How do I troubleshoot my RemotePro® or UPSPro® system?

How do I troubleshoot my RemotePro® or UPSPro® system?

Applicable systems:

RemotePro, UPSPro, or MobileSolarPro systems:

Minimum Equipment Needed:
- A voltmeter that can show DC voltage. 
- Wire Ferrules sized 12-18AWG is suggested depending on the system.

Testing Batteries:
 Measure the battery voltage at the solar charge controller ports and then on the battery terminals to verify the voltages are the same.
The LOAD output ports can be tested using the voltmeter to make sure it is the same as the battery voltage.
The batteries should be wired for 12, 24, or 48V depending on your load requirements.  The solar voltage should always be higher than the battery voltage, so the batteries can charge.  
Ex. A 12VDC battery bank needs to be charged to 12.8V to be considered fully charged, but while charging the battery can go higher.
Ex. A 24VDC battery bank needs to be charged to 29.2V.
Ex. A 48VDC battery bank needs to be charged to 54.6V to 58.8 in some cases.
Solar panel expected voltage 
Ex. A 12V solar panel will generate up to 22VDC
Ex. A 24V solar panel will generate up to 38VDC
Ex. A 48V solar panel will generate up to 76VDC
(Note): Voltage can go higher than the voltages listed but should not exceed 100VDC on Tycon MPPT controllers.
  • FUSE: The battery cables may have a protection fuse. If no power, check the fuse to see if it is blown. Replace with type is 3AG 20A 250V Glass Cartridge (Shurter 0001.1037 or similar). Available at Digikey and Mouser.

LEDs for TP-SCPOE Battery/Solar Charge Controllers:
  • LOA – LOA Light will be on, and the load outputs (Green connector and RJ45 POE Out) should have voltage when the battery is within the usable range. When the battery drops to below 11.2V the LOA will turn off. It won’t turn back on till the battery reaches 12V. On 24V systems LOA turns off at 20V and back on at 24V
  • POE – The POE LED will only show when the controller has a POE input in the bottom connector.
  • CHA – will be steady state when charging and it will be flashing when the controller is float charging the batteries.
  • SOL – The SOL LED will be on whenever there is voltage on the solar input.
  • FUSE – There is a battery fuse in the front of the controller. Fuse type is 5mm x 20mm 10A 125V (Littlefuse 0233010.MXP or similar)

TP-BCxx-300 High-Capacity UPS Charge Controller

Before Troubleshooting Make Sure:

  • Back voltage switch is set for your AC voltage (115VAC or 220VAC).
  • Battery type is set to GEL (for GEL or AGM) or WET for automobile type batteries.
  • The Battery Switch on the front is switched to ON. This can be switched to OFF to disconnect the battery from the charger.
  • LOAD – Load power is on. The load will turn off when battery voltage is too low and will turn back on when battery voltage reaches a stable voltage.
  • PWR – AC Power is ON
  • BATT – Battery is connected.
  • CHD – Battery is fully charged and is float charging.
  • CHG – Battery is charging.

TP-SC24-20 Solar Charge Controller

Use the ON/OFF button (the one that looks like a lightbulb) to manually toggle power to the load.

Use the following tables to help identify and address any issues.


Batteries

When testing batteries that are wired in parallel, you must disconnect the battery, so it is isolated from other batteries. When batteries are wired in series you can test each battery without disconnecting them. A fully charged 12V battery will have a battery voltage greater than 12.5VDC without a load.

To see if you have a bad cell, disconnect any load and fully charge the battery, wait a few minutes, measure and record the battery voltage, wait at least 15-30 minutes and measure the battery voltage again. The voltages should be within about 0.5V of each other. If the 30 minute measurement is too low, then the battery is not good and should be replaced.

Tycon Batteries are designed to be charged with Tycon Chargers that are designed for AGM or GEL batteries. Using automobile chargers can be used in an emergency but they shouldn’t be left connected to the battery for a long time or the battery will be damaged. We recommend not to exceed 4hrs if connected to an automobile battery charger. And only use for emergencies, not for regular charging.

Tycon Batteries should never be left in a discharged state, especially in cold weather. If your UPSPro® or RemotePro® system is having charging issues, make sure that you disconnect the load and leave the batteries in a charged state while troubleshooting. Leaving the batteries in a discharged state for a few days or a week can permanently kill the battery.