ZXDT22 SF01: Maintenance Guide

ZXDT22 SF01
Integrated Power Energy System

Maintenance Guide
Version: V1.0
ZTE CORPORATION
No. 55, Hi-tech Road South, ShenZhen, P.R.China
Postcode: 518057
Tel: +86-755-26771900
Fax: +86-755-26770801
URL: http://support.zte.com.cn
E-mail: 800@zte.com.cn
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Revision History
Revision No. Revision Date Revision Reason
R1.0 2014-08-01 First edition
Serial Number: SJ-20140730091132-002
Publishing Date: 2014-08-01 (R1.0)
SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Contents
About This Manual ........................................................................................ I
Chapter 1 Safety Instructions.................................................................... 1-1
1.1 Common Precautions ........................................................................................ 1-1
1.2 Personal Safety Information ................................................................................ 1-2
1.3 System Safety Information ................................................................................. 1-4
Chapter 2 Tools Preparation...................................................................... 2-1

Chapter 3 Basic Knowledge of Maintenance ........................................... 3-1
3.1 Network Architecture ......................................................................................... 3-1
3.2 Real-Time Alarm Query ..................................................................................... 3-3
Chapter 4 Routine Maintenance................................................................ 4-1

4.1 Routine Maintenance of the Diesel Generator ..................................................... 4-1
4.2 ATS Control Cabinet Routine Maintenance ......................................................... 4-3
4.3 Routine Maintenance of the Integrated Power Cabinet.......................................... 4-4
4.4 Routine Maintenance of the Battery ..................................................................... 4-6
4.5 Routine Maintenance of the Busbar Box ............................................................ 4-10
4.6 Routine Maintenance of the Solar Photovoltaic Module and Racks ...................... 4-10
4.7 Wind Generator Controller Routine Maintenance ................................................4-11
4.8 Wind Generator Routine Maintenance .............................................................. 4-13
Chapter 5 Common Faults Troubleshooting............................................ 5-1

5.1 System Faults Troubleshooting ........................................................................... 5-1
5.2 Rectifier Troubleshooting .................................................................................... 5-2
5.3 Photovoltaic Module Troubleshooting .................................................................. 5-3
5.4 Busbar Box Troubleshooting ............................................................................... 5-4
5.5 Solar Power Module Troubleshooting .................................................................. 5-5
5.6 Battery Troubleshooting ...................................................................................... 5-5
5.7 ATS Troubleshooting ......................................................................................... 5-7
5.8 Integrated Power Cabinet Troubleshooting........................................................... 5-8
5.9 Diesel Generator Troubleshooting ...................................................................... 5-9
5.10 Battery Charger Troubleshooting ..................................................................... 5-10
5.11 Wind Generator Controller Troubleshooting ......................................................5-11
5.12 Wind Generator Troubleshooting .................................................................... 5-12
Chapter 6 Parts Replacement.................................................................... 6-1

6.1 Replacing the Rectifier........................................................................................ 6-1
6.2 Replacing the Solar Power Module...................................................................... 6-3
6.3 Replacing the Lightning Protection Module........................................................... 6-4
6.4 Replacing the Air Circuit Breaker......................................................................... 6-5
6.5 Replacing the CSU............................................................................................. 6-6
Chapter 7 Site Maintenance Record Table ............................................... 7-1

7.1 Battery Maintenance Record Form ...................................................................... 7-1
7.2 Integrated Power Cabinet Maintenance Record Form ........................................... 7-3
7.3 Diesel Generator Maintenance Record Form........................................................ 7-3
7.4 Busbar Box and Solar Photovoltaic Module Maintenance Record Form ................. 7-5
7.5 Wind Generator and Wind Generator Controller Maintenance Record Table .......... 7-7
7.6 ATS Maintenance Record Table .......................................................................... 7-8
Glossary .......................................................................................................... I
II

About This Manual
Purpose
This manual is applicable to ZXDT22 SF01 Integrated Power Energy System (hereinafter
the ZXDT22 SF01).
It provides guidance on product routine maintenance, parts replacement and the
troubleshooting of common faults.
Intended Audience
This manual is intended for maintenance engineers.
What Is in This Manual

This manual contains the following chapters.
Chapter 1 Safety Instructions Describes common precautions, human safety tips and equipment
safety items that need to be paid attention to during system
maintenance.
Chapter 2 Tools Preparation Describes tools needed for system maintenance.
Chapter 3 Basic Knowledge Describes the basic knowledge of system maintenance.

of Maintenance
Chapter 4 Routine Describes the routine maintenance methods of various system parts.
Maintenance
Chapter 5 Common Faults Describes the troubleshooting methods of common faults with
Troubleshooting various system parts.
Chapter 6 Parts Replacement Describes how to replace major parts.
Appendix A Site Maintenance Provides the routine maintenance record table for major parts.
Record Table
Related Documentation
The following documentation is related to this manual:
l ZXDT22 SF01 (V1.0) Integrated Power System Quick Installation and Debugging
Guide
l ZXDT CSU510B (V1.00.00.00) Monitoring Unit Operation Guide
l ZXDT22 SF01 (V1.0) Integrated Power System Product Description
Conventions
This manual uses the following conventions.

Danger: indicates an imminently hazardous situation. Failure to comply will
result in death or serious personal injury.
Warning: indicates a potentially hazardous situation. Failure to comply can result
in death or serious personal injury.
Caution: indicates a potentially hazardous situation. Failure to comply can result
in moderate or minor personal injury.
Notice: indicates equipment or environment safety information. Failure to comply

can result in equipment damage, data loss, equipment performance degradation,
environmental contamination, or other unpredictable results.
This part does not include personal injury.
Note: provides additional information about a topic.
II

Chapter 1
Safety Instructions
Table of Contents
Common Precautions ................................................................................................1-1
Personal Safety Information .......................................................................................1-2
System Safety Information ........................................................................................1-4
1.1 Common Precautions

Read this section carefully before operations to minimize the risk of personal injury. For
any safety questions, consult the supervisor or the local ZTE office.
The installation, configuration, operation, and maintenance of the ZXDT22 SF01 must
comply with the local laws and regulations. The information contained in this section is a
supplement to the local laws and regulations.
Personnel Requirements
All personnel who operate the ZXDT22 SF01 must meet the following requirements:
l Only well-trained and certified personnel are allowed to install, configure, operate and
maintain the ZXDT22 SF01.
l Only the personnel certified or authorized by ZTE are allowed to replace or change
devices or components, including software.
Grounding Requirements
l When connecting cables, connect the grounding cable first.
l When dismounting the ZXDT22 SF01, disconnect the grounding cable last.
l Install grounding conductors before operations.
l Permanently connect the ZXDT22 SF01 to the Protective Earth (PE).
Operation Requirements
Take the following precautions to avoid injuries during operations:
l Before an operation, obtain the approval of the equipment administrator and learn
about the problems that this operation may cause.
l Remove watches, bracelets, rings, or other conductive objects before operations.
l Pay attention to the hazard symbols and cautions or warnings attached to the
equipment.
l Use insulated tools for electrical connections.
Take the following precautions when installing, replacing, or checking equipment:
1-1

ZXDT22 SF01 Maintenance Guide
l Before installing, replacing components, or checking equipment, you must pay

attention to the following precautions.
l Place components, screws, and tools carefully during component replacement to
avoid falling into operating fans. Failure to comply can result in fan or equipment
damage.
l Avoid obstructing vents when the system is operating.
l Use special tools to tighten screws when installing panels or components.
l After completing equipment installation or component replacement, clear empty
packing materials from the equipment area.
1.2 Personal Safety Information

Electric Shock Hazards
Danger!
l Only qualified electricians are allowed to install or construct electrical equipment.
Improper electrical installation can result in fire, electric shock, or explosion that is
likely to be fatal.
l Avoid direct or indirect contact with the main power supply. Failure to comply may
result in personal injury.
l Always shut off the power supply before connecting or disconnecting a power cable.
If the core of a power cable contacts with a conductor, electric arcs or electric sparks
may occur and result in fire or eye injury.
l Ensure that the equipment is well grounded before power-on because high current
leakage occurs during operations.
l Connect the equipment to the PE before connecting the AC power live and neutral
cables.
Energy Hazards
Caution!
Rectifiers contain energy storage devices with high energy levels, for example capacitors
and inductors. Only professional maintenance personnel are allowed to maintain such
products.
1-2

