ZXDU58/ZXDU68 Series

DC Power System

Maintenance Manual
Version: V5.0

ZTE CORPORATION
NO. 55, Hi-tech Road South, ShenZhen, P.R.China
Postcode: 518057
Tel: +86-755-26771900
Fax: +86-755-26770801
URL: http://ensupport.zte.com.cn
E-mail: support@zte.com.cn

LEGAL INFORMATION
Copyright 2011 ZTE CORPORATION.
The contents of this document are protected by copyright laws and international treaties. Any reproduction or
distribution of this document or any portion of this document, in any form by any means, without the prior written
consent of ZTE CORPORATION is prohibited.

Additionally, the contents of this document are protected by

contractual confidentiality obligations.

All company, brand and product names are trade or service marks, or registered trade or service marks, of ZTE
CORPORATION or of their respective owners.
This document is provided as is, and all express, implied, or statutory warranties, representations or conditions
are disclaimed, including without limitation any implied warranty of merchantability, fitness for a particular purpose,
title or non-infringement. ZTE CORPORATION and its licensors shall not be liable for damages resulting from the
use of or reliance on the information contained herein.
ZTE CORPORATION or its licensors may have current or pending intellectual property rights or applications
covering the subject matter of this document. Except as expressly provided in any written license between ZTE
CORPORATION and its licensee, the user of this document shall not acquire any license to the subject matter
herein.
ZTE CORPORATION reserves the right to upgrade or make technical change to this product without further notice.
Users may visit ZTE technical support website http://ensupport.zte.com.cn to inquire related information.
The ultimate right to interpret this product resides in ZTE CORPORATION.

Revision History
Revision No.

Revision Date

Revision Reason

R1.0

2011-05-19

First edition

Serial Number: SJ-20110329110245-005

Publishing Date: 2011-05-19 (R1.0)

Contents
About This Manual ......................................................................................... I
Chapter 1 Safety Precautions.................................................................... 1-1
1.1 Personal Safety.................................................................................................. 1-1
1.2 Equipment Safety............................................................................................... 1-2

Chapter 2 Maintenance Preparation ......................................................... 2-1

2.1 Tools Preparation ............................................................................................... 2-1
2.2 Learn the Products ............................................................................................. 2-1
2.2.1 System Structure and System Specifications.............................................. 2-1
2.2.2 Rectifier Models and Features................................................................... 2-2
2.2.3 Rectifier Indicators.................................................................................... 2-2
2.2.4 Monitoring Unit and Monitoring Software.................................................... 2-3
2.2.5 Monitoring Unit Indicators ......................................................................... 2-4

Chapter 3 System Startup and Shutdown................................................ 3-1

3.1 System Startup .................................................................................................. 3-1
3.2 System Shutdown .............................................................................................. 3-2
3.3 Emergency Shutdown......................................................................................... 3-2
3.4 Manual Power Recovery..................................................................................... 3-3

Chapter 4 Routine Maintenance................................................................ 4-1

4.1 Daily Maintenance.............................................................................................. 4-1
4.2 Monthly Maintenance ......................................................................................... 4-1

Chapter 5 Alarm Instructions .................................................................... 5-1

5.1 Alarm Levels and Alarm Prompts ........................................................................ 5-1
5.2 Muting the Alarm Buzzer..................................................................................... 5-1

Chapter 6 Monitoring Unit Troubleshooting ............................................ 6-1

6.1 Monitoring Unit Troubleshooting .......................................................................... 6-1
6.2 Emergency Handling of Monitoring Unit Faults ..................................................... 6-2
6.3 Restarting the Monitoring Unit ............................................................................. 6-2

Chapter 7 Rectifier Troubleshooting ........................................................ 7-1

7.1 Rectifier Troubleshooting .................................................................................... 7-1
7.2 Emergency Handling of Rectifier Faults ............................................................... 7-2

Chapter 8 Replacing Faulty Components ................................................ 8-1

8.1 Replacing an SPD .............................................................................................. 8-1
I

8.2 Replacing a Rectifier With System Operating ....................................................... 8-1

8.3 Uninstalling Built-In Fans of the Rectifier .............................................................. 8-3
8.4 Replacing the Monitoring Unit With System Operating .......................................... 8-4

II

About This Manual

Purpose of This Manual
This manual applies to the V5.0RxMx version of the ZXDU58/ZXDU68 DC power systems
(generally called the ZXDU58/ZXDU68 systems). It provides information that is needed
for the maintenance of the ZXDU58/ZXDU68 systems, including routine maintenance,
component replacement and troubleshooting.

