane or whether there are bulges inside the PCB.
B. Check whether all the diodes on the backplane are proper: Remove the CPMU01 and then remove the backplane. Set the multimeter to the diode mode and check whether there is short-circuit of each diode on the backplane. Checking method: measure the polarities of a diode with the red and the black probes of the multimeter. Exchange the probes and measure again. If the multimeter emits a beep at each measurement, it indicates that the diode is broken down. The diodes that require special attention are D6, D22 to D 29, D33, D36, D43 to D51, and D55 to D62.
C. Check whether all the PTCs on the backplane are proper: Remove the CPMU01 and then remove the backplane. Set the multimeter to the diode mode and check whether the RT1, RT2, RT3, or RT4 is disconnected. If the RT1, RT2, RT3, or RT4 is disconnected, it indicates that the PTC is damaged.
D. Check whether the varistors and the gas discharge tubes on the backplane are proper: Remove the CPMU01 and then remove the backplane. See the related description in this chapter for the checking methods.
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6 Replacing Main Components
6
1. 2. 3. 4. 5.
Replacing Main Components
This chapter describes how to replace main components.
Replacing the Rectifier Module ( also called PSU or Power Supply Unit)
Unscrew the screws on the PSU panel using a flat-head screwdriver. Pull the handle of the PSU outwards, and then remove the PSU from the plug-in frame, as shown in Figure 6-1. Insert the PSU to the corresponding slot in the plug-in frame. Then, unscrew the screws on the handle and pull out the handle. Slide the PSU into the plug-in frame slowly along the guide rails. Then, lock the handle. Tighten the screws on the handle, as shown in Figure 6-2.
Figure 6-1 Removing the old PSU
Figure 6-2 Installing the new PSU
Replacing the PMU

1. 2. 3.
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Unscrew the screws on the PMU panel using a phillips screwdriver. Pull the PMU outwards. Insert the new PMU.
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4. 5.
Tighten the screws on the handle. Set the parameters of the new PMU.
Figure 6-3 Replacing the PMU
Replacing the AC surge protector

1. 2. Remove the faulty surge protector. Insert the new surge protector.
Figure 6-4 Replacing the AC surge protector
Replacing the Power Monitoring Interface Board

The Power Monitoring Interface Board is at the rear of the monitoring module. Therefore, you can see it only when you remove the cover plate of the plug-in frame, as shown in Figure 6-5. 1. 2. 3. Remove the monitoring module. Remove the cover plate of the plug-in frame using a screw driver. Attach labels to the cables connected to the Power Monitoring Interface Board, and then remove the cables. When disconnecting the dry contact signal cable, press the contact plate slightly using a flat-head screwdriver and unplug the signal cable.
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4. 5. 6. 7. 8.
Unscrew the screws on the Power Monitoring Interface Board using a Phillips screwdriver, and then remove the Power Monitoring Interface Board. Install the new Power Monitoring Interface Board. Connect the cables to the Power Monitoring Interface Board in previous mode. Insert the monitoring in previous mode and tighten the screws. Install the cover plate of the plug-in frame and tighten the screws.
Figure 6-5 Installation position of the Power Monitoring Interface Board
Replacing the Fuse

1. 2. 3. 4. Disconnect the fuse loop. Remove the damaged fuse using a fuse extraction tool, as shown in Figure 6-6. Install the new fuse, as shown in Figure 6-7. Connect the fuse loop,
Figure 6-6 Removing the fuse
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Figure 6-7 Installing the fuse
Replacing the AC Detection Board

The AC detection board is next to the monitoring module. Therefore, you can see it only when you remove the cover plate of the plug-in frame and the protection board of the AC detection board, as shown in Figure 6-8. 1. 2. 3. 4. 5. 6. 7. Set the AC input MCB to OFF. Remove the cover plate of the plug-in frame and the protection board using a screwdriver. Attach labels to the cables connected to the AC detection board and then remove the cables. Unscrew the screws on the AC detection board using a Phillips screwdriver, and then remove the AC detection board. Install and fix the new AC detection board. Connect the cables to the AC detection board in previous mode. Install the protection board and cover plate, and then tighten the screws.
Figure 6-8 Installation position of AC detection board
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TP48300B & TP48600B Maintenance Guide (V100R001 - 02)

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