Date: 201207
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Light: Night
Aircraft: MD-80 Series (DC-9-80) Undifferentiated or Other Model
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Taxi
ATC / advisory: Ground ZZZ
Aircraft component: DC Battery
Reporter organization: Air Carrier
Reporter function: Other / Unknown
Reporter qualification: Maintenance Airframe; Maintenance Avionics; Maintenance Powerplant
Human factors: Situational Awareness; Confusion; Communication Breakdown; Training / Qualification
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Flight Deck / Cabin / Aircraft Event Smoke / Fire / Fumes / Odor
Detector: Person Flight Crew
When detected: Taxi
Result: Flight Crew Returned To Gate; General Maintenance Action; General Flight Cancelled / Delayed
Contributing factors: Aircraft; Human Factors; Incorrect / Not Installed / Unavailable Part
Primary problem: Human Factors

Narrative: Aircraft [was] in ZZZ1 and the Captain called me stating that his Battery Charger Circuit Breaker popped and would not reset. I contacted Contract Maintenance and had them remove external power from the aircraft. Without power on the aircraft the circuit breaker would stay in; but with power on; it remained out and would not reset. Knowing that the aircraft has two types of battery chargers and two types of batteries (ACME or Marathon) and it is required to have a matching set; I gave [Stores-Parts shipping] for Aircraft on Ground (AOG); both types of batteries and chargers part numbers. They informed me that we only had the Marathon charger in stock and they shipped a matching set of Marathon batteries and battery charger. I also had them send the R2-56 Charger Transfer Relay.When the parts arrived; I had the Contract Mechanic replace the charger and the circuit breaker then remained in [closed]. I had the Contract Mechanic perform the Emergency Power Check and the amp meter showed a deflection to the left indicating the charger was charging the batteries. Being that the batteries were showing 25-Volts at the time of the battery charger replacement; I told the Contract Mechanic not to replace the batteries because they should be good. The aircraft logbook was signed-off and the aircraft was pushed out. I was then informed that the aircraft was taxiing back to the gate because of smoke in the cabin. The Captain pulled the Battery Charger Circuit Breaker and the smoke dissipated. There was a company Mechanic flying on the aircraft and I had him