Intended Audience
This manual is intended for the following engineers:
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Operation engineer
Maintenance engineer

What Is in This Manual

This manual contains the following chapters:
Chapter

Summary

Chapter 1 Safety Precautions

Describes the items that should be noticed and obeyed in order to

ensure personal and equipment safety.

Chapter 2 Maintenance

Provides tools that should be prepared and the product information.

Preparation
Chapter 3 System Startup and

Describes the procedures for system startup, system shutdown,

Shutdown

emergency shutdown and manual power recovery.

Chapter 4 Routine

Describes the daily and monthly maintenance.

Maintenance
Chapter 5 Alarm Instructions

Describes the alarm levels (or grades) and corresponding prompts

and how to mute the alarm buzzer.

Chapter 6 Monitoring Unit

Describes the monitoring unit troubleshooting and how to restart

Troubleshooting

the monitoring unit.

Chapter 7 Rectifier

Describes the rectifier troubleshooting.

Troubleshooting
Chapter 8 Replacing Faulty

Describes the methods of replacing components.

Components

Conventions
This manual may use the following typographical conventions.
Typeface

Meaning

Italics

Variables in commands. It may also refers to other related manuals and documents.
I

Typeface

Meaning

Bold

Menus, menu options, function names, input fields, option button names, check boxes,
drop-down lists, dialog box names, window names, parameters and commands.

CAPS

Keys on the keyboard, buttons on screens, and company name.

Constant

Text that you type, program codes, filenames, directory names, function names.

width
[]

Optional parameters.

{}

Mandatory parameters.

Separates individual parameters in series of parameters.

Danger: Indicates an imminently hazardous situation, which if not avoided, will result in
deaths or serious injuries.
Warning: Indicates a hazard that, if not avoided, could result in serious injuries,
equipment damage or interruptions of major services.

Caution: Indicates a potential hazard that, if not avoided, could result in moderate
injuries, equipment damage or partial service interruption.
Note: Provides additional information about a certain topic.

Checkpoint: Indicates that a particular step needs to be checked before proceeding

further.
Tip: Indicates a suggestion or hint to make things easier or more productive for the
reader.

II

Chapter 1

Safety Precautions
Table of Contents
Personal Safety..........................................................................................................1-1
Equipment Safety .......................................................................................................1-2

1.1 Personal Safety

When operating the power equipment, observe the local safety codes and related
regulations and pay attention to the following requirements on personal safety.

Professionals Only
People in charge of the equipment installation, operation and maintenance should be
professionals who are trained and qualified for the operation of high voltage, AC power,
and other related.

Weather Requirement
Never install the equipment or connect cables in thunderstorm weather.

Insulation Protection
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Never wear watches, hand chains, rings or other conductive objects during the
equipment operation. Wear special gloves for protection.
Use insulated tools.

High Voltage
Part of the components carry high voltage during the equipment running. Direct contact
with or indirect contact through damp objects with the high-voltage components may cause
deaths.

High Current Leakage

High current leakage occurs during the equipment running. The equipment must be well
grounded before being powered on.

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Connecting or Disconnecting Power Cables

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Before connecting or disconnecting power cables, turn off the corresponding circuit
breakers (or remove the corresponding fuses) to ensure that the operation is
performed with power-off.
Before cable connection, make sure that the cable specifications and labels are
compliant with the requirement.

Proper Battery Operation

Batteries are the energy-storing equipment. During the battery operation, never touch the
positive and negative terminals at the same time. Otherwise, electric shocks may occur.

1.2 Equipment Safety

When operating the power equipment, observe the following requirements on equipment
safety.

No Stacking
No heavy objects should be stacked on top of the cabinet to avoid damaging the equipment.

No Foreign Objects Should Fall Into the Cabinet

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No water, metal or any other foreign object should fall into the cabinet.
Never install the equipment in the place where there is water evaporating or liquid
dropping.
Immediately turn off the power supply when finding water or damp on some charged
component of the equipment.

