Maintenance and Service

This section describes preventative maintenance procedures, how often to perform the procedures, and where to find further maintenance details.

Cleaning

Caution Always disconnect the AC power cable, and switch the Main Breaker (CB Outlet) to the OFF position, before cleaning or servicing the system.
Attention Débranchez toujours le câble d'alimentation CA et mettez le disjoncteur principal (CB Outlet) en position OFF avant de nettoyer ou de réparer le système.

The required maintenance schedule is as follows:

  • Cleaning the exterior—As needed
  • Cleaning air intake filters—Monthly, as needed

Cleaning the Exterior

Notice Do not wash the front- or rear-panel connectors or switches. Cover these components while cleaning the measurement rack.
Notice Do not use harsh chemical cleaning agents or abrasive compounds on any part of the measurement rack; they may damage the system. Avoid chemicals that contain benzene, toluene, xylene, acetone, or similar solvents.
  1. Clean exterior surfaces with a dry lint-free cloth or a soft-bristle brush.
  2. If any dirt remains, wipe with a cloth moistened in a mild soap solution.
    Notice Avoid getting moisture inside the system during exterior cleaning. Use only enough moisture to dampen the cloth.
  3. Remove any soap residue by wiping with a cloth moistened with clear water.

Cleaning Air Intake Filters

  1. Remove the four screws securing the 4U air inlet panel located on the rear of the measurement rack.
  2. Remove the air intake filters from the air inlet panel.
  3. Clean the air intake filters using warm water with a mild soap solution.
  4. Air dry the filters to remove moisture.
    Notice Avoid installing wet filters into the measurement rack. Verify that the filters are thoroughly dry before installing.
  5. Replace the air intake filters in the air inlet panel.
  6. Secure the 4U air inlet panel to the measurement rack with the four screws.

Maintenance

Maintenance includes fuse replacement and calibration.

Replacing the DC Power Fuse

Complete the following steps to replace the DC power fuse on the PS-16 terminal block.
  1. Using a flathead screwdriver, turn the fuse holder cap counter-clockwise to release it from the terminal block.
  2. Gently pull the fuse to release it from the fuse holder cap.
  3. Slide the replacement fuse into the fuse holder cap.
  4. Screw the cap clockwise to replace it.

Customer-Accessible System-Level Compensation

There is no system-level calibration for the Battery Test System measurement rack. However, you can access calibration reports in VeriStand; refer to Calibrating a Hardware Channel at Run Time in the VeriStand Manual.

Instrument Calibration

NI provides calibration services for instruments in the Battery Test System that require calibration. NI recommends that you adhere to the calibration interval for all supported instruments in your system. For the latest information about available calibration service levels for your instrument, refer to ni.com/r/nical.

Table 13. Instrument Calibration Intervals
Component Recommended Calibration Interval (Years)
cDAQ-9189 1
FD-11613 1
FD-11614 1
NI-9212 + TB-9212 1
NI-9213 1
NI-9224 2
NI-9225 1
NI-9227 1
NI-9228 2

Factors such as shelf life and storage temperature can affect an instrument's recommended calibration interval. Refer to the specifications document for your instrument at ni.com/manuals to calculate the appropriate calibration interval.

The following Battery Test System instruments and components do not require calibration:

  • cRIO-9047
  • cRIO-9805
  • Ethernet Switch
  • GPIB-RS232
  • NI-9375
  • NI-9422
  • NI-9423
  • NI-9437
  • NI-9475
  • NI-9482
  • NI-9860
  • NI-9870
  • PDU
  • PS-16
  • RMX-4101
  • UPS

Battery Test System Replacement Parts

Refer to the tables of replacement parts for the Battery Test System to identify replaceable parts and to determine the level of replacement service NI provides for those parts.

Notice Ensure that Battery Test System repair procedures are performed only by qualified personnel.
Notice The AC power cords used in the Battery Test System are specially designed for the Battery Test System. Do not use these power cords in other electrical appliances.
Notice To prevent damage to cables inside the Battery Test System, use caution when sliding the mass interconnect from the test rack.
Note NI provides Advanced Replacement Service for replacement parts in the following table unless otherwise noted.