Chapter 1 Safety Instructions
Fire Hazards
Caution!
l If a fire occurs, evacuate the building or site immediately. Raise the nearest fire
alarm, or call the emergency number. Do not re-enter a burning building under any
circumstances. Failure to comply may result in serious personal injury or death.
l Do not expose the equipment to combustible or explosive gases or fumes, or operate
the equipment in such an environment. Failure to comply may result in fire and
personal injury.
Common fire precautions are described as follows:

l All flammable or volatile liquids must be stored in approved and properly labeled cans
or containers. All aerosol cans and flammable solvents should be stored in metal
cabinets. Alternatively, flammable materials may be stored 30 feet away from the
building.
l The storage of chemicals should conform to the hazardous substance policy, that is,
incompatible chemicals should be separated.
l Keep the floor and aisle space clean and free of obstacles. Use non-flammable
cleaning agents whenever possible.
l Remove empty packaging material and installation debris from the site.
l Verify that there is an adequate number of carbon dioxide fire extinguishers for
electrical fires in the equipment room.
Mechanical Damage Hazards
Caution!
l Do not put fingers or any tools in an operating fan. Failure to comply may result in
personal injury. Keep tools away from an operating fan.
l Sharp metal edges may exist in this equipment. Wear protective clothing and gloves
when operating or moving the equipment. Failure to comply may result in personal
injury.
l Wear protective clothing and gloves when using power tools. Improper use of power
tools can result in personal injury.
l Do not use damaged tools.
l Switch off the tools when they are not in use or when replacing tool parts.
l Do not wear loose clothing, tie, or jewelry during operations, because they might be
caught by the rotating parts of tools. Failure to comply may result in personal injury.
l Do not place the equipment on a floor with a tilting angle of more than ten degrees.
Failure to comply may result in personal injury.
1-3

Battery Operation Requirements
Danger!
Current spikes caused by short circuits release electrical energy, which can result in
personal injury and battery damage. Therefore, avoid short circuiting batteries.
Short circuits might be caused by the following operations:

l During cable connections, the positive and negative cables of a battery or battery pack
are connected in reverse.
l Shorting the positive and negative output terminals of a battery or battery pack by
conductive objects.
l Touching the positive and negative output terminals of a battery or battery pack with
bare hands at the same time.
1.3 System Safety Information

Battery Safety
Caution!
You must check the overheat flag on the lead-acid battery. If the battery temperature is
too high, the battery may be deformed or damaged and electrolytes may overflow. The
overflow of electrolytes would cause potential harm of devices, corrode metal objects and
boards, and finally damage the device.
If the temperature of the lead-acid battery exceeds 60 °C, you must check whether the
electrolytes overflow. If so, you must absorb and neutralize the electrolytes in time. The
substances used to absorb and neutralize electrolytes must comply with the requirements
of the battery manufacturers. Typical neutralizers include:
l Sodium bicarbonate (baking soda): NaHCO3

l Sodium carbonate (soda ash): Na2CO3
1-4

Cable Safety
Danger!
Excessive load of cables can result in high temperatures, short circuits, or fire hazards.
l The diameter of a cable should not only adapt to the capacity of a load but also to the
capacity of a breaker (a circuit breaker or fuse). If the capacity of the breaker (circuit
breaker or fuse) is higher than that of the load, the diameter of the cable should adapt
to the circuit breaker capacity.
l When using cables with non-standard colors, select black cables and mark them
using heat-shrinkable tubing or insulated tape in corresponding colors to avoid errors.
For the detailed requirements for cable colors, refer to the ZXDZ10 D001 (V2.0R02)
Hybrid Energy Solution Installation and Commissioning Guide. If local regulations
have different requirements for cable colors, always follow the local regulations.
l At a corner of a cabling route, the bend radius should be at least 10 times larger than
the diameter of the cable to avoid short circuits due to the damage caused by the
over-bending cable.
Electrostatic Protection
When storing or transferring circuit boards, use the original package or other antistatic
materials for electrostatic protection.
Caution!
During maintenance, verify that the equipment is grounded properly and an Electrostatic
Discharge (ESD) wrist strap is used to prevent the equipment from being damaged.
Before using the ESD wrist strap, verify that the metal buckle of the ESD wrist strap is in
good contact with your skin and the other end of the wrist strap is plugged into the ESD
jack on the equipment (identified as ), see Figure 1-1.
1-5

Figure 1-1 Wearing ESD Wrist Strap
Caution!
l Avoid contacts between boards and clothing. Because the ESD wrist strap cannot
prevent the electrostatic that occurs when your clothes contact a board.
l When the ESD wrist strap is in good condition, the resistance of the system ranges
from 0.8 MΩ to 1.2 MΩ. In general, an ESD wrist strap has a service life of two years.
It should be replaced when the resistance is out of the range.
Short-Circuit Protection
Warning!
Avoid short circuits at all times because short circuits can result in equipment damage.
l Avoid foreign objects that results in short circuits.
à Do not install indoor equipment where conductive objects such as metal pieces
or water can fall into the equipment.
à Take protective measures for external cabling holes during installing outdoor
equipment to avoid short circuits caused by insects entering the equipment.
à Do not leave extraneous pieces of metal in the cabinet during equipment

installation. If unnecessary pieces of metal are observed, remove them
immediately.
l Avoid improper operations that result in short circuits.
1-6

à Never short circuit positive and negative circuits, or short circuit a non-ground
pole to the ground.
à Never short circuit the AC circuits that do not require short circuits.
Avoiding Heavy Objects Stacking on the Cabinet
Caution!
Do not stack heavy objects on top of the cabinet. Failure to comply may result in damage
to equipment.
1-7

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1-8

Chapter 2
Tools Preparation
For a list of tools needed, refer to Table 2-1.
Table 2-1 Maintenance Tools
Diagram Name Function
Cross Screwdriver Fastening Screw
Flathead Screwdriver Fastening Screw
Spanner Fastening Bolt
Diagonal Pliers Trims wire fasteners
Wire Stripper Strips off the cable

sheath
Hydraulic Crimper Crimps the copper

lug
2-1

Diagram Name Function
Insulation Tape Insulates naked wire
Multimeter Measures
resistance and
voltage
Checks whether the
wire is conductive
Cable Fastener Binds cables
Gloves Wear them

during equipment
installation
2-2

Chapter 3
Basic Knowledge of
Maintenance
Table of Contents
Network Architecture .................................................................................................3-1
Real-Time Alarm Query .............................................................................................3-3
3.1 Network Architecture

The ZXDT22 SF01 can be configured flexibly, so its networking modes are varied. This
section describes the network architectures of three typical application scenarios. The
network architectures of other application scenarios are the same, which are not further
described here.
Network Architecture of Pure-Light Application Scenario

Figure 3-1 shows the network architecture of a pure-light application scenario.
Figure 3-1 Network Architecture of Pure Light Application Scenario
3-1

Network Architecture of Light-Oil-Electricity Application Scenario

Figure 3-2 shows the network architecture of a light-oil-electricity application scenario.
Figure 3-2 Network Architecture of Light-Oil-Electricity Application Scenario
Network Architecture of Wind-Light-Oil-Electricity Application Scenario

Figure 3-3 shows the network architecture of a wind-light-oil-electricity application
scenario.
3-2

Chapter 3 Basic Knowledge of Maintenance
Figure 3-3 Network Architecture of Wind-Light-Oil-Electricity Application Scenario
3.2 Real-Time Alarm Query

You can query real-time alarms through the menu, see Figure 3-4.
Figure 3-4 Querying Real-Time Alarms
1. Indicates that there are 8 2. Occurrence time of the 5. Output relay

real-time alarms and the alarm
current alarm is the second 3. Alarm name
one. 4. Alarm grade
3-3

3-4

Chapter 4
Routine Maintenance
Table of Contents
Routine Maintenance of the Diesel Generator ...........................................................4-1
ATS Control Cabinet Routine Maintenance ................................................................4-3
Routine Maintenance of the Integrated Power Cabinet ...............................................4-4
Routine Maintenance of the Battery............................................................................4-6
Routine Maintenance of the Busbar Box...................................................................4-10
Routine Maintenance of the Solar Photovoltaic Module and Racks...........................4-10
Wind Generator Controller Routine Maintenance .....................................................4-11
Wind Generator Routine Maintenance .....................................................................4-13
4.1 Routine Maintenance of the Diesel Generator
Note:
l The actually configured diesel generator routine maintenance of the ZXDT22 SF01
may be different from the contents described in this section. Therefore, you should
take the user manual of the diesel generator as the standard. This section only
describes common diesel generator routine maintenance.
l By default, the Centralized Supervision Unit (CSU) issues a maintenance notice
every 350 hours. The maintenance notice should be cleared after each routine
maintenance.
Routine Maintenance Before Each Startup