Good Ventilation
Air vents should not be blocked during the equipment running.

DC Short Circuit
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For the DC power supply equipment of constant voltage, DC short circuit should be
avoided to prevent equipment damage.
Never short the positive and negative polarities. Never short a non-grounding polarity
to the earth.

Battery Safety
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Batteries adopted should be of the same type.

Old and new batteries should not be used together.

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Chapter 1 Safety Precautions

Batteries are the energy-storing equipment. Never short them in any way to avoid
damage.

Electrostatic Damage
Electrostatic discharges generated by human bodies may damage the sensitive
components such as circuit boards and IC chips. Thus, before touching these sensitive
components, wear an antistatic wrist strap with the other end well grounded.

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Chapter 2

Maintenance Preparation
Table of Contents
Tools Preparation .......................................................................................................2-1
Learn the Products .....................................................................................................2-1

2.1 Tools Preparation

Tools listed in Table 2-1 might be used during the equipment maintenance.
Table 2-1 Tools List

2.2 Learn the Products

2.2.1 System Structure and System Specifications
The corresponding product description manual is available for each equipment. Users can
refer to such a manual to learn the equipment details, including:
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System structure
Interface definitions
Component functions
Technical specifications
Electrical connection diagram

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2.2.2 Rectifier Models and Features

Different models or versions of the DC power systems are configured with different rectifier
models. Table 2-2 illustrates the corresponding relationship.
Table 2-2 DC Power System and Corresponding Rectifier
DC Power System

Rectifier Model and Electrical Feature

ZXDU58 (V5.0) series

Rectifier Model: ZXD2000

AC input mode: Single-phase input (L/N/PE)
Rated output voltage: 53.5 V
Maximum output power: 2,000 W (when the input voltage is
176 to 300 V and the environment temperature is -40 to 65 )

ZXDU68 (V5.0) series

Rectifier Model: ZXD3000

AC input mode: Single-phase input (L/N/PE)
Rated output voltage: 53.5 V
Maximum output power: 3,000 W (when the input voltage is
176 to 300 V and the environment temperature is -40 to 55 )

Figure 2-1 shows the appearance of the ZXD2000/ZXD3000 rectifier.

Figure 2-1 Rectifier Appearance

1. Indicators
2. QUY (query) button

3. Handle
4. Fan

2.2.3 Rectifier Indicators

Figure 2-2 shows the indicators of the ZXD2000/ZXD3000 rectifier.
Figure 2-2 Rectifier Indicators

1. Power indicator
2. Running indicator

3. Alarm indicator
4. Fault indicator

The indicators signify the working status of the rectifier. Refer to Table 2-3 for details.

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Chapter 2 Maintenance Preparation

Table 2-3 Rectifier Indicators

Indicator

Working With

Sleeping

Stable Voltage

Current

Communication

Alarm

Fault

Limit

Interruption

Occurrence

Occurrence

Solid ON

Flash

Solid ON

Solid ON

Solid ON

Solid ON

Solid ON

OFF

Flash

OFF

Flash

Solid ON

OFF

OFF

OFF

Solid ON

The - mark in the table means that the status of the corresponding indicator is not fixed.

2.2.4 Monitoring Unit and Monitoring Software

Different models or versions of the ZXDU58/ZXDU68 systems are configured with different
monitoring units and different monitoring software.
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Product model: ZXDU58/ZXDU68

Product version: V5.0RxxMxx (RxxMxx is the sub-version of the ZXDU58/ZXDU68
systems)
Model and appearance of the monitoring unit: CSU500x (x is the sub-version of
the monitoring software, which can be A, B, or the other); Figure 2-3 shows the
appearance.
Figure 2-3 Monitoring Unit

1. USB interface
2. Ethernet interface

3. Indicators
4. Handle

5. LCD
6. Buttons

Monitoring software: Each version of the monitoring software has a corresponding

operation manual, such as the ZXDU58/ZXDU68 CSU500 (V1.0) Monitoring Unit
Operation Manual. Refer to such a manual to learn the menu functions and operating
methods of the monitoring software.
To learn the software version, operate keys of the monitoring unit to query it, or refer
to the product description manual of the ZXDU58/ZXDU68 system.
Figure 2-4 shows how to query the software version.

