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DL380-G5 power supplies overheat when plugged in but off

oldtrlrnr
Occasional Advisor

DL380-G5 power supplies overheat when plugged in but off

I recently installed a couple of new ProLiant DL380-G5 servers with max everything including RPS. I noticed one of them that had been powered off but had both its power supplies plugged into AC outlets, was very hot at the left rear corner where the power supplies are. Seems these over heat when RPS modules are plugged in but not turned on.

Anyone else seen this?
34 REPLIES
Ivan Kuznetsov
Frequent Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hello!

I see too. Not only on DL380 G5 but on some other DLs too.

I suspect that at some condirions server completly turn off air cooling. PS does not have own cooler inside so it became hot (~50C). I think this temperature is not critically high

Regards, Ivan Kuznetsov
RaMpaNTe
Trusted Contributor

Re: DL380-G5 power supplies overheat when plugged in but off

That's normal since these power supplies don't have a fan inside, so when the server is off (therefore its fans) The power supply might get hot but once you turn the server on they will be cooled and there will be no problem at all. This does no occur with the DL580 G3 since those PS have fans.
You heve a question... I have an aswer!!!
KennyLogsdon
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

I have about 24 of the new DL380-G5 servers all with dual RPS and I have replaced three power supplies so far in the last month to due to failure. I am browsing posts to see if there is a known problem with the design of the new G5 power supply and to see if others are having excessive failures like I am. I see that the RPS for the G5 does have two small fans inside but I do not know if they run while the server is powered off. None the less, I have also noticed the power supplies getting hot (almost too hot to handle) while the server is off but plugged in. I wonder if sitting in this state for a while can damage them. This has never been a problem with previous models that I am experienced with. In fact, I have only replaced a handful of server power supplies in my whole career.
Prabhulj
Valued Contributor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi All,

Hope this Customer Notice Explains the heating Issue.

This behavior occurs by design to reduce noise levels and does not affect the performance or functionality of the server, the power supplies, or the fans.

Check the Customer Notice
Link:
http://h20000.www2.hp.com/bizsupport/TechSupport/Document.jsp?lang=en&cc=us&objectID=c00772855&jumpid=reg_R1002_USEN

Regards,
Prabhu
KennyLogsdon
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Thanks for the link to the customer notice which was interesting to see.
Prabhulj
Valued Contributor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi Kenny,

Saw your post reporting that you have replaced the power Supplies.
I remember seeing a customer Advisory regarding False Power Supply failure Alerts on SMH (Sorry Cant re-call the Advisory) will try to get them.

May be the P/S's replaced could have been a false alert ( My thoughts) :-)

Regards,
Prabhu
KennyLogsdon
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

We have a server farm with about 175 HP servers which we monitor using HPSIM 5.1. HPSIM reported the power supply bad in all three cases and HP gladly replaced them each time. None the less, prior to creating a case with HP, I try to verify that the PS indeed is bad by verifying power to the PS and swapping with a known good spare PS. In all cases the LED on the back of the failed PS was dark but lights briefly when the power cord is unplugged and re-plugged in then goes dark again. I did not test by unplugging the remaining power supply to see if the server would stay up since these are production systems. I can't help but believe that there is an issue with the design of this guy and so far I have not seen if HP has addressed this. Maybe it is just my bad luck. We'll see.
Dave Simon
Occasional Visitor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi.

I am now replacing my 3rd power supply in dl380g5s. This is the second supply to go in the same box.

Is this another issue like we had with the 360g1's?
c.wolf
Frequent Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi,
we replaced 3 PS on 2 Servers DL380G5. They was bought Nov 2006.
I wonder that the new PS have different Part Numbers.
defect PS PartNr: 379123-001
new PS PartNr: 379124-001

Anyone an idea what HP have done?

Greetings
Chris
Jian_2
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi,

We bought 5 Proliant DL380 G5 servers last November 2006, but only started using them January 2007. All power supply of each server (5 servers), starting from the top of the rack to the bottom failed. The first one failed 2weeks before the second and the the rest with a gap of 2 to 3 days only. We did have some prower failures in our area but the servers are attached to a 5KVA APC UPS with 2 external battery packs.



mhutchesson
Occasional Visitor

Re: DL380-G5 power supplies overheat when plugged in but off

Well guess what I can confirm there is a problem HP told me they had 1500 on back order into Australia to meet the need, I have had around 8 die since Sept 2006

When I have had them fail, the normal response has been none available in the country but escalation to higher levels normally finds one for me

They talk about the 03M version being good but I have had them all fail, theres one model around thats 300 grams lighter than the rest ( dont know why , but this model has also died )

Michael
c.wolf
Frequent Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hello,
a HP Technican had told us that the Charge of defect PS all have Sparepartnumber SPN: 403781-001

The bad one have Partnumber
P/N: 379123-001 REV 03M (without green Point)

following Partnumbers are ok
- P/N: 379123-001 REV 03M (with a green Point)
- P/N: 379123-001 REV 04M (with or without green Point)
- P/N: 379124-001 (alle Revisions)

good luck

Jian_2
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Thanks for the info guys. I'll check the part numbers of the 2nd PS that have not failed yet and the new ones that I got as a replacement.

With regards to replacement, we don't seem to have any problem or long delays in our location here in U.A.E.