Routine maintenance should be performed on the diesel generator before each startup.
For details of routine maintenance, refer to Table 4-1.
Table 4-1 Routine Maintenance Before Each Startup
Maintenance Item Check Method Fault Determination Troubleshooting
Check the fasten Visual inspection The fasten bolts and Fasten the fasten bolts and
bolts and shock shock pads of the diesel shock pads.
pads of the diesel generator set are loose.
generator set
4-1

Check the diesel Visual inspection The diesel generator Fasten the leaking parts.
generator leaks, including water
leakage, oil leakage,
and diesel leakage.
Check belts Visual inspection Belts are loose. Fasten the belts.
Check the amount Visual inspection The amount of diesel is Fill diesel oil.
of diesel oil insufficient
Check the amount Visual inspection The amount of engine If amount of engine oil is
of engine oil oil is insufficient insufficient, you should add
the engine oil of the same
brand and same class in time
until reaching the upper-limit
of the vernier.
Check the cable Visual inspection The cable connections Fasten the cables.
connections of the of the control panel and
control panel and engine set are loose
diesel generator set
Check the Visual inspection Fasteners inside the l If cable connections are
fasteners inside control panel are loose loose, fasten the cables.
the control panel or damaged. l If fasteners are
damaged, replace
them.
Check the Visual inspection Fasteners inside the l If cable connections are
fasteners inside ATS cabinet are loose or loose, fasten the cables.
the ATS cabinet damaged. l If fasteners are
damaged, replace
them.
Check the battery Multimeter The battery voltage is l If the battery voltage is
voltage measurement abnormal and the cable abnormal, replace it.
connections are loose. l If the cable connections
are loose, fasten the
cables.
Check the battery Battery charging The battery charger Replace the battery charger.
charger does not work.
Periodic Maintenance
Periodic maintenance should be performed on the diesel generator after it continuously
operates for a period of time or after a specific time interval. For details of periodic
maintenance, refer to Table 4-2.
4-2

Chapter 4 Routine Maintenance
Table 4-2 Periodic Maintenance of the Diesel Generator
Maintenance Period Maintenance Item
Winter Add antifreeze to the cooling system and enable the water jacket
heater.
Summer Keep the cooling system clean.
The diesel generator Replace lubricating oil.

continuously operates for
Replace filters, including:
250 hours or after every two
l Air filter
years
l Oil filter
l Diesel filter
l Coolant filter
Release the water and sediment from the water separator.
Add grease to the fan bearing of the diesel generator (large diesel
generator set).
Check AC generator terminals.
Check the control system of the diesel generator set, fasten cables,
and clean up dust and foreign matters.
The diesel generator Check and adjust the throttle gap.

Check and adjust the oil gush time.
1500 hours or after every two
Check the abrasions of the drive belts of the fan, water pump, and
years
charging generator.
If the belts are abraded seriously, you should replace them.
Check and thoroughly clean the cooling system, including rinsing the
cooling fin and cleaning the water channel.
The diesel generator Clean and calibrate the injector and fuel pump.
Check, repair, or replace the booster assembly.
5000 hours or after every four
Check, repair, or replace the water pump assembly.
years
Add grease to the bearing of the AC synchronous generator.
4.2 ATS Control Cabinet Routine Maintenance

Routine maintenance should be performed on the Automatic Transfer Switch (ATS) control
cabinet every half year. For details of the routine maintenance, refer to Table 4-3.
4-3

Table 4-3 ATS Control Cabinet Routine Maintenance
Maintenance Items Check Method Fault Determination Trou-

bleshooting
Check indicators Visual inspection The alarm indicator is lit. Query alarms
through the
monitoring
unit, and then
handle the
alarms.
Check the overview of Visual inspection l The paint on the cabinet is l Re-paint
the cabinet peeled off and the surface of the
the shell is scratched. cabinet.
l The cabinet is deformed. l If the
cabinet
is de-
formed
seri-
ously, re-
place it.
Check the inside Visual inspection There are foreign matters inside Clear the
environment of the the cabinet. foreign
cabinet matters.
Check cables Visual inspection l Cables are damaged. Replace

l Cable terminals are rusty or the cables
loose. and cable
terminals.
4.3 Routine Maintenance of the Integrated Power

Cabinet
The routine maintenance of the integrated power cabinet is classified into daily
maintenance and monthly maintenance.
Daily Maintenance
Daily Maintenance refers to maintenance tasks that are carried out by the maintenance
personnel on outdoor power cabinets every day. For details of the daily maintenance of
the integrated power cabinet, refer to Table 4-4.
4-4

Table 4-4 Daily Maintenance Items
Maintenance Check Method Fault Determination Troubleshooting

Item
Check anti-dust Visual inspection The cabinet surface has Clean the dust.
conditions accumulated dust.
Check the Visual inspection The status window displays Replace the Lightning
lightning red Protection Module
protection
module
Check the alarm View real-time There are real-time alarms, Troubleshoot according to
status alarms and or repeated appearances of the handling suggestions
historical alarms the same historical alarms. of the alarms, and contact
through the ZTE technical support if
monitoring unit troubleshooting fails.
Check the Visual inspection l The power indicator is Troubleshoot according to

operational not lit. the troubleshooting methods
status of the l The alarm indicator is lit. of the monitoring unit.
monitoring unit l The running indicator is
solid ON or OFF.
Monthly Maintenance
Monthly Maintenance refers to equipment maintenance tasks that are carried out by
the maintenance personnel every month. For details of the monthly maintenance of the
integrated power cabinet, refer to Table 4-5.
Table 4-5 Monthly Maintenance Items

Item
Check the cable Visual inspection l The cable connector Replace the cable.
connection is loose or in poor
contact, and or is
partially oxidized.
l The cable is partially
overheated, aging,
or deformation
caused by metal
compression.
Check View the parameters on Some parameters do Reset parameters so

parameters the monitoring unit. not conform to site that they conform to site
requirements. requirements.
4-5


Item
Check system l Storage function Storage or battery 1. Restart the

management check: simulate management functions monitoring unit.
functions alarms and check are not working properly. 2. If the fault persists,
whether the replace the
monitoring unit monitoring unit.
records alarm
messages.
l Battery management
function check:
Adjust battery
charging methods in
the monitoring unit,
and check whether
the adjustment is
effective.
Check the Visual inspection Fans, baffles and dust l For cabinets
air duct dust filters are blocked or have installed with dust
accumulation accumulated dust. filters, regularly
clean or replace the
dust filters.
l For direct ventilation
cabinets, regularly
disassemble and
clean the fans and
baffles.
4.4 Routine Maintenance of the Battery

To achieve the maximum life of the battery, routine maintenance is necessary. Based
on the frequency of maintenance activities, routine maintenance can be classified into:
monthly maintenance, quarterly maintenance and annual maintenance.
Monthly Maintenance
Monthly Maintenance on the battery should be performed, following the maintenance items
and methods listed in Table 4-6.
4-6

Table 4-6 Monthly Maintenance Items
Maintenance Maintenance Method Reference Troubleshooting Procedure

Item Standard
Check the When the battery is The detected value 1. If the detected value of the
floating in floating charging of the floating floating charging voltage is
charging status, use a multimeter charging voltage inconsistent with the value
voltage of the to measure the output is consistent as the displayed in the monitoring
battery pack voltages on the positive value displayed in unit, the detected value
and negative terminals of the monitoring unit shall prevail.
the battery pack. (after temperature 2. Adjust the displayed value
compensation, the on the monitoring unit; if
floating charging the adjusted value cannot
voltage ≤ ±50 mV). satisfy the tolerance
requirements, then it is
necessary to replace the
monitoring unit.
Check battery Viewing the floating Both the floating If the settings do not conform
parameter charging voltage and charging voltage to site requirements, report to
settings equal charging voltage on and equal charging the management personnel
the monitoring unit. voltage satisfy site and modify after receiving
requirements. confirmation.
Viewing the charging The charging current

current threshold on the threshold satisfies
monitoring unit. site requirements.
In the monitoring unit, view The voltage alarm

the voltage alarm (low thresholds satisfy
voltage alarm, high voltage site requirements.
alarm) thresholds of the
battery.
Check the Checking battery The appearance Replace the battery if

battery appearance visually is normal, without appearance defects affect
appearance bulging, acid its normal use.
leakage or
damages.
The appearance is Use wet cloth to clean the dust

clean without dust or and dirt.
dirt.
Checking battery polarities The polarities should Use cotton cloth to clean dirt,
visually. be free of dust, use abrasive paper to remove
stains or damages. the rust, replace the connecting
wire and apply antirust agent.
4-7