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Figure 2-4 Querying the Software Version

2.2.5 Monitoring Unit Indicators

Figure 2-5 shows the indicators of the monitoring unit.
Figure 2-5 Monitoring Unit Indicators

1. Power indicator

2. Running indicator

3. Alarm indicator

The indicators and the working status they signify are described in Table 2-4.
Table 2-4 Monitoring Unit Indicators
Indicator

Working Normally

Breaking Down

Alarm Occurrence

Solid ON

Solid ON

Solid ON

Flash

Solid ON/OFF

OFF

Flash

The - mark in the table means that the status of the corresponding indicator is not fixed.

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Chapter 3

System Startup and

Shutdown
Table of Contents
System Startup...........................................................................................................3-1
System Shutdown ......................................................................................................3-2
Emergency Shutdown ................................................................................................3-2
Manual Power Recovery ............................................................................................3-3

3.1 System Startup

Prerequisites
The equipment has passed the electrical check and been qualified for debugging.

Note:
The quick installation & commissioning guide of the equipment details the electrical check
and debugging.

Steps
1. Turn on the battery breakers, or install the battery fuses.
The equipment can be configured with battery breakers or battery fuses. Perform this
step according to the actual configuration.
2. Wait for the monitoring unit to start up. Go to the next step when the monitoring unit
displays main menus.
3. Turn on the external AC input breaker (in the AC distribution box of the site).
4. Turn on the internal AC input breaker of the equipment.
5. Turn on the rectifier breakers.
Omit this step if the equipment has no rectifier breaker.
6. If a load needs power-on, turn on the DC output breaker connected to this load or
install the load fuse.
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The equipment can be configured with DC output breakers, load fuses, or both of them.
Perform this step according to the actual configuration.
End of Steps

3.2 System Shutdown

Prerequisites
The equipment is running without loads, or the loads connected allows power interruption.

Warning!
System shutdown will cause power supply interruption to the loads connected.
cautious!

Be

Steps
1. Switch to another power supply system to power the loads, or turn off the loads, to
make the system free of loads.
2. Turn off the DC output breakers and unplug the load fuses.
The equipment can be configured with DC output breakers, load fuses, or both of them.
Perform this step according to the actual configuration.
3. Turn off the battery breakers, or unplug the battery fuses.
The equipment can be configured with battery breakers or battery fuses. Perform this
step according to the actual configuration.
4. Turn off the rectifier breakers.
Omit this step if the equipment has no rectifier breaker.
5. Turn off the internal AC input breaker of the equipment.
6. Turn off the external AC input breaker (in the AC distribution box of the site).
End of Steps

3.3 Emergency Shutdown

Context
Perform emergency shutdown immediately when the fire, flooding or other emergency
occurs.

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Chapter 3 System Startup and Shutdown

Steps
1. Turn off the external AC input breaker (in the AC distribution box of the site).
2. Turn off the battery breakers, or unplug the battery fuses.
The equipment can be configured with battery breakers or battery fuses. Perform this
step according to the actual configuration.
End of Steps

Result
Power supply for the equipment is cut off. The system is shut down and all the loads
connected are powered off.

3.4 Manual Power Recovery

Abstract
When the system is in the state of LLVD1 or BLVD disconnection, if the monitoring unit
is ineffective despite that the AC recovers and the rectifiers output DC power, users can
perform the following steps to manually connect the disconnected branch(es).

Prerequisites
Connection buttons are configured in the equipment, as shown in Figure 3-1.
Figure 3-1 Connection Buttons

1. LLVD1 ON button

2. BLVD ON button

Context
Table 3-1 describes the functions of the connection buttons.
Table 3-1 Functions of Connection Buttons
Connection Button

Function

LLVD1 ON button

Used to manually close the LLVD1 contactor to connect the LLVD1

branch to the system

BLVD ON button

Used to manually close the battery disconnection contactor to

connect the battery branch to the system

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Steps
1. Press the LLVD1 ON button to connect the LLVD1 branch to the system. The LLVD1
loads are powered on.
2. Because there is no monitoring unit that can limit the output current of the rectifiers, to
avoid high-current charge of the batteries, calculate the quantity of the rectifiers that
need to work according to the total load power and the power required by the battery
charge. Shut down the abundant rectifiers according to the calculation (note: keep
three-phase balance).
3. Press the BLVD ON button to connect the battery branch to the system and charge
the batteries.
Omit this step if the BLVD disconnection has not occurred.
End of Steps

Follow-Up Action
After the monitoring unit works normally, turn on the rectifiers that are shut down.

