TP48300B & TP48600B Maintenance Guide (V100R001_02)

Huawei Proprietary and Confidential

Copyright © Huawei Technologies Co., Ltd.

TP48300B & TP48600B

V100R001

Maintenance Guide

Issue 02

Date 2012–11–02

Part Number

Huawei Proprietary and Confidential


Huawei Technologies Co., Ltd. provides customers with comprehensive technical support and service. For any assistance, please contact our local office or company headquarters.

Huawei Technologies Co., Ltd.

Address: Huawei Industrial Base

Bantian, Longgang

Shenzhen 518129

People's Republic of China

Website: http://www.huawei.com

Email: [email protected]

Copyright © Huawei Technologies Co., Ltd.2012. All rights reserved.

No part of this document may be reproduced or transmitted in any form or by any means without prior written consent of Huawei Technologies Co., Ltd.

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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.

http://www.huawei.com/

mailto:[email protected]

TP48300B & TP48600B

Maintenance Guide Contents

Issue 02 (2012–11–02) Huawei Proprietary and Confidential


i

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

TP48300B & TP48600B

Maintenance Guide Figures



iii

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

TP48300B & TP48600B

Maintenance Guide Tables



v

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

TP48300B & TP48600B

Maintenance Guide About This Document



1

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 Version

TP48600B V100R001

TP48300B V100R001

Intended Audience

This document is intended for:

Technical engineers

Maintenance engineers

Change History

Version Change History

01 (2009-07-25) Initial release.

02 (2010-04-21) Secondly release.

03 (2012-11-02) Port description is modified

About This Document

TP48300B & TP48600B

Maintenance Guide

2 Huawei Proprietary and Confidential


Issue 02 (2012–11–02)

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.

TP48300B & TP48600B

Maintenance Guide 1 Safety Information



1-1


This chapter describes the safety precautions for the maintenance of the power system.

Safety Precautions

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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Maintenance Guide

1-2 Huawei Proprietary and Confidential


Issue 02 (2012–11–02)

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.

Leakage Current

− 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

TP48300B & TP48600B

Maintenance Guide 1 Safety Information



1-3

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.

Fuse

− To ensure that the system runs safely, when a fuse blows, replace it with a fuse of the

same type and specifications.

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

TP48300B & TP48600B

Maintenance Guide 2 Maintenance Preparation



2-1


Before performing the maintenance, you need to familiarize yourself with the conditions of

the site and arrange for maintenance tools.

Getting Familiar with the Site

Before performing maintenance, you need to familiarize yourself with the conditions of sites

and the drawings and installation procedures of the power system.

Arranging for Tools

Tool Picture Function

Multimeter

Used for checking the

electrical connections and

electrical parameters

Phillips screwdriver (M3,

M6) Used for connecting cables

and fastening screws

Flat-head screwdriver (M3,

M6)

Used for connecting cables

and fastening screws

Socket wrench

Used for fastening bolts

Torque wrench


Adjustable wrench


Hex key (M5)


Crimping tool

Used for making wiring

terminals


TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

Tool Picture Function

Diagonal pliers

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

Sand paper

Used for removing rust

Paint

Used for preventing rust

TP48300B & TP48600B

Maintenance Guide 3 Routine Maintenance



3-1

3 Routine Maintenance

This chapter describes the routine maintenance tasks of the power system.

Routine Maintenance

Perform regular inspection of the power system at six-month intervals and solve the faults in

time.

Maintenance Item

Maintenance Task

Check Item Check Method

Handling Condition

Handling Method

Electricity Voltage output Multimeter The voltage of

the battery

shutdown

branch or load

shutdown

branch exceeds

the configured

range.

For the

handling

method, see

Troubleshootin

g.

Fault inspection Indicator Visual

inspection

Alarms are

generated.

Appearance The paint and

electroplated

coating on the

surface of the

cabinet are

intact.

Visual

inspection

The surface of

the cabinet is

damage or

deformed.

Repaint or

repair the

cabinet.

TP48300B & TP48600B

Maintenance Guide 4 Troubleshooting



4-1

4 Troubleshooting

This chapter describes the troubleshooting of the power system.

Figure 4-1 shows internal structure of the power system.