Item Standard
Check the Using the infrared The surface When the temperature is above
battery temperature tester temperatures of 35 ºC, investigate the reason
temperature to detect the surface battery terminals and take proper measures.
temperatures of battery and the battery base
terminals and the battery should be below 35
base. ºC.
Check the Using a spanner to check The fastening Fasten any loose screws or
connecting whether the fastening screws and bolts bolts found during the check.
pieces screws and bolts are loose. are firmly fixed and
not loose.
Checking whether the The battery In case of slight erosion,

battery connectors and connectors and disassemble the connector
terminals are clean or have terminals are clean and soak it in water to remove
erosion. and free of erosion. the erosion. In case of severe
erosion, replace the connector,
clean the connecting points
with steel brushes, and
re-fasten the connector.
Check the Holding the safety valve The safety valve is Re-fasten the installation of the
battery safety in your hand and shaking firmly installed and safety valve if it is found to be
valve (2V gently to check whether it not loose. loose.
battery) is firmly installed.
Checking whether the Air bubbles appear It is abnormal that the safety
safety valve is discharging regularly around the valve is constantly open or
correctly. Apply foam safety valve. shut, in either case it needs
liquid around the valve and to be replaced. (Meanwhile,
then observe whether the you must check the water loss
discharging is normal. conditions of the battery.)
Quarterly Maintenance Items

Quarterly Maintenance on the battery should be performed, following the maintenance
items and methods listed in Table 4-7.
4-8

Table 4-7 Quarterly Maintenance Items

Item Standard
Check the When the battery is in After temperature If the benchmark voltage (2.23
floating floating charging status, compensation, the V) is exceeded, discharge
charging use a multimeter to floating charging the battery pack and perform
voltage of the measure the output voltage of the each equal discharging, then move
each single voltages on the positive single battery shall on to floating discharging
battery and negative terminals of not exceed the and observe for one or two
each single battery. benchmark voltage months. If the battery voltage
(2.23 V) ± 45 mV. still exceeds the benchmark
voltage, it should be replaced
in time.
Activate First, discharge the battery – This operation is applicable

charging and until it has approx. 70% of for batteries that haven't been
discharging the nominal capacity left, discharged for over six months.
and then perform equal
charging.
Annual Maintenance Items

Annual Maintenance on the battery should be performed, following the maintenance items
and methods listed in Table 4-8.
Table 4-8 Annual Maintenance Items

Item Standard
Discharge Disconnecting the AC After discharging is If the terminal voltage of the

electricity for power and discharging over, the terminal battery is still lower than the
verification the battery with the loads voltage of each benchmark value (1.90 V)
purposes connected, until approx. single battery after discharging, discharge
30-40% of the nominal should exceed 1.90 the battery pack and perform
capacity of the battery is V. equal discharging, then move
left. on to floating discharging
and observe for one or two
months. If the terminal voltage
is still below the benchmark
voltage, the battery should be
replaced in time.
Test the capacity Using an online capacity The battery can If capacity test fails, the
tester or false load to be successfully battery needs to be replaced
discharge the battery until discharged to in time.
approx. 20%-50% of the 20%-50% of its
nominal capacity is left. nominal capacity.
4-9

4.5 Routine Maintenance of the Busbar Box

Routine maintenance should be performed on the busbar box every half year. For details
of the routine maintenance, refer to Table 4-9.
Table 4-9 Busbar Box Routine Maintenance
Check the appearance Visual inspection Whether the Replace the busbar
appearance is box.
damaged.
Check the cable Visual inspection The cable is damaged Replace broken cables;
or broken. apply insulation tapes
outside damaged
cables.
Check connection Visual inspection Connection is loose. Re-fasten connection

terminals terminals.
4.6 Routine Maintenance of the Solar Photovoltaic

Module and Racks
Routine maintenance should be performed on the solar photovoltaic module and its racks
every half year; in areas with heavy winds and sand conditions, the maintenance cycle
should not exceed three months. For details on the routine maintenance of the solar
photovoltaic module and its racks, refer to Table 4-10.
Table 4-10 Routine Maintenance of the Solar Photovoltaic Module and Racks
Check the module Visual inspection l The surface is l If the surface is

appearance covered with dust, covered with dust,
snow or oil, etc. snow or oil, etc.,
l The surface clean with soft
is damaged, cotton cloth.
for example: l If the surface
broken glass, is damaged or
burnt backplane, contains bubbles,
obvious color replace the
changes. module.
l The photovoltaic
module contains
bubbles that
form channels
4-10

to module edges
or any circuits.
Check the module rack Visual inspection The rack is rusty or l If the rack is rusty
eroded or eroded, de-rust
l The rack is rusty or and then apply a
eroded. new coating.
l The rack rods are l If the rack rods are
deformed. deformed, replace
l Bolts are loose at the rods.
joints of the rack. l If bolts are loose at
joints of the rack,
fasten the loose
bolts or screws.
Check the cable Visual inspection The cable is damaged Replace broken cables;
or broken. apply insulation tapes
outside damaged
cables.
Check connection Visual inspection Connection is loose. Re-fasten connection

terminals terminals.
Check electrical Use a multimeter The open-circuit Replace the solar

parameters to measure the voltage of the solar photovoltaic module.
open-circuit voltage photovoltaic module is
of the single solar not within the 80 V -
photovoltaic module 100 V range.
(the cascade voltage of
two solar photovoltaic
modules).
4.7 Wind Generator Controller Routine Maintenance

Routine maintenance should be performed on the wind generator controller every half year.
For details of the routine maintenance, refer to Table 4-11.
4-11

Table 4-11 Wind Generator Controller Routine Maintenance
Maintenance Items Check Method Fault Determination Troubleshooting
Check the voltage and 1. Check the voltage l The difference 1. Restart the
current and current between the wind generator
displaying on the displayed voltage controller.
LCD screen of the and measured 2. If the faults still
wind generator voltage is more exist, contact ZTE
controller. than 10%. technical support.
2. Use a clamp meter l The difference
to measure the between the
charging current displayed current
of the battery, and measured
and then compare current is larger
the measured the than 2 V.
current with the
current displayed
on the LCD screen.
3. Use a multimeter
to measure the
voltage of the
battery, and then
compare the
measure voltage
with the voltage
displayed on the
LCD screen.
Check the overview Visual inspection The paint on the wind Re-paint the wind
of the wind generator controller is peeled off generator controller.
controller and the surface of the
shell is scratched.
Check cables Visual inspection Cables are damaged or Replace the broken
broken. cables and use
insulating tapes to
wrap the damaged
cables.
Check the insulation Use a megger Insulation value<50 Replace the cables.
value of phase wiring to measure the MΩ
insulation value of
the three-phase wiring
between the wind
generator and the wind
controller.
4-12

4.8 Wind Generator Routine Maintenance

Routine maintenance should be performed on the wind generator every half year. For
details of the routine maintenance, refer to Table 4-12.
Table 4-12 Wind Generator Routine Maintenance
Maintenance Items Check Method Fault Determination Troubleshooting
Check fasteners Slightly shake Fasteners and bolts Fasten the fasteners
fasteners and bolts. are loose. and bolts.
Check cables Visual inspection Cables are damaged or Replace the broken
broken. cables and use
insulating tapes to
wrap the damaged
cables.
Check the fin Visual inspection The fin is damaged. Replace the fin.
Check the wind Visual inspection The wind deflector is Replace the wind
deflector damaged. deflector.
Check the tower Visual inspection Tower rods are loose, Replace the damaged
cracked, or broken. rods and fasten the
loose rods.
4-13