Ivan Kuznetsov
Frequent Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hello!

I measured current which server takes from mains in different modes.

Hardware is DL380 G5 with 2 CPUs, P400 RAID controller and 8 SAS SFP 10K HDDs, two redundant PSU (p/n 379123-001 REV 04M).

Mains is 230V AC 50Hz

Just 1 PSU is connected:
stand-by: 0.25-0.27A
Startup: 1.48A max
Working (running tests): 1.24-1.38A

Both PSUs are connected:
stand-by: 0.25-0.28A
Working (running tests): 0.72-0.77A

Therefore server takes ~60VA of power for each of connected PSU while in stand-by mode.
I don't know and can't measure power factor for PSU, let's consider it 0.7. PSU dissipates most of the power as heat (~40W). It is sufficient to make some parts of PSU (transistors, transformer and coils) wery hot if there is no air flow trough.

Total power taken is ~120VA (~80W) if two PSUs are connected and server is standby. I'm surprized


Jun.K
Occasional Visitor

Re: DL380-G5 power supplies overheat when plugged in but off

Hello.
Could you teach Difference point
of Measures parts and parts before Rev03M
(measures Electric element)
My best regards.
Ivan Kuznetsov
Frequent Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hello!

No, I can't. Now we do not have DL380 G5 with old different power supply revisions

I measured temperature inside a PSU which was in standby mode for ~12h. It's 60-65C. The hotest part is the small transformer which is about 80C

Regards, Ivan Kuznetsov
George Jires
Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi,
our customer bought five DL380G5 servers last year and now the customer notice,that five of redundant PSs are failed. I don`t know if those PSs failed at one time (and customer didn`t know too) . Customer also complained about strong overheating in PSs area.All failed PSs are PN 379123-001,REV. O3,serial number ATZD0638153xxx (xxx= 320,323,229,319,960) ,without any green or yellow points on the label.
(Nobody know,what those points does mean ??? I have already seen green,yellow and red points on different spare parts which came from HP,and I remember that SystemBoard-DL360 R01- with the red point has got the same fault as the bad one. Are those parts recycled ?)
So,new PSs from HP are same PN,but REV.06,all with yellow point. Serial Number ATZD0726878xxx . Should be rest of original PSs replaced ?
George
David Stavert
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

I searched this forum looking to see if anyone else was concerned about the lack of redundant fans. In February HP dropped redundant fans. No longer an option although the marketing literature now claims that all the G5s have redundant fans as standard equipment. With fewer fans (6 rather than 12) and no fan in the power supply it might explain the failures. Power supply failures have been very rare in my experience. Certainly the lack of redundancy and heat issues.

I have always liked Compaq equipment since it first came out and perhaps mostly for its engineering and thoughtful design. I have purchased ProLiant servers because I believed they were building good reliable equipment. It helped me sleep at night. Even after ProLiant acquired an HP logo I still felt that comfort. They still felt the same looked the same and sounded the same. I could still see the same design thoughtfulness.

I don't have hundreds of servers in my racks but like everyone they need to be reliable. My perception of security has been shaken after twenty some years I am sorry to say. My sleep is a little less easy today.
Brian Akey
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

We also purchased our first DL380-G5's. I got 5 of them for a specific project, all with redundant power. We had a data center test with a power outage and these servers didn't get turned back on for a decent period of time after the power was turned back on. I had 2 of the RPS fail immediately and now a 3rd has failed.

After reading the other posts here, it makes sense that they were damaged by having the power applied but the server not turned on to have any heat dissipation. Sounds like a serious design flaw to me. I can understand trying to save on power by removing the fans from the PS, but then they should run in a reduced power mode. I'm sure they still need to be active because of the ILO and management agents, etc...but not a good plan to have them cook themselves.

I'm sure that HP will gladly replace the PS' now, but what about when they come out of warranty? Do I have to run around and unplug my servers when they are powered down but still have power available to them?
So much for remote administration...

Brian
Paul Haldane
Occasional Visitor

Re: DL380-G5 power supplies overheat when plugged in but off

We're seeing an unusually high number of failures of G5 PSUs (hardly ever had PSU failures with previous generations).

Is there a way to query the revision of the installed PSUs via SNMP?
chongkan
Trusted Contributor

Re: DL380-G5 power supplies overheat when plugged in but off

No, the revision can only be determined by taking a look at the sticker..
blairono
Occasional Visitor

Re: DL380-G5 power supplies overheat when plugged in but off

Hi everyone,

I must agree that there is a serious problem with those PSU. I work for a service provider "partner" of HP, and we are ordering several psu form that model per week. I only saw that kind of problem +- 6years ago with the release of the first proliant ML350.
For the 379123-001, i noticed that the rev 03M was particularly hit by failure.
I don t know if it's a bad design or bad component quality, since i never found an official Service Advisory from HP.
Thank if someone can link me to an official advisory, so we could take ProActive action for our customers
chongkan
Trusted Contributor

Re: DL380-G5 power supplies overheat when plugged in but off

For HP and Channel Partner Internal Use

Do you know what INTERNAL means? "PARTNER"
Adie
Occasional Advisor

Re: DL380-G5 power supplies overheat when plugged in but off

Replaced nearly all my DL380-G5 PSU's (80 odd). They started to melt the white gunk in the rear of the units. Serious safety issue in my mind.