Listed part numbers are NI part numbers unless otherwise indicated.

Replacement Instrumentation

Table 14. Battery Test System Replacement Parts: Instrumentation
Model Description Part Number
cDAQ-9189 CompactDAQ Chassis (8-Slot Ethernet) 785065-01
cRIO-9047 8-Slot CompactRIO Controller with Kintex-7 70T FPGA 785621-01
cRIO-9805 4-Port 802.1AS Ethernet Switch Expansion Module for CompactRIO 786993-01
NI-9977* Slot Filler Module 196917-01
NI-9860 C Series Vehicle Multiprotocol Interface Module 787687-01
TRC-8546 LIN Transceiver Cable, 18 in. 783702-02
TRC-8543 NI-XNET CAN XS (LS/FT, HS/FD) Transceiver Cable, 18 in. 783701-02
ISO-5B31-10 Analog Isolation Module, Voltage/Current Input, ±40 V Input, 0 V to 5 V Output ISO-5B31-10
NI-9870 C Series 4-Port RS232 Serial Interface Module 787688-01
NI-9482 C Series 4-Channel SPST Relay Output Module 782999-01
NI-9475 C Series 8-Channel High-Speed Sourcing Digital Output Module 780132-01
NI-9437 C Series 8-Channel High-Voltage Digital Input Module 783393-01
NI-9423 C Series 8-Channel Sinking Digital Input Module 779009-01
NI-9422 C Series 8-Channel Sinking/Sourcing Digital Input Module 779522-01
NI-9375 C Series 32-Channel Digital Input/Output Module 781030-01
NI-9228 C Series 8-Channel, Channel-to-Channel Isolated Analog Input Module 783861-01
NI-9227 C Series 4-Channel Current Input Module 781099-01
NI-9225 C Series 3-Channel Analog Input Module 780159-01
NI-9224 C Series 8-Channel, Channel-to-Channel Isolated Analog Input Module 783862-01
NI-9213 C Series 16-Channel Thermocouple Module 785185-01
NI-9212 with Screw Terminal C Series 8-Channel, Channel-to-Channel Isolated Thermocouple Module 782975-01
NI-9212 with Mini-TC Terminal C Series 8-Channel, Channel-to-Channel Isolated Thermocouple Module 785259-01
GPIB-RS232 GPIB Instrument Control Device 787689-01
* Customer Responsible. Customer Responsible means that these components are not covered products as per NI Terms of Service, and customers need to purchase such system parts individually and replace them by themselves.