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Chapter 4

Routine Maintenance
Table of Contents
Daily Maintenance......................................................................................................4-1
Monthly Maintenance .................................................................................................4-1

4.1 Daily Maintenance

Daily maintenance refers to the maintenance that should be performed every day. Table
4-1 describes the maintenance items.
Table 4-1 Daily Maintenance
Item
Cleanness

Maintenance Suggestion

Criterion for Reference

Check the cabinet surface and parts

All the parts are clean, neat and free from

inside the cabinet

dust

Surge

Check SPDs every day or after

An SPD is damaged if its window is red

protection

thunderstorm

device (SPD)
Alarm function

Query history alarms through the

No critical alarm; no alarm repeats

monitoring unit
Rectifier status

Observe the rectifier indicators

Refer to the section Rectifier Indicators to

make sure that the rectifiers are working
in normal status

4.2 Monthly Maintenance

Monthly maintenance refers to the maintenance that should be performed every month.
Table 4-2 describes the maintenance items.
Table 4-2 Monthly Maintenance
Item

Maintenance Suggestion

Criterion for Reference

Cable

Check the connection terminals and

The cable connection terminals are not

connection

material conditions of the cables

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No cable connection terminal oxidizes

The cables are free from partial

loose or in poor contact

overheat, aging, or distortion due to

crush
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Item

Maintenance Suggestion

Criterion for Reference

Parameter

Check all parameters in the

All parameters satisfy the requirement on

monitoring unit

site. No one is abnormal

Information recording: Simulate

The information recording and battery

an alarm and check whether the

management functions are normal

System
management

monitoring unit can record it

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Battery management: Change

a battery charge mode in the
monitoring unit and check
whether the change can come
into effect

Air vent and

Clean the air filter (if any)

The air filter, fan and baffle plate are free

dust

Remove the fan and baffle plate

from obstacles or dust

to clean them

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Chapter 5

Alarm Instructions
Table of Contents
Alarm Levels and Alarm Prompts ...............................................................................5-1
Muting the Alarm Buzzer ............................................................................................5-1

5.1 Alarm Levels and Alarm Prompts

The alarms are divided into five levels (or grades). Different levels of the alarms have
different prompts, as described in Table 5-1.
Table 5-1 Alarm Levels and Alarm Prompts
Alarm Level

Alarm Prompt

Critical

Alarm buzzer: rings intermittently at the frequency of 2 Hz

Alarm indicator of the monitoring unit: flashes at the frequency of 2 Hz

Alarm buzzer: rings intermittently at the frequency of 1 Hz

Alarm indicator of the monitoring unit: flashes at the frequency of 2 Hz

Alarm buzzer: does not ring

Alarm indicator of the monitoring unit: flashes at the frequency of 2 Hz

Alarm buzzer: does not ring

Alarm indicator of the monitoring unit: flashes at the frequency of 1 Hz

Alarm buzzer: does not ring

Alarm indicator of the monitoring unit: no response

Major

Minor

Warning

Mask

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Note:
In case of any alarm except the masked ones, the alarm information can be queried
through the monitoring unit.
The alarm levels can be set through the monitoring unit.

5.2 Muting the Alarm Buzzer

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In case of a critical or major alarm, the alarm buzzer rings. And if the alarm is not
removed, the buzzer will not stop ringing automatically.
Users can press any key of the monitoring unit to mute the buzzer temporarily. If the
alarm is not removed within half an hour, the buzzer will ring again.
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Chapter 6

Monitoring Unit
Troubleshooting
Table of Contents
Monitoring Unit Troubleshooting .................................................................................6-1
Emergency Handling of Monitoring Unit Faults ...........................................................6-2
Restarting the Monitoring Unit ....................................................................................6-2

6.1 Monitoring Unit Troubleshooting

Refer to Table 6-1 for the monitoring unit troubleshooting. If a symptom persists, contact
the equipment dealer or the local maintenance center.
Table 6-1 Monitoring Unit Troubleshooting
Symptom

Cause and Solution

Power-on fails, and thus

The monitoring unit is not installed in position. Re-install it.

the power indicator of the

The polarities of the battery packs are reversely connected.

monitoring unit is not on

Correct it.
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The battery fuses are not installed or the rectifier breakers are
not turned on.

