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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
Copyright © Huawei Technologies Co., Ltd.
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.
Trademarks and Permissions
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
1-1
1 Safety Information
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.
1 Safety Information
TP48300B & TP48600B
Maintenance Guide
1-2 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
2-1
2 Maintenance Preparation
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
Used for fastening bolts
Adjustable wrench
Used for fastening bolts
Hex key (M5)
Used for fastening bolts
Crimping tool
Used for making wiring
terminals
2 Maintenance Preparation
TP48300B & TP48600B
Maintenance Guide
2-2 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
4-2 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
4-4 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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)
SIM2 Port 2 for voltage-type analog (0 V to 64 V)
TP48300B & TP48600B
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
4-5
Port Description
WIRE Port for Voltage-type analog (0 V to 64 V) to monitor the status of
the DDF
SIM4 Port 4 for voltage-type analog (0 V to 5 V)
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
4-6 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
TP48300B & TP48600B
Maintenance Guide
4-8 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
4-9
Figure 4-7 PMU01 panel
Figure 4-8 Checking alarm information
4 Troubleshooting
TP48300B & TP48600B
Maintenance Guide
4-10 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
4-11
Fault Fault Analysis Handling Method
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
4-12 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
Issue 02 (2012–11–02)
Fault Fault Analysis Handling Method
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.
5. Check whether the contactor is faulty and
whether it can be connected or disconnected. If
the contactor is faulty, replace it.
TP48300B & TP48600B
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
4-13
Fault Fault Analysis Handling Method
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.
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.
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
4-14 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
Issue 02 (2012–11–02)
Fault Fault Analysis Handling Method
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
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
4-16 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Maintenance Guide 4 Troubleshooting
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
5-1
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.
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.
5 Common Component Faults
TP48300B & TP48600B
Maintenance Guide
5-2 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
5 Common Component Faults
TP48300B & TP48600B
Maintenance Guide
5-4 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
6-1
6 Replacing Main Components
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.
6 Replacing Main Components
TP48300B & TP48600B
Maintenance Guide
6-2 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
Issue 02 (2012–11–02) Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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
6 Replacing Main Components
TP48300B & TP48600B
Maintenance Guide
6-4 Huawei Proprietary and Confidential
Copyright © Huawei Technologies Co., Ltd.
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