Replacement Cables and Accessories

Table 15. Battery Test System Replacement Parts: Hardware Assembly Components
Model Description Part Number
Fan Top Kit for RMX-10011 19 in. Rack, 6-Fan, Low-Power (540 CFM), Gray 787441-01
3U Filler Panels for RMX-10011* 19 in. Rack, QTY 3, Gray 787443-01
1U Filler Panels for RMX-10011* 19 in. Rack, QTY 5, Gray 787442-01
Spare Panel Kit for Battery Test System Shelf, Front, Electronics, Slide Clearances* 19 in. Rack, Gray 133983-01
Spare Panel Kit for Battery Test System Front, Slide-Mounted Electronics Tray* Full Height, Blank, 19 in. Rack, Gray 134780-01
Blank Panel for RMX Power Supplies* Filler Panel for RMX-410x Rackmount Kit 786187-01
Rackmount Kit for Power Distribution Unit* Rackmount Kit for 1U RMX Power Distribution Unit 787261-01
Rackmount Kit for Uninterruptable Power Supply* Rackmount Kit for APC SRT2200RMXLI UPS 785599-01
E/NS 35 N* DIN Rail End Clamp, 9.5 mm, Gray Phoenix Contact 0800886
UT 2.5-Twin* DIN Rail Terminal Blocks, 2.5 mm.2 rated cross section, Gray Phoenix Contact 3044513
UK 10-DRESHI (6.3×32)* DIN Rail Fused Modular Terminal Block, Black Phoenix Contact 3005507
RMX 10040 Power Entry Panel* 1-Phase, 16 A, Gray 787471-01
Mounting Bracket for ECUTS 24U* Mounting Bracket for Ethernet Switch 132876-01
Rackmount Kit for RMX-410x 2U DC Power Supplies* Holds up to 6 Supplies 786186-01
GPIB Rack Mount* Rackmount Kit for GPIB-120B, GPIB-RS232, GPIB-RS485/422 194906-01
Slide Rail Kit * Fits 22 in.–26 in. Deep Racks, Supports 180 lbs 788130-01
1U Brush Cable Entry Panel for RMX-10011* 19 in. Rack, Gray 787470-01
* Customer Responsible. Customer Responsible means that these components are not covered products as per NI Terms of Service, and customers need to purchase such system parts individually and replace them by themselves.
Table 16. Battery Test System Replacement Parts: System Cables
Description Part Number
Spare Kit, Cable Assembly, Equipment Ground, 3 m 156690-03
Spare Kit, Equipment Ground, 2.5 m, Cable 861167-01
Spare Kit, BTS, Cable Assembly, Equipment Ground, 0.25 m 156690-0R25
Spare Kit, BTS, Cable Assembly, Twisted Pair, 16 AWG, 2.5 m 132844-2R5
Spare Kit, BTS, Cable Assembly, Twisted Pair, 16 AWG, 0.5 m 132844-0R5
Spare Kit, BTS, Cable Assembly, Twisted Pair, 22 AWG, 2.5 m 131294-2R5
Spare Kit, Cable Assembly, Twisted Pair, 22 AWG, 1.5 m 131294-1R5
Spare Kit, BTS, Cable Assembly, Twisted Pair, 22 AWG, 1.0 m 131294-01
Spare Kit, BTS, Cable Assembly, Twisted Pair, 22 AWG, White and Black, 0.5 m 131294-0R5
Spare Kit, BTS, Cable Assembly, PDU, ACOK, 3.75 m 132843-3R75
Spare Kit, BTS, Cable Assembly, PDU, ACOK, 2.5 m 132843-2R5
Spare Kit, Cable Assembly, 16 AWG, 0.15 m 132884-0R15
Spare Kit, BTS, Cable Assembly, EPO, External, EV, 2.5 m 132847-2R5
Grounding Cable, 1 m 785631-01
Spare Kit, BTS, Cable Assembly, 2POS Female, Microfit to Pigtail, 1.5 m 132890-1R5
RS232 Null-Modem Cable, DB-9 Female to DB-9 Female, 1 m 182238-01
Cable Assembly, Serial, 10POS Modular Plug to 9POS DSUB Plug, Type S8, 1 m 182845-01
Cable Assembly, CAT-5E Ethernet, Thin Profile, 5 m* 151733-05
Spare Kit, BTS, Cable Assembly, CAT-5E Ethernet, Thin Profile, 3 m 151733-03
Cable Assembly, CAT-5E Ethernet, Thin Profile, 2 m* 151733-02
Cable Assembly, CAT-5E Ethernet, Thin Profile, 1 m* 151733-01
Cable Assembly, CAT-5E Ethernet, Thin Profile, 0.3 m* 151733-0R3