4-14

Chapter 5
Common Faults
Troubleshooting
Table of Contents
System Faults Troubleshooting ..................................................................................5-1
Rectifier Troubleshooting............................................................................................5-2
Photovoltaic Module Troubleshooting .........................................................................5-3
Busbar Box Troubleshooting ......................................................................................5-4
Solar Power Module Troubleshooting .........................................................................5-5
Battery Troubleshooting .............................................................................................5-5
ATS Troubleshooting .................................................................................................5-7
Integrated Power Cabinet Troubleshooting .................................................................5-8
Diesel Generator Troubleshooting .............................................................................5-9
Battery Charger Troubleshooting ..............................................................................5-10
Wind Generator Controller Troubleshooting .............................................................5-11
Wind Generator Troubleshooting .............................................................................5-12
5.1 System Faults Troubleshooting

For the troubleshooting methods of system faults, refer to Table 5-1.
Table 5-1 System Faults Troubleshooting
Fault Symptom Fault Analysis Troubleshooting
The system does not work after l The power cable between 1. Check whether the power
power-on. the system and the load is cable between the system
abnormal. and the load is damaged
l The air circuit breaker on or connected to reversed
the corresponding load is polarities, and rectify any
not closed or is damaged. errors found.
l The load is faulty. 2. Check whether the
corresponding has
unclosed or broken air
circuit breakers, and close
or replace the air circuit
breakers accordingly.
3. Check and troubleshoot
internal errors of the load.
5-1

The solar power module does l The photovoltaic input 1. Check whether the cable
not work after the system voltage is abnormal. of the solar power plate
receives photovoltaic input l The solar power input cable is damaged, and whether
is reversely connected. connection is reliable;
l The solar power module is replace the cable or fasten
damaged. the connection if necessary.
2. Check the input polarities
of the solar power input
module, and rectify any
reverse connections.
3. Replace the solar power
module.
The running indicator of the The solar power module is 1. When the system load
solar power module flashes overloaded. exceeds the nominal load,
add solar power modules
to increase system nominal
capacity.
2. When the system load does
not exceed the nominal
load, replace existing solar
power modules with new
ones.
5.2 Rectifier Troubleshooting

For the troubleshooting of a rectifier, refer to Table 5-2.
Table 5-2 Rectifier Troubleshooting
Fault Type Fault Analysis Troubleshooting
The operation The rectifier is 1. If load power exceeds rated power, add a new
indicator is overloaded. rectifier to increase the rated power of the system.
flashing. 2. If load power does not exceed rated power,
replace the rectifier and configure the address.
5-2

Chapter 5 Common Faults Troubleshooting
The alarm The communication 1. If the communication of a single rectifier is

indicator is of the rectifier is interrupted, replace the rectifier and configure the
flashing. interrupted. address.
2. If the communications of three modules in one
row is interrupted simultaneously, check whether
the communication cable between the rectifier
and system is good condition and whether the
connection sockets of matching resistors are
installed properly. If not, correct them.
The alarm The rectifier detects Process the alarms detected by the rectifier.
indicator is solid alarms.
on.
The fault The rectifier is damaged. Replace the damaged rectifier.

indicator is solid
on.
5.3 Photovoltaic Module Troubleshooting

For the troubleshooting methods of photovoltaic module faults, refer to Table 5-3.
Table 5-3 Photovoltaic Module Troubleshooting
The solar power module has no l The solar power module is 1. Check whether the cable
output faulty. is reversely connected
l Cable connection fault. to the polarities, loose or
l Busbar box fault. damaged. If yes, replace
the cable and reconnect.
2. Under good sunshine
conditions, check whether
the output voltage of each
single solar photovoltaic
module is between 40
VDC and 48 VDC; if not,
this photovoltaic module
is faulty and needs to be
replaced.
3. Check whether the busbar
box is damaged; if yes,
replace the busbar box.
5-3

Solar power anti-theft alarm l The solar power module is l Please call the police if
stolen. the solar power module is
l Solar power anti-theft signal stolen.
cable fault. l If the solar power anti-theft
signal cable is faulty,
reconnect the anti-theft
signal cable.
5.4 Busbar Box Troubleshooting

For the troubleshooting methods of busbar box faults, refer to Table 5-4.
Table 5-4 Busbar Box Troubleshooting
No output l Cable connection fault. 1. Check whether the cable

l Solar photovoltaic module is disconnected, loose or
fault. damaged. If yes, replace
the cable and reconnect.
2. Use the multimeter to check
whether output voltage
exists for each path of
photovoltaic input in the
busbar box. Use the
clamp-on ammeter to check
whether current exists on
each path of photovoltaic
input; if not, check the
photovoltaic module on this
path.
3. Under good sunshine
conditions, check whether
the output voltage of each
single solar photovoltaic
module is between 40 VDC
and 48 VDC; if not, replace
this photovoltaic module.
4. Replace the busbar box.
Output voltage polarity error Input cable polarity reversed Check whether the circuit
polarity is correctly connected;
if not, reconnect after reversing
the polarity.
5-4

5.5 Solar Power Module Troubleshooting

For the troubleshooting method of solar power module faults, refer to Table 5-5.
Table 5-5 Solar Power Module Troubleshooting
Running indicator flashing The solar power module is 1. When the system load
overloaded. exceeds the nominal load,
add solar power modules
to increase system nominal
capacity.
2. When the system load does
not exceed the nominal
load, replace existing solar
power modules with new
ones and set the addresses.
Alarm indicator on and flashing Communication to the solar 1. If communication to any

power module is interrupted. single solar power module
is interrupted, replace the
module with a new one and
set the address.
2. If communication to three
modules in the same
row is interrupted, check
the intactness of the
communication cable
between the power module
and the system, and
whether the matching
resistance connection
socket is correctly installed,
then rectify any errors
found.
The alarm indicator is solid on. The solar power module detects Handle the alarm message(s)
one or more alarm messages. detected by the solar power
module.
The fault indicator is solid on The solar power module is Replace it with a new module.
damaged
5.6 Battery Troubleshooting

For the troubleshooting methods of battery faults, refer to Table 5-6.
5-5

Table 5-6 Battery Troubleshooting
When the battery pack is at the l The battery terminal l Fasten the bolt.
initial discharging period, the connection bolt is loose. l Clean the dirt and re-install
voltage of a certain battery and l The battery terminal or the bolt.
the entire battery pack drops battery connection cable
too fast has dirty on the surface,
increasing the connection
voltage drop.
The battery pack can discharge In the power system settings, Adjust the protection voltage to
normally during the early stage the battery low-voltage a smaller value based on the
of use, but is disconnected soon disconnect protection voltage is actual conditions.
after connecting with loads. too high.
The measured total voltage of One battery in the battery Check whether the battery is
the battery pack is approx. 4 pack has reversed polarity correctly connected according
V lower than the calculated connection. to the polarity signs on
voltage battery terminals or the
positive/negative symbols on
battery lids, and correct any
wrong connections in time.
In the same battery pack, the This may be caused by minor The voltages will become
voltages of different batteries differences in battery internal consistent after floating charging
will vary to a certain extent structure, battery storage or the batteries for three months.
during initial use. transportation.
High Temperature Alarms The battery temperature 1. Check whether the

sensor detects that the battery temperature sensor is
temperature exceeds the set in an environment with a
value. high ambient temperature.
If yes, eliminate factors that
cause the high ambient
temperature.
2. Check whether the
temperature sensor is
damaged. If yes, replace
the temperature sensor.
3. Check whether the cooling
system in the battery
compartment is faulty. If
yes, remove the fault.
The alarm will disappear
automatically after the
temperature drops.
5-6

Over-voltage and under-voltage The battery pack voltage 1. Check whether the battery
alarms exceeds the range of 45 V - connection pieces are rusty
58.5 V. or oxidized; if yes, remove
the rust or oxidized layer.
Overcurrent alarm The current of the battery pack
2. Check whether the
exceeds the upper threshold.
connection pieces are firmly
connected, and re-fasten
any loose connections.
3. Measure the voltages of
each single battery one by
one when the battery pack
is in discharging status. If
any battery has a voltage
lower than 90% of the
average voltage, it shall be
deemed as faulty and be
replaced with a new one.
5.7 ATS Troubleshooting