Disorderly LCD display

Re-install the monitoring unit to reset it.

If the symptom persists, take out the monitoring unit to

troubleshoot it.

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Communication interruption

with the monitoring

background

Install a standby monitoring unit and properly set the parameters.

Make sure that the communication cable is firmly connected to
the corresponding communication interface.

Make sure that the communication parameters of the monitoring

unit are correctly set according to the networking requirement.

If the symptom persists, take out the monitoring unit to

troubleshoot it.

Install a standby monitoring unit and properly set the parameters.

Remark: The communication parameters include Port Baudrate,

Remote IP, Remote Port and Device Addr. For specific parameter
values, consult the network management engineer.

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Symptom

Cause and Solution

Invalid keypad operation

It might be the hardware or software fault of the monitoring unit.

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Re-install the monitoring unit to reset it.

If the symptom persists, take out the monitoring unit to

Install a standby monitoring unit and properly set the parameters.

troubleshoot it.

The monitoring unit issues an

Query the real-time alarm information and take measures according

alarm

to the alarm prompts.

6.2 Emergency Handling of Monitoring Unit Faults

Fault
Faults of the monitoring unit, such as the chaos of charge and shutdown control, affect the
security of DC power supply.

Emergency Handling
Unplug the monitoring unit, as shown in Figure 6-1.
Figure 6-1 Unplugging the Monitoring Unit

6.3 Restarting the Monitoring Unit

Prerequisites
In case of invalid keypad operation or disorderly LCD display, restart the monitoring unit.

Context
The monitoring unit has no power switch. To restart the unit, re-install it according to Figure
6-2.

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Chapter 6 Monitoring Unit Troubleshooting

Figure 6-2 Restarting the Monitoring Unit

Steps
1. Unfasten the bolts (at both ends of the monitoring unit) anticlockwise.
2. Unplug the monitoring unit 50 mm out of the cabinet.
3. Insert the monitoring unit until the unit is locked in position.
4. Fasten the bolts (at both ends of the monitoring unit) clockwise.
End of Steps

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Chapter 7

Rectifier Troubleshooting
Table of Contents
Rectifier Troubleshooting............................................................................................7-1
Emergency Handling of Rectifier Faults......................................................................7-2

7.1 Rectifier Troubleshooting

Refer to Table 7-1 for the rectifier troubleshooting. If a symptom persists, contact the
equipment dealer or the local maintenance center.
Table 7-1 Rectifier Troubleshooting
Symptom

Cause and Solution

Rectifier power-on fails, and

1. Make sure that the AC input breaker is turned on.

thus the power indicator of the

2. Make sure that the AC input voltage is within the working voltage

rectifier is not on

of the rectifier.
3. If the above are not the causes, re-install the rectifier or change
a slot and then re-install the rectifier.
4. If the symptom persists, troubleshoot the faulty rectifier.
5. Install a new rectifier in the original slot and set Device Addr. for
this new rectifier.

Rectifier alarm

The cause might be that the AC input voltage is too high or too
low, the temperature is too high, the load-sharing quality is bad or
the addresses conflict. The alarm might be caused by surrounding
conditions or the other equipment and might not be caused by the
rectifier itself. Check the alarm information through the monitoring
unit and take measures accordingly.

Rectifier fault

The cause might be that the output voltage/current is too high, the
fan is faulty or the output fuse is blown.
1. Re-install the rectifier.
2. If the symptom persists, troubleshoot the faulty rectifier.
3. Install a new rectifier in the original slot and set Device Addr. for
this new rectifier.