* Customer Responsible. Customer Responsible means that these components are not covered products as per NI Terms of Service, and customers need to purchase such system parts individually and replace them by themselves.
Table 17. Battery Test System Replacement Parts: Miscellaneous
Model Description Part Number
Ethernet Switch for NI Test Systems 16-Port Unmanaged Ethernet Switch 132788-01
Rack Safety Thermostat Safety Thermostat Spare for ATE Core Configurations 787002-01
EV Battery Test System 2.0 Accessory Kit, Fuses and Fasteners 133440B-01
Cable Holders, Style S For ½" Maximum Bundle Diameter, Push-In, Nylon* McMaster 7565K76
Screw-In Mount Cable Holders, Style Q For 1" Maximum Bundle Diameter and Number 10 Screw, Screw-in Mount* McMaster 7572K27
Screw-In Mount Cable Holders, Style Q For ½" Maximum Bundle Diameter and Number 10 Screw, Screw-in Mount* McMaster 7572K24
Screw-In Mount, Style B Screw-In Hook and Loop Cable Tie Mount, for ¾" Maximum Cable Tie Width and Number 10 Screw, Nylon Plastic* McMaster 1256N1
Slotted Wire Duct with Snap-On Cover 2-1/4" High × 1-1/2" Wide, 6-1/2" Long, Gray* McMaster 7578K17
RMX Cable Wrap Roll Cable Management Strips, for RMX-1001119 in. Rack, 8 in., QTY 10* 785519-01
Light Duty Blended EPDM Foam Strip with Adhesive Back 1" Wide, 1/8" Thick, 50 ft.Long, Black* McMaster 8694K68
RMX-10060 Emergency Power Off Panel for RMX-1001119 in. Rack, 1U, Gray* 787440-01
ZB 5: UNBEDRUCKT Zack Marker Strip for Terminal Block,5.2 mm Width, 5.1 × 10.5 mm Lettering Field Size, 10 Individual Labels, White* Phoenix Contact 1050004
FBS 5-5 Plug-In Bridge, 5.2 mm Width, Red* Phoenix Contact 3030190
FBS 2-5 Plug-In Bridge, 5.2 mm Width, Red* Phoenix Contact 3030161
D-UT 2.5/4-TWIN End Cover, 56.8 mm Length × 2.2 mm Width × 39.8 mm Height, Gray* Phoenix Contact 3047141
Threaded-Hole Round Pull Handle Dull Black Anodized Aluminum, 6" Center-to-Center Width* McMaster 1568A47
* Customer Responsible. Customer Responsible means that these components are not covered products as per NI Terms of Service, and customers need to purchase such system parts individually and replace them by themselves.
Table 18. Battery Test System Replacement Parts: Power Supplies and Cords
Model Description Part Number
PS-16 Power Supply, 24 VDC, 10 A, 100-120/200-240 VAC Input, Spring-Clamp Terminals 781094-01
RMX-10050 1-Phase Power Distribution Unit with DC (1U, 100–240 V, 16 A. 12/24/24/48 VDC) 785341-01
Spare PDU for NI Test Systems Rack PDU, Basic, 0U/1U, 100–240 V/20 A, 220–240 V/16 A, (13) C13 788138-01
Spare Power Cord for NI Test Systems NEMA 5-15P to C13 - 10 A, 125 V, 18 AWG, 1 ft., Black 788140-0R3
Power Cable for NI Test Systems Spare Kit, BTS, PC-MF4-PTC Series Microfit Power Cable Female to Pigtail, 1.5 m 132845-1R5
Spare Power Cord for NI Test Systems 14 AWG, 250 V, ZLOCK C14 to ZLOCK C15, 1.5 m 133084-1R5
Spare Power Cord for NI Test Systems 17 AWG, ZLOCK C14 to Open, Ferrule Tips, 2.5 m 133114-2R5
RMX-4101 2U DC Power Supply, 1/6 Rack width 786008-01
Power Cable for NI Test Systems Spare Kit, DC Power Cords 2 m PWR CBL Straight 2.0 mm Lock STIP/TIN 787690-01
IEC Power Cord AC, IEC C20 To C19, 100–240 V, Universal 2.5 m 785710-02
IEC Power Cord AC, IEC C20 To NEMA 5-20R, 100–125 V, 0.25 m 785707-01
IEC Power Cord AC, IEC C19 To NEMA 5-20P, 100–125 V, 2.5 m 785708-01
Spare Power Cord for NI Test Systems AC, IEC C14 to C19, 100–240 V, 2 ft 788139-01
APC Uninterruptible Power Supply 2 kW, 120 V 784834-01
APC Uninterruptible Power Supply 2 kW, 240 V 784835-01