For the troubleshooting methods of ATS faults, refer to Table 5-7.
Table 5-7 ATS Troubleshooting
The battery voltage of the l The battery charger of 1. Handle battery charger
diesel genset is too low or too the diesel generator is faults.
high. abnormal. 2. Replace the battery of the
l The battery of the diesel diesel generator.
generator is damaged.
The mains supply is The mains supply grid is faulty. 1. Check whether the cable
over-voltage, under-voltage, connections of the ATS
or lack-phase. controller are normal and
fixed. If cables are damaged
or loose, replace or fasten
them.
2. Use a multimeter to check
whether the voltage of the
mains supply is normal.
l If the voltage is
abnormal, contact the
electricity supplier.
5-7

l If the voltage is normal,

replace the ATS
controller.
The diesel generator is The diesel generator is faulty. Repair the diesel generator.
under-voltage or over-voltage.
The conversion switch fails to l The cable connections of 1. Based on the cable
be closed. the conversion switch are connection diagram, check
loose or incorrect. whether the circuit of
l The conversion switch is the conversion switch is
damaged. loose, open, or connected
improperly. If so, correct it.
2. Replace the conversion
switch.
The ATS is unable to control l The connections of the 1. Check whether the cables
the enabling or disabling of the cables that are used to that are used to control the
diesel generator. control the enabling or enabling or disabling of the
disabling of the diesel diesel generator are loose or
generator is loose or connected improperly. If so,
incorrect. connect the cables properly
l The diesel generator is and fasten them.
faulty. 2. Check whether the diesel
l The ATS controller is faulty. generator is faulty. If so,
solve the faults.
3. Replace the ATS controller.
5.8 Integrated Power Cabinet Troubleshooting

For the troubleshooting methods of the common faults of the integrated power cabinet,
refer to Table 5-8.
Table 5-8 Integrated Power Cabinet Troubleshooting
The system is l The AC voltage of the 1. Check whether the AC voltage of the
connected to an system is abnormal. system meets the input requirements.
AC power supply. l The AC air circuit 2. Close the AC air circuit breaker of the
The rectifier does not breaker of the system is system.
work. not closed. 3. Completely re-install the rectifier in the
l The rectifier is not slot.
completely installed in 4. Replace the rectifier.
the slot.
5-8

l The rectifier is
damaged.
The solar power l The photovoltaic input 1. Check the connection of the solar power
module does not voltage is abnormal. plate.
work after the system l The solar power input 2. Check the input voltage and polarities of
receives photovoltaic cable is reversely the solar power input module.
input. connected. 3. Replace the solar power module.
l The solar power module
is damaged.
The load does not l The power cable 1. Check whether the power cable between
work after power-on. between the system and the system and the load is intact or
the load is abnormal. connected to correct polarities.
l The air circuit breaker 2. Check whether the voltage from the air
on the corresponding circuit breakers of the corresponding load
load is not closed. to the busbar is normal, and close the air
l The load is faulty. circuit breakers.
3. Check for internal errors of the load.
5.9 Diesel Generator Troubleshooting

For the troubleshooting methods of diesel generator faults, refer to Table 5-9.
Table 5-9 Diesel Generator Troubleshooting
The diesel generator fails l The battery of the diesel 1. Check the battery of the diesel
to start. generator is low. generator. If the battery is low,
l The battery cables and replace the battery.
connectors of the diesel 2. Check whether the battery
generator are loose. cables and connectors of the
l The relay is not started. diesel generator are loose. If
l The control circuit is broken. so, fasten them.
l The starter is faulty. 3. Check whether the relay is
operating properly. If not,
correct it.
4. Check two emergency stop
buttons are set to the normal
positions. If not, reset them.
5. Repair or replace the starter.
5-9

When the diesel generator The output air circuit breaker of the 1. Check whether the output air
is operating, there is no diesel generator is not closed. circuit breaker of the diesel
AC output. generator is closed. If not,
close it.
2. If there is still no AC output
after the output air circuit
breaker is closed, repair
the regulator of the diesel
generator.
The diesel generator l The diesel supply is not 1. Verify that the oil circuit
rotates at a certain speed smooth. between the oil tank and the
but cannot be launched. l Air penetrates into the fuel oil pump is not blocked. For
system. example, the fuel filter and fuel
l The fuel solenoid valve is pipe are not blocked.
faulty. 2. Open the exhaust screw of the
fuel filter to exhaust air.
3. Replace the fuel solenoid
valve.
During debugging, it is l Air penetrates into the fuel 1. Open the vent of the fuel filter
difficult to use the manual pipe. to exhaust air.
oil pump. l The manual oil pump is 2. Remove the manual oil pump,
jammed. and then blow dirt or clean the
l The fuel level of the oil tank is pump with fuel.
too low. 3. Refuel the oil tank.
The diesel generator fails l The working mode of the 1. Set the working mode of the
to start automatically. diesel generator is set to diesel generator to automatic.
manual rather than automatic. 2. Check whether the start relay
l The start relay is connected is connected properly. If not,
improperly. reconnect it.
5.10 Battery Charger Troubleshooting

For the troubleshooting methods of battery charger faults, refer to Table 5-10.
5-10

Table 5-10 Battery Charger Troubleshooting
The battery charger of the l The input of the battery 1. The input of the battery charger
diesel generator does not charger is abnormal. is received from a load of the
work. l The output voltage of the system. Verify that cables are
battery changer is selected complete, the polarities of the
improperly. cables are correct, and the air
l The battery charger is circuit breaker on the load is
damaged. closed.
2. The output voltage of the battery
charger can be selected as
required. Check whether the
selected output voltage matches
with the diesel generator battery.
If not, select a correct output
voltage.
3. Replace the battery charger.
5.11 Wind Generator Controller Troubleshooting

For the troubleshooting methods of wind generator controller faults, refer to Table 5-11.
Table 5-11 Wind Generator Controller Troubleshooting
The over-current indicator The load current exceeds the 1. Disconnect loads.
is lit. maximum bearing capacity of the 2. Check whether the total load
system. current exceeds the maximum
bearing capacity of the system.
3. If the total load current is within
the allowable range of the
system, check whether a short
circuit or leakage occurs, and
then solve load faults.
4. After removing the faulty loads,
close the switches on the loads.
The over-voltage indicator l The battery voltage exceeds 1. Check the over-voltage
is lit. the over-voltage protection protection value and ensure
value. that it is set properly.
l The over-voltage protection 2. Disconnect load devices in turn
value is set too low. to determine the faulty load.
3. Replace the faulty load.
5-11

The under-voltage indicator l The battery voltage is lower 1. Check the under-voltage
is lit. than the under-voltage protection value and ensure
protection value. that it is set properly.
l The under-voltage protection 2. Measure the battery voltage.
value is set too high. If the battery voltage is
lower than the under-voltage
protection value, it is the normal
phenomenon.
The load voltage is 0. If over-current, over-voltage, or It is the normal phenomenon and no

under-voltage protection occurs, action is required. After protection
the system automatically stops disappears, the power supply
supplying power for loads. restores automatically.
When powering on, The battery performs reverse Check whether the battery cables
the battery switch trips polarity protection. are connected reversely. If so,
automatically. reconnect them.
There is no input but the The output voltage is the battery It is the normal phenomenon and
output voltage is not 0. voltage. no action is required.
The output voltage is 0. The system is faulty. Contact ZTE technical support.
The output current is higher The system is faulty. Contact ZTE technical support.
than the maximum current.
The displayed input voltage The system controller is 1. Set the switch of the wind
is higher than 400 V. over-voltage. generator to the ON position.
2. Check whether the cable
connections of the unloading
device are fixed and whether
cables are in good condition.
If so, proceed to the next step.
Otherwise, reconnect or replace
the cables.
3. Contact ZTE technical support.
5.12 Wind Generator Troubleshooting

For the troubleshooting methods of wind generator faults, refer to Table 5-12.
5-12

Table 5-12 Wind Generator Troubleshooting
In the off-grid system, The regulation voltage Adjust the over-voltage protection point.
the battery is not fully of the controller is set
charged. too low.
The electricity Remove loads.

consumption of loads
is high.
In the off-grid system, The battery is aging. Replace the battery.

the battery can be
The battery capacity is Increase battery capacity.
quickly fully charged
low.
or the controller
is always in the
unloading status.
In the off-grid system, The regulation voltage Contact ZTE technical support.
the battery voltage is of the wind generator
too high. controller is set too
high.
Impellers are rotating The input switch on the Set the input switch on the window wind generator
but the running window wind generator controller to the ON position.
indicator on the wind controller is set to OFF
generator controller position.
is not lit.
The control circuit is Contact ZTE technical support.
faulty.
The rotate speed of The input switch on the Set the input switch on the window wind generator
the wind generator is window wind generator controller to the ON position.
too high. controller is set to OFF
position.
The output circuit of Connect generator cables to the wind generator

the wind generator is controller.
open.
The unloading module Replace the unloading module.