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

Figure 4-1 Internal structure of the TP48600B

(1) Load shutdown

fuse (LLVD fuse)

(2) BLVD MCB (3) Copper transfer bar (4) PMU

(5) Rectifier

module (PSU)

(6) N-type wiring

terminal

(7) Grounding busbar of the

cabinet

(8) AC input

MCB

(9) Battery fuse (10) Positive

busbar of the DC

output

(11) Power Monitoring

Interface Board (under the

cover plate)

(12) AC surge

protector

(13) BLVD switch (14) LLVD switch (15) LLVD MCB

TP48300B & TP48600B




4-3

Figure 4-2 Internal structure of the TP48300B

(1) Load shutdown

fuse (LLVD fuse)

(2) BLVD MCB (3) Copper transfer bar (4) PMU

(5) Rectifier

module (PSU)

(6) N-type wiring

terminal

(7) Grounding busbar of the

cabinet

(8) AC input

MCB

(9) Battery fuse (10) Positive

busbar of the DC

output

(11) Power Monitoring

Interface Board (under the

cover plate)

(12) AC surge

protector

(13) BLVD switch (14) LLVD switch

Common Fault Handling Procedure

1. Observe the fault indictors of each module and conduct initial fault location according to

the indicators.

2. Query the fault information by entering each monitoring module.

3. Record the state of the indicators on module panels and monitor all fault information of

the modules.

4. Classify the faults (for example, DC, AC, module, battery, and monitoring faults).

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

5. Analyze fault causes according to fault types by referring to maintenance examples or

maintenance tables.

6. Troubleshoot the faults.

7. Record the handling procedure and the data obtained in the handling process.

8. Confirm that all faults are cleared by querying information once again.

9. 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 Description

DC_SPD Fault alarm port for DC surge protector

AC_SPD Fault alarm port for AC surge protector

JTD1 Standby input port 1 for Boolean value

JTD2 Standby input port 2 for Boolean value

TEM_HUM Port for humidity/temperature sensors

VTEM2 Port for temperature sensor

VBTEM1 Port 1 for the temperature sensor of storage batteries

VBTEM2 Port 2 for the temperature sensor of storage batteries

J19 Port for controlling the powering on and powering off of batteries

and loads

SIM1 Port 1 for voltage-type analog (0 V to 64 V)


TP48300B & TP48600B




4-5

Port Description

WIRE Port for Voltage-type analog (0 V to 64 V) to monitor the status of

the DDF


Authentication

Center (AC)

AC detection port

J18 Port for connecting the negative poles of the batteries and the busbar

J3 Port for monitoring busbar voltage

FUS1 Port 1 for monitoring the disconnection of the battery fuse

FUS2 Port 2 for monitoring the disconnection of the battery fuse

LAMP Port for cabinet lamp

J15 Port for monitoring the battery current

BATF Port for monitoring the fuse of the primary load shutdown

LOADF Port for monitoring the fuse of the secondary load shutdown

J16 The RS485 port: the communication port between the PMU and the

PSU

J17 The RS485 port: the communication port between the PMU and the

PSU

J1 Backplane connector connected to the PMU signal port

J2 Backplane connector connected to the PMU power port

DB9 MODEM communication port

J11 Port RS232/RS422: communication port between the PMU and the

main equipment

J12 Commissioning port

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

Introduction to the DC surge protector

Figure 4-4 DC surge protector

Table 4-2 Description on ports of the DC surge protector

Port Description

J1 Port for connecting -48 V power supply

J2 Port for connecting the positive busbar of the DC output

J3 Port connecting to the ground

J4 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

TP48300B & TP48600B




4-7

Figure 4-5 AC detection board

Table 4-3 Description on ports of the AC detection board

Port Description

J1 1 Connected to phase N

2 —

3 —

4 Connected to phase L1

J2 Port for reporting the AC voltage, connected to the AC port on the

monitoring backplane

J3 Port for detecting the AC input, similar to J1

BAT —

Introduction to the PSU

PSU is a component that implements conversion from AC to DC. Figure 4-6 shows the panel.

4 Troubleshooting

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Maintenance Guide



Issue 02 (2012–11–02)

Figure 4-6 PSU Panel

(1) Power indicator (2) Protection indicator (3) Fault indicator

Table 4-4 Description of the PSU indicators

Indicator

Indicator Color

Normal Status

Abnormal Status

Exception Cause

Power

indicato

r

Green On Off The mains supply is faulty (no AC input, AC input

overvoltage, or AC input undervoltage), or the

rectifier module has no power output.

Protecti

on

indicato

r

Yello

w

Off On 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.)

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.

TP48300B & TP48600B




4-9

Figure 4-7 PMU01 panel

Figure 4-8 Checking alarm information

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

Table 4-5 Descriptions of the PMU01 panel

Indicator/Key Description

RUN green indicator 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.

↓ or ↑ Before setting the PMU01 menu, press ↓ or

↑ to select options and set values.

Enter 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.

Cancel Press Cancel to cancel the operation and

exit to the upper-level menu without saving

the configuration.

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 Fault Analysis Handling Method

AC phase

loss

AC input cable fault

Main supply fault

or diesel generator

(also called DG)

fault

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.

TP48300B & TP48600B




4-11


AC power

off

AC input cable fault

Main supply fault

or DG fault

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

overvoltage

and

undervoltage

Improper setting of

PMU AC

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.

