SYMMETRAF Generic fault error message?

[electriceye_apc]

This was originally posted on APC forums on 4/27/2011

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Hello All-

Our SYMMETRAF 16KVa (full frame) UPS seems to have one or more gremlins lurking. The unit powers up ok, with no faults, but as soon as we switch the load on (which is zero at the moment BTW) the unit fails with a generic message- 'Unable due to fault'. There is no fault code or numbers displayed, just that generic message which is less than helpful. We did recently replace the bypass contactor with a new one, so we're pretty sure its not that. It used to fault on that saying that the 'Bypass contactor was stuck in the online position'. So now we are stuck again with a different error message and a non-functional UPS. What tests or checks can we do to help narrow down what's wrong? FYI- All batteries are new, they all charge O.K. and both Main and Backup Intelligence modules show as ok as well. Running out of things to check...

[electriceye_apc]

This was originally posted on APC forums on 4/28/2011

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Clarkson-

Thanks for the reply- Here's what we do and what we see:

1. Turn on UPS via switch on back, unit comes to life.
2. PowerView display lights up, says please wait...
3. NO LED's are lit at this time on either the PowerView Display or the MIM or RIM's
4. PowerView display shows Fuel @97%, Load @ 0%, 211 Volts In, 0 Volts out, 60Hz, Runtime 4 Hr, 31 Min (only 3 batteries in system)
5. Via PowerView display, we hit ESC\ Control\ Turn Load On...
6. "UPS has been commandeed to turn load power on"
7. Bypass Contactor down below clicks 3 times
8. Load turns on, but PowerView display also lights fault LED and Bypass LED
9.Message on Powerview display- "UPS in Bypass due to Fault, Press Any Key..."
10. Lights on MIM = Left LED= ORANGE RIgfht LED = GREEN
11. Lights on RIM = BOTH GREEN
12. We can Turn load OFF successfully via the PowerView display.
13. All Power Supplies show O.K.
14. All Batteries show O.K. 137.7 volts + 3 batteries, 0 Bad, Cap = 12 KVa, Fault Tol= n+2, Total Power supplies = 3, Bad = 0, IM= O.K. RM= O.K.

[electriceye_apc]

This was originally posted on APC forums on 5/2/2011

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CLarkson-

Are you sure there is only one green LED on the MIM when the display reports that it is in bypass?
Is the orange LED on the IM solid? or is it flashing with a pattern? Typical LED patters are: off, solid, very slow flash, fast flash, combination flash (mix of slow and flash).
-Yes. Upper module is the RIM and it has 2 GREEN LED's lit. Lower module is MIM and left LED is solid Orange with right LED solid Green.


Also, when the bypass contactor was replaced, was it just the bypass contact itself? or the entire tray that housees that assembly as well as many other components? This is known as the AC try (part no. 0M-612).
-We replaced the whole bypass contactor with a Brand new one. This included all of the contacts and even the micro switch. It is certified brand new and operational. The A/C tray was not replaced due to the cost

When the UPS says "in bypass due to fault" is there power being output? This can be checked via the display and verified at the block (or outlets if this model has them) with a multimeter if you have one.
-Yes. Output voltage is there and within spec.

Also, when it is in this state, can you provide the raw status of the MIM?
-Either with load on or off, the status of both the RIM and MIM shows as O.K. according to the status report from the PowerView display

[electriceye_apc · Accepted solution]

This was originally posted on APC forums on 5/3/2011

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Clarkson-

You NAILED IT! Nice job. Turns out it was the RIM that was giving the problem, not the Main. I stripped it down to One Power and Battery module like you said and added them all back in one section at a time. As soon as I put the redundant IM back, problem returned. Unit is up & running now without it. Guess we will have to figure out why the diags said both were o.k. when in fact they were not.

Thanks again, you rock!

E.E.