of the wind generator
controller is faulty.
The wind wheel and Fasten wind wheel bolts based on torque
spindle are loosely requirements.
connected.
5-13

The wind generator Blades are unbalanced Power off the wind generator, and then remove
jitters periodically. or not installed ice or wait for ice to melt. If blades are damaged,
unbalancedly. replace the blades.
If the wind speed is It is the normal phenomenon and no action is

low, the wind generator required.
jitters normally.
When large blades Blades are damaged Replace the blades.

are rotating, they emit and blade tips harden.
sharp, humming, or
tapping sounds.
When there is wind, The input switch on the The input switch on the window wind generator
the wind generator window wind generator controller is set to OFF position.
rotates at a low speed controller is set to ON
or does not rotate. position.
The output cable of After laying the wind generator and unlocking the
the wind generator slip ring brush holder, measure the resistances
is three-phase between three phase wires of the wind generator.
short-circuit or l If the resistance is unbalanced, replace the
unbalanced. wind generator.
l If the resistance is normal, the wind generator
is normal. Check the slip ring brush holder. If
there are faults, replace it.
The rotatory module is Power off the wind generator and replace the
faulty. rotatory system.
Multiple wind It is the normal phenomenon and no action is

generators are required.
installed together. If
the wind speed is low,
some wind generators
rotate but some do not.
When the wind The wind deflector is Power off the wind generator and fasten the bolts
generator is rotating, loose. on the wind deflector.
the generator or
The nuts on the wind Power off the wind generator and fasten the nuts
tower rack produces
wheel fall into the wind on the wind wheel.
a “pop”, “click”, or
deflector.
buzzing sound.
The connection bolts Power off the wind generator and fasten all the
of the tower are loose. bolts on the tower.
5-14

There are foreign Replace the rotor or use a cloth to remove the
matters between the foreign matters in the sliding bearing.
rotor bottom and sliding
bearing.
The wind generator Lay the wind generator on the floor, and fasten the
tail beam or other bolts of all parts.
connection bolts are
loose.
The shock absorption Replace the shock absorption cushion.

cushion of the rear
cover is missing.
The system is in the It is the normal phenomenon and no action is

unloading status. required.
5-15

5-16

Chapter 6
Parts Replacement
Table of Contents
Replacing the Rectifier ...............................................................................................6-1
Replacing the Solar Power Module.............................................................................6-3
Replacing the Lightning Protection Module.................................................................6-4
Replacing the Air Circuit Breaker................................................................................6-5
Replacing the CSU.....................................................................................................6-6
6.1 Replacing the Rectifier

Damaged rectifiers should be replaced in time to guarantee the normal operation of the
system.
Context
Caution!
Reducing rectifiers can reduce the load capacity of the DC power system. Be cautious
with the operation.
During the replacement of rectifiers, there is no need to shut down the DC power supply
of the ZXDT22 SF01. Figure 6-1 shows how to replace the rectifier.
6-1

Figure 6-1 Replacing the Rectifier
Steps
1. Turn the bolts on both sides of the rectifier in the counter-clockwise direction to loosen
the bolts, and then remove the rectifier.
Danger!
Large capacitors exist within the rectifier. To avoid burning or electric shocks, do not
directly contact interfaces at the rear side of the rectifier!
2. Insert the new rectifier into the slot until the handle fits into the spacing hole, then
screw the bolts on both sides of the rectifier in the clockwise direction
Caution!
The rectifier should be placed in position in the cabinet. Poor contact with the electrical
interfaces may cause heating problems.
3. Observe the indicators on the rectifier. If the indicator is not lit, re-install this
rectifier, or change another slot for installation.
If the indicator and indicator are lit, it indicates that the rectifier is operating
properly.
– End of Steps –
6-2

Chapter 6 Parts Replacement
6.2 Replacing the Solar Power Module

Damaged solar power modules should be replaced in time to guarantee the normal
operation of the system.
Context
Caution!
If solar power is the only power supply, reducing solar power modules can reduce the load
capacity of the DC power system!
Figure 6-2 shows how to replace the solar power module.
Figure 6-2 Replace the Solar Power Module
Steps
1. Turn the bolts on both sides of the solar power module in the counter-clockwise
direction to loosen the bolts, and then remove the solar power module.
Danger!
Large capacitors exist within the solar power module. To avoid burning or electric
shocks, do not directly contact interfaces at the rear side of the solar power module!
6-3

2. Insert the new solar power module into the slot until the handle fits into the spacing
hole, then screw the bolts on both sides of the solar power module in the clockwise
direction.
Caution!
The solar power module should be placed in position in the cabinet; poor contact with
the electrical interfaces may cause heating problems.
3. Observe the indicators on the solar power module. If the indicator is not lit,
re-install the solar power module, or change another slot for installation.
If the indicator and indicator are lit, it indicates that the solar power module
is operating properly.
6.3 Replacing the Lightning Protection Module

The lightning protection module needs to be replaced in time to guarantee the normal
operation of the system.
Prerequisite
Before replacement, turn off the air circuit breaker of the corresponding lightning protection
module.
Context
Figure 6-3 shows how to replace the lightning protection module.
6-4

Figure 6-3 Replace the Lightning Protection Module
Steps
1. Turn off the air circuit breaker of the corresponding lightning protection module.
2. Hold the lightning protection module with your hand.
3. Remove the lightning protection module with a proper force.
4. Install the new lightning protection module on to the module base.
5. After installation, turn on the air circuit breaker of the corresponding lightning protection
module.
6.4 Replacing the Air Circuit Breaker

Damaged air circuit breakers should be replaced in time to avoid potential dangers.
Steps
1. Disassemble the damaged air circuit breaker according to the following diagram.
6-5

2. Install a new air circuit breaker according to the following diagram.
6.5 Replacing the CSU

A damaged CSU should be replaced in time. When replacing the CSU, the ZXDT22 SF01
system does not need to be shut down. When battery capacity is below 80% and the
battery is charging, redundant rectifier modules should be removed to prevent overload
due to overcurrent during charging.
Context
Caution!
Replacing the CSU may lead the shutdown of the diesel generator. Therefore, standby
power supplies must be provided, such as wind power supply, mains power supply, battery
power supply, or solar power supply.
Figure 6-4 describes how to replace the CSU.
6-6

Figure 6-4 Replace the CSU
Steps
1. Calculate the sum of the actually measured total current of loads (IB) and battery
charging current (IL) to determine the number of rectifiers to be removed.
Three-phase must be balanced.
2. Calculate the number of running rectifiers =(IB + IL)/50A. The calculation result is
rounded up. Remove the superfluous standby rectifiers.
3. Turn the bolts on both sides of the CSU in the counter-clockwise direction to loosen
the bolts, and then plug out the CSU.
4. Insert the new CSU into the slot until the handle fits into the spacing hole, then screw
the bolts on both sides of the CSU in the clockwise direction.
5. Set site parameters for the new CSU.
6. Re-install the removed rectifiers in the original slots.
6-7

6-8

Chapter 7
Site Maintenance Record
Table
Table of Contents
Battery Maintenance Record Form .............................................................................7-1
Integrated Power Cabinet Maintenance Record Form ................................................7-3
Diesel Generator Maintenance Record Form..............................................................7-3
Busbar Box and Solar Photovoltaic Module Maintenance Record Form......................7-5
Wind Generator and Wind Generator Controller Maintenance Record Table ..............7-7
ATS Maintenance Record Table .................................................................................7-8
7.1 Battery Maintenance Record Form

During the routine maintenance of batteries, fill in the maintenance table. See Table 7-1.
Table 7-1 Battery Maintenance Record Form
Problem Type Check Items Qualification Standard Maintenance

Record
Battery appearance Check for dirt and dust No dirt or dust.
Bulging or acid leakage Battery is not bulging or

having acid leakage.
Connection between Whether connection is Connection is firm and not

battery cells loose loose
Whether the connection The connection wire is not

wire is aging, or the aging; the insulation layer
insulation layer is is intact.
damaged
Whether the connection The temperature of the

wire is overheated connection wire does
not exceed 40 ºC; does
not feel scorching when
touched with bare hands
7-1

