Maintenance and Field Repair
7.8 Battery Failure; Detection, Prevention & Corrective Action
7.8.4 String/Cell Replacement
1. Assemble temporary battery string if the power system is equipped with only one battery string.
2. Match temporary battery string voltage to main power system voltage by either using an external charger to raise the voltage of the temporary string or by lowering the voltage on the power system to match the temporary string voltage (voltage should be within .5 volts).
3. Connect temporary string on line.
4. Disconnect battery string in question.
5. Perform boost charging, cell replacement and/or maintenance on battery string.
6. Match power system voltage to the voltage of the disconnected battery string.
7. Connect battery string on line.
8. Disconnect temporary string.
CHAPTER
Troubleshooting
8.1 Power System and System Controller
To use the following troubleshooting guide, look for the specific symptom that you are experiencing. Then check the numbers in the left column to verify which power equipment it applies to, then check the solution in the right column.
1. RST rectifiers.
2. RSM 48/100 rectifiers.
3. RSM 48/50 and 24/100 rectifiers.
4. RSM 48/30 and 24/50 rectifiers.
5. RSM 48/10 rectifier systems.
6. RSM 48/7.5 rectifier systems.
7. SD 03 and 05 supervisory panels.
8. SD 02 and 04 supervisory panels.
9. SM 02 supervisory panel.
10. Temperature compensation panel.
11. Circuit breaker, fuse and distribution centers.
12. Battery back-up.
13. CS converters.
14. CSM converters.
15. Pathfinder 1.5, 3, 10 kW rectifiers.
16. SM 03 supervisory panel.
See equipment manuals for additional details.
Units Symptom Solution 1-5, 15 Rectifier fail
alarm indication.
Check that the voltage on each rectifier is set to the same value.
Check that there is a load on the system greater than 5% of the current capacity of a single rectifier in the system or that a battery is connected to the system.
2-4 Module not
responding to commands.
Perform a microprocessor reset, see rectifier manual.
3-4, 6 Alarm relay contacts not functional.
Check yellow alarm relay fuse located behind left module (3) or “resistor style” fuse behind SCI PCB (4). Check “resistor style” supervisory control fuses on backplane of rectifier cabinet (6).
2-4 Rectifiers not sharing current evenly > 10 % difference in current between modules.
Set the slope on rectifier to the same value (0.5% preferred).
Enable the forced sharing on each rectifier.
Adjust the float and equalize voltage on each rectifier to the same value off-line (output breaker off).
Connect rectifier on line.
Repeat with each rectifier in the system.
Units Symptom Solution not sharing current evenly > 10 % difference in current between modules.
Systems not SM equipped
Set the slope on rectifier/converter to the same value, 1%
preferred (1,6,13) non-adjustable (5,14).
Adjust the output voltage on each unit while monitoring the voltage at the batteries or load. Ensure that the battery or load voltage is correct and the load current is split evenly between the units.
Repeat for the equalize voltage setting (1).
2-4,15 9,16.
Rectifiers not sharing current evenly > 10 % difference in current between modules.
Systems.
Systems SM equipped
Set the slope on rectifier to the same value (0.5% preferred).
Enable the forced sharing on each rectifier.
Adjust the float and equalize voltage on each rectifier to the same value off-line (output breaker off).
Download the settings to the rectifiers.
1-6, 15. Rectifier fail and/or AC Mains fail alarm
Check AC voltage level in the rectifier status display (2-4) or at rectifier input circuit breaker/termination (1,5,6,13,14).
Check input feeder circuit breaker.
Reset breaker as required.
Check and replace rectifier input fuse (15) 2-4, 6,
15
Fan fail/speed error. Check fan cable connection Replace fan assembly.
1,13 Rectifier/converter control and/or alarm problem.
Replace front panel control PCB, see maintenance and field repair section.
3, 4,5, 6,14
No module fail alarm. Check module fail dip-switch (4), defeat plug (3) or jumpers (5,6,14).
Check the cooling vents for obstruction or excessive dust build up.
Clean as required.
Reset unit.
1-6, 15 Input breaker/fuse trip/blow.
Turn off AC feeder circuit breaker.
Turn on rectifier input circuit breaker (1-6).
Turn on feeder breaker.
If breaker trips again rectifier has been damaged, check and/or replace MOV in rectifier (1,2,3,6,15) or send for repair (1-6,15).
Units Symptom Solution 1-6, 15 OVP (over voltage
protection) trip or HVSD (high voltage shutdown).
Check that the OVP and float settings are correct.
If module continues to trip off due to OVP, set OVP setting to the maximum setting and float voltage to the minimum setting i.e. manually adjust potentiometers (1,5,6) or adjust stored setting in the
microprocessor with the input breaker off and a power source connected to the DC output (2,3,4).