DC

overvoltage

and

undervoltage

Improper setting of

PMU DC

undervoltage or

overvoltage

threshold

Main supply fault

or DG fault

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.

Charging

overcurrent

Improper setting of

PMU charging

parameters

Load loop or

battery loop fault

1. Check whether PMU charging parameters are

set according to actual conditions. If not, set the

parameters properly.

2. Check whether the battery loop is

short-circuited or other faults.

3. Check whether batteries are faulty. If

batteries are faulty, replace faulty batteries.

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)


Load

shutdown

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

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.

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 the battery shutdown

permission is set.

4. Check whether the battery cables or the

connectors are faulty. Replace the cables or

connectors if they are faulty.




TP48300B & TP48600B




4-13


Battery loop

failure

Battery loop fault

Contactor fault

Battery fault

1. Check whether cables of the battery loop or

connectors are faulty. Replace the cables or

connectors if they are faulty.




3. Check whether batteries are faulty. If

batteries are faulty, replace faulty batteries.

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.

Ambient

temperature

sensor failure

Poor contact

Temperature sensor

fault

Power Monitoring

Interface Board

fault

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.

Battery

sensor failure

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.

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)


Humidity

sensor failure

Poor contact

Humidity sensor

fault

Power Monitoring

Interface Board

fault

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.

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.

Door control

alarm

Opened cabinet

door

Door status sensor

fault

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.

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.

TP48300B & TP48600B




4-15

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.

4 Troubleshooting

TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

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.

TP48300B & TP48600B




4-17

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

TP48300B & TP48600B

Maintenance Guide 5 Common Component Faults



5-1


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.

Varistor

Checking method of the varistor: If the exterior of the varistor is burnt or not intact, you can

infer that the varistor is damaged.

Gas Discharge Tube

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.


TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

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.

TP48300B & TP48600B

Maintenance Guide 5 Common Component Faults



5-3

AC Detection Board

The AC detection board PW31ACDA is taken as an example to the procedure of checking an

AC detection board.

1. Remove the cover plate of the power subrack and the protection board of the AC

detection board using a screwdriver.

2. 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. Set the AC circuit breaker to OFF to disconnect the battery loop.

2. Remove the rear plate of the cabinet and find the DC surge protector.

3. 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.)

4. 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.

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


TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

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.

TP48300B & TP48600B

Maintenance Guide 6 Replacing Main Components



6-1


This chapter describes how to replace main components.

Replacing the Rectifier Module ( also called PSU or Power Supply Unit)

1. Unscrew the screws on the PSU panel using a flat-head screwdriver.

2. Pull the handle of the PSU outwards, and then remove the PSU from the plug-in frame,

as shown in Figure 6-1.

3. Insert the PSU to the corresponding slot in the plug-in frame. Then, unscrew the screws

on the handle and pull out the handle.

4. Slide the PSU into the plug-in frame slowly along the guide rails. Then, lock the handle.

5. 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. Unscrew the screws on the PMU panel using a phillips screwdriver.

2. Pull the PMU outwards.

3. Insert the new PMU.


TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

4. Tighten the screws on the handle.

5. Set the parameters of the new PMU.

Figure 6-3 Replacing the PMU

Replacing the AC surge protector

1. Remove the faulty surge protector.

2. 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. Remove the monitoring module.

2. Remove the cover plate of the plug-in frame using a screw driver.

3. 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.

TP48300B & TP48600B

Maintenance Guide 6 Replacing Main Components



6-3

4. Unscrew the screws on the Power Monitoring Interface Board using a Phillips

screwdriver, and then remove the Power Monitoring Interface Board.

5. Install the new Power Monitoring Interface Board.

6. Connect the cables to the Power Monitoring Interface Board in previous mode.

7. Insert the monitoring in previous mode and tighten the screws.

8. 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. Disconnect the fuse loop.

2. Remove the damaged fuse using a fuse extraction tool, as shown in Figure 6-6.

3. Install the new fuse, as shown in Figure 6-7.

4. Connect the fuse loop,

Figure 6-6 Removing the fuse


TP48300B & TP48600B

Maintenance Guide



Issue 02 (2012–11–02)

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. Set the AC input MCB to OFF.

2. Remove the cover plate of the plug-in frame and the protection board using a

screwdriver.

3. Attach labels to the cables connected to the AC detection board and then remove the

cables.

4. Unscrew the screws on the AC detection board using a Phillips screwdriver, and then

remove the AC detection board.

5. Install and fix the new AC detection board.

6. Connect the cables to the AC detection board in previous mode.

7. Install the protection board and cover plate, and then tighten the screws.

Figure 6-8 Installation position of AC detection board

Documents

TP48300B & TP48600B Maintenance Guide (V100R001_02)