Problem Type Check Items Qualification Standard Maintenance

Record
Battery voltage Conformation to standard l Voltage of single

batteries (2V): 1.9 V
- 2.35 V
l Voltage of the battery
pack : 45.6 V - 56.4 V
Battery temperature Whether the temperature The surface temperature

exceeds 35 ºC. does not exceed 35 ºC.
Battery capacity Whether the battery After discharging at 0.1 C

pack capacity satisfies for 10 hours, the voltage
requirements measured at the battery
pack terminals is no lower
than 45.6 V.
Whether there are After discharging at 0.1

disqualified batteries C for eight hours, the
voltage measured at the
terminal of each single
battery is no lower than
1.9 V.
Parameter settings Whether the capacity The capacity conforms to

settings are correct the actual capacity of the
battery pack.
Whether the equal Satisfies site

charging/floating charging requirements (by default,
setting is correct the equal charging voltage
is 56.4 V, and the floating
charging voltage is 53.5
V)
Whether the charging Satisfies site

current coefficient setting requirements (by default,
is correct the charging current
coefficient is 0.15 C)
Whether the low-voltage Satisfies site

disconnect settings of the requirements (by default,
loads and batteries are the first low-voltage
correct disconnect voltage is 45
V, and second low-voltage
disconnect voltage/battery
low-voltage disconnect
voltage is 44 V.)
7-2

Chapter 7 Site Maintenance Record Table
7.2 Integrated Power Cabinet Maintenance Record

Form
During the routine maintenance of the integrated power cabinet, fill in the maintenance
table. See Table 7-2.
Table 7-2 Integrated Power Cabinet Maintenance Record Form
Check Items Qualification Standard Maintenance Record
Whether the wind tunnel The wind tunnel is not

is blocked blocked.
Whether the cabinet The cabinet surface has

surface has accumulated no accumulated dust.
dust
Whether the lightning The lightning protection

protection module window module window displays
displays red no color or green.
Whether the monitoring The monitoring unit has

unit has alarms no alarms.
Whether the monitoring The monitoring unit is

unit is working properly working properly; all
functions are available.
Whether cable connection The cable is reliably

is reliable connected, without aging
or deformation.
Whether the operating The operating parameters

parameters in monitoring in monitoring unit conform
unit are correctly set to site requirements.
7.3 Diesel Generator Maintenance Record Form

During the routine maintenance of the diesel generator, fill in the maintenance table. See
Table 7-3.
Table 7-3 Diesel Generator Maintenance Record Form
Add antifreeze to the Perform this operation in

cooling system and the winter.
enable the water jacket
heater
7-3

Keep the cooling system Perform this operation in

clean the summer.
Replace lubricating oil Perform this operation

and filters when the diesel generator
cumulatively operates for
Release the water and
250 hours or after every
sediment from the water
two years.
separator
Add grease to the fan

bearing of the diesel
generator (large diesel
generator set)
Check AC generator
terminals
Check the control system

of the diesel generator
set, fasten cables, and
clean up dust and foreign
matters
Check and adjust the Perform this operation

throttle gap when the diesel generator
Check and adjust the oil
gush time
two years.
Check the abrasions of
the drive belts of the fan,
water pump, and charging
generator
If the belts are abraded
seriously, you should
replace them
Check and thoroughly

clean the cooling system,
including rinsing the
cooling fin and cleaning
the water channel
7-4

Clean and calibrate the Perform this operation

injector and fuel pump when the diesel generator
Check, repair, or replace
the booster assembly
four years
Check, repair, or replace
the water pump assembly
Add grease to the bearing

of the AC synchronous
generator
7.4 Busbar Box and Solar Photovoltaic Module

Maintenance Record Form
During the routine maintenance of the busbar box and the photovoltaic module, fill in the
maintenance table. See Table 7-4.
Table 7-4 Busbar Box and Solar Photovoltaic Module Maintenance Record Form
Product Check Items Qualifica- Maintenance Record

Name tion Stan-
dard
Busbar Box Whether the –

appearance
is damaged
Whether The
the cable is fasteners
damaged or and bolts are
broken not loose.
Whether the The cable is

connection not damaged
terminals are or broken.
loose
7-5

Product Check Items Qualifica- Maintenance Record

Name tion Stan-
dard
Solar Whether the The surface

photovoltaic surface is is free of
module covered with dust, snow
dust, snow or or oil.
oil
Whether the The surface

surface is is not
damaged damaged.
Whether There are

the solar no bubbles
photovoltaic that form
module has channels.
bubbles
that form
channels
Whether The cable is

the cable is not damaged
damaged or or broken.
broken
Whether the The

connection connection
terminals are terminals are
loose not loose
Whether the The open-

open-circuit circuit
voltage of the voltage of
single solar the solar
photovoltaic photovoltaic
module (the module is
cascade volt- within the 80
age of two V - 100 V
solar photo- range.
voltaic mod-
ules) meet
the corre-
sponding re-
quirements.
7-6

7.5 Wind Generator and Wind Generator Controller

Maintenance Record Table
During the routine maintenance of the wind generator and wind generator controller, fill in
the maintenance table. See Table 7-5.
Table 7-5 Wind Generator and Wind Generator Controller Maintenance Record Table
Product Type Check Items Qualification Standard Maintenance

Record
Wind Generator Whether fasteners and Fasteners and bolts are

bolts are loose. not loose.
Whether cables are Cables are not damaged

damaged or broken. or broken.
Whether the fin or wind The fin or wind deflector

deflector is damaged. is not damaged.
Whether the tower rack is The tower rack is not

loose or broken. loose or broken.
Wind Generator Controller Voltage and current l The difference

between the
displayed voltage and
measured voltage is
more than 10%.
l The difference
between the
displayed current and
measured current is
larger than 2 V.
Whether the paint on the The paint on the wind

wind controller is peeled controller is not peeled
off and the surface of the off and the surface of the
shell is scratched. shell is scratched.

damaged or broken. or broken.
The insulation value Insulation value<50 MΩ

of the three-phase
wiring between the wind
generator and the wind
controller
7-7

7.6 ATS Maintenance Record Table

During the routine maintenance of the ATS, fill in the maintenance table. See Table 7-6.
Table 7-6 ATS Maintenance Record Table
Whether the alarm The fault indicator or

indicator is lit alarm indicator is not lit.
Whether the overview of The overview of the

the cabinet is damaged or cabinet is not damaged or
deformed deformed
Whether there are There are no accumulated

accumulated foreign foreign matters in the
matters in the cabinet cabinet.

damaged or fall off or fall off.
7-8

Glossary
ATS
- Automatic Transfer Switch
CSU
- Centralized Supervision Unit
ESD
- Electrostatic Discharge
PE
- Protective Earth

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ZXDT22 SF01

Integrated Power Energy System

Revision No. Revision Date Revision Reason

R1.0 2014-08-01 First edition

Serial Number: SJ-20140730091132-002

Publishing Date: 2014-08-01 (R1.0)

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Chapter 2 Tools Preparation...................................................................... 2-1

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

Chapter 5 Common Faults Troubleshooting............................................ 5-1

Chapter 6 Parts Replacement.................................................................... 6-1

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Chapter 7 Site Maintenance Record Table ............................................... 7-1

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

What Is in This Manual

Chapter 2 Tools Preparation Describes tools needed for system maintenance.

Chapter 3 Basic Knowledge Describes the basic knowledge of system maintenance.

Chapter 6 Parts Replacement Describes how to replace major parts.

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Notice: indicates equipment or environment safety information. Failure to comply

Note: provides additional information about a topic.

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

1.1 Common Precautions

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

l Before installing, replacing components, or checking equipment, you must pay

1.2 Personal Safety Information

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Common fire precautions are described as follows:

Mechanical Damage Hazards

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Battery Operation Requirements

Short circuits might be caused by the following operations:

1.3 System Safety Information

l Sodium bicarbonate (baking soda): NaHCO3

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

jack on the equipment (identified as ), see Figure 1-1.

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Figure 1-1 Wearing ESD Wrist Strap

l Avoid foreign objects that results in short circuits.

à Do not leave extraneous pieces of metal in the cabinet during equipment

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Avoiding Heavy Objects Stacking on the Cabinet

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

This page intentionally left blank.

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Table 2-1 Maintenance Tools

Diagram Name Function

Cross Screwdriver Fastening Screw

Flathead Screwdriver Fastening Screw

Spanner Fastening Bolt

Diagonal Pliers Trims wire fasteners

Wire Stripper Strips off the cable

Hydraulic Crimper Crimps the copper

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential

Diagram Name Function

Insulation Tape Insulates naked wire

Cable Fastener Binds cables

Gloves Wear them

SJ-20140730091132-002|2014-08-01 (R1.0) ZTE Proprietary and Confidential