Turn rectifier on.
Readjust settings to the correct value.
5,6,9,10, 16
OVP (over voltage protection) trip or HVSD (high voltage shutdown) at low temperature only.
Check that the temperature compensated float voltage does not exceed the OVP setting when maximum voltage boost is occurring i.e. at low temperatures.
Check and adjust the OVP and/or float voltage settings as necessary, see battery temperature compensation section for more details. There should be at least 1 volt between the maximum float voltage and the OVP setting.
1,2,3,4, 15
AC on, no DC output after reset and LVA.
Check start delay setting, rotary switch (1) or programmed setting (2,3,4).
Wait for delay to elapse or reset delay to zero.
3,4,5,6, 15
New installation or rectifier addition - rectifier not operational.
Check that AC is actually connected and energized to module position.
6,7,8 Supervisory panel fail, LVD open or incorrect non-functional alarms.
Check power fuse for supervisory panel located on the front-GMT type (8), on the rear-GMT type (7) or on the backplane-”resistor style”(6).
5,6,7,8 Supervisory panel fail, LVD open or incorrect non-functional alarms.
Replace supervisory control PCB.
Units Symptom Solution 5,6,11 Load circuit
breaker/fuse trip.
Check for fault condition.
Reset circuit breaker or replace fuse.
Check that load on circuit breaker does not exceed 75-80% of the fuse/c.b. rating using a clamp on ammeter.
If load is within limits, monitor the situation and replace circuit breaker if there is a reoccurrence.
If the load is exceeding limit upgrade the fuse/circuit breaker size and associated wiring if required.
11 Circuit breaker alarm not functional.
Check alarm signaling jumpers on rear of circuit breaker, ensuring continuity of alarm path. Check operation if possible by turning breaker off.
Check that jumper setting on alarm PCB is correctly configured for voltage application.
5-9,12, 16
On power failure - no battery back up.
Check battery circuit for poor or missing connection. (12).
Check battery for open cell (12).
Check that the supervisory panel LVD control settings are correct.
(5-9).
5-9,12, 16
On power failure - short battery back up.
Check battery circuit for poor or missing connection. (12).
Check that battery is sized correctly for load and back-up time required (12).
Check battery performance (12).
Check that the supervisory panel LVD control settings are correct.
(5-9).
Units Symptom Solution 15 Module fail & AC mains
OK
Ensure that the rectifier is seated correctly and that the mounting screws are tight
Verify rectifier settings and download (from SM02) Check AD and DC fuses
Replace module 15 Module fail & AC mains
fail
Check AC feeder breaker and circuit 15 Module minor alarm (red
LED flashing). Note:
LED will flash when the rectifier is in current limit if the feature is enabled
Check AC input voltage
Ensure that the rectifier is seated correctly and that the mounting screws are tight
Verify rectifier settings and download (from SM02) Check and/or replace fan, connections, etc.
Replace module 15 No display, no power
up.
If new rectifier module is installed in the early version of the pathfinder cabinets the module interlock jumper must be set correctly. This jumper is located below the DC output connectors on the module. It is the jumper on the left and it should be installed on the center and the left most pin if used in an older system (3kW only)
9,16 Out of tolerance. Verify rectifier settings and download (from SM) to the rectifiers.
9,16 Communications lost alarm
Check cables Verify baud rate Enable remote access
Verify that rectifier mounting screws are tight 9,16 Measurement error Calibrate analog channel
9 RS 232 communications
problems.
Verify cable; must be “null” modem Verify communications speed
If a baud rate change has been made the reset button must be depressed to activate the new communications speed.
Enable remote access Reset SM02
Activate communications program from DOS to be sure that windows isn’t taking control of the communications port.
Units Symptom Solution
9 Modem communications
problems.
Same as above.
Must use jumper configurable modem not “plug and play”
Ensure that IRQ is set to 3, com port 4
9 Function keys locked
out.
Reset microprocessor.
Depower SM controller and reapply power.
9 No rectifier ID aquistion. Make sure rectifier mounting screws are tight.
Check and/or replace RS 485 communications cable.
Check that the RSM count is set to zero if using pathfinder type rectifiers. Set the count to the quantity of RSM type rectifiers in the system when using RSM type.
9 Display hard to read Use left/right arrow keys in Normal operation mode to adjust the view angle.
9 Alarm messages on
display with (clear).
Depress visual alarm reset button (VAR) to clear.
9 Rectifier “Lockout message.”
This message will appear on the SM02 if the rectifiers are equipped with local display/control and the keys in the rectifier have been depressed. Return to normal operation in the rectifier menu to clear this alarm.
Ensure that remote access and remote adjust have been enables in all the rectifiers.