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7.2 Emergency Handling of Rectifier Faults

Fault
Either of the following can be regarded as a serious rectifier fault and needs emergency
handling.
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All the rectifiers encounter over-voltage protection and cannot recover automatically.
Most of the rectifiers cannot work normally and cannot supply power for the load.

Emergency Handling
1. On the premise that the battery packs can supply power normally, turn off all the rectifier
breakers, or refer to Figure 7-1 to unplug all the rectifiers.
Figure 7-1 Unplugging a Rectifier

Danger!
Great capacitance exists inside the rectifier, so do not touch the interfaces at the back
of the rectifier. Otherwise, scalds and electric shocks may occur!

2. Turn on the rectifier breakers one by one, or refer to Figure 7-2 to insert the rectifiers
one by one.
Figure 7-2 Inserting a Rectifier

3. If the over-voltage protection occurs again when some rectifier is powered on, unplug
this rectifier.

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Chapter 8

Replacing Faulty
Components
Table of Contents
Replacing an SPD ......................................................................................................8-1
Replacing a Rectifier With System Operating .............................................................8-1
Uninstalling Built-In Fans of the Rectifier ....................................................................8-3
Replacing the Monitoring Unit With System Operating................................................8-4

8.1 Replacing an SPD

An SPD is damaged if its window is red. Replace it in time.
Steps
1. Use force to unplug the damaged SPD.
Figure 8-1 shows how to unplug an SPD.
Figure 8-1 Unplugging an SPD

1. Window

2. Install a new SPD of the same type in the original position.

8.2 Replacing a Rectifier With System Operating

Context
When a rectifier is faulty, replace it in time. During the replacement, the ZXDU58/ZXDU68
system does not need shutdown.
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ZXDU58/ZXDU68 Series Maintenance Manual

Caution!
Uninstalling a rectifier will reduce the load carrying capacity of the ZXDU58/ZXDU68
system. Be cautious!

Steps
1. Turn off the corresponding rectifier breaker.
Omit this step if the equipment has no rectifier breaker.
2. Refer to Figure 8-2 to unplug the faulty rectifier slowly.
Figure 8-2 Unplugging the Faulty Rectifier

Danger!
Great capacitance exists inside the rectifier, so do not touch the interfaces at the back
of the rectifier. Otherwise, scalds and electric shocks may occur!

3. Refer to Figure 8-3 to insert a new rectifier into the slot slowly with even force.
Figure 8-3 Inserting a New Rectifier

4. Turn on the corresponding rectifier breaker.

Omit this step if the equipment has no rectifier breaker.
5. Observe the indicators of the rectifier. If the
indicator is not lit, re-install the
rectifier or change a slot and then re-install the rectifier.
and
are lit.
The rectifier works normally if the indicators
End of Steps
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Chapter 8 Replacing Faulty Components

8.3 Uninstalling Built-In Fans of the Rectifier

Context
Each rectifier has two built-in fans. When the fans are damaged, replace them in time.

Steps
1. Use a screwdriver to unfasten all the bolts on the cover and front panels to remove
these panels, as shown in Figure 8-4.
Figure 8-4 Removing the Cover and Front Panels

2. Use a cross screwdriver to unfasten the fixing bolts of the fans on the front panel of
the rectifier, as shown in Figure 8-5.

Note:
Each fan is fixed by four bolts. If only one fan needs to be uninstalled, unfasten the
four corresponding bolts only.

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ZXDU58/ZXDU68 Series Maintenance Manual

Figure 8-5 Unfastening the Fixing Bolts on the Front Panel

3. Unplug the power cables of the fans. Then the fans can be taken out from the rectifier.
End of Steps

8.4 Replacing the Monitoring Unit With System

Operating
Abstract
When the monitoring unit is faulty, replace it in time.
ZXDU58/ZXDU68 system does not need shutdown.

During the replacement, the

Steps
1. Refer to Figure 8-6 to unplug the monitoring unit slowly.
Figure 8-6 Unplugging the Faulty Monitoring Unit

2. Refer to Figure 8-7 to insert a new monitoring unit into the slot.

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Chapter 8 Replacing Faulty Components

Figure 8-7 Inserting a New Monitoring Unit

3. Set parameters in the new monitoring unit.

Note:
The quick installation & commissioning guide of the equipment describes the
parameter settings.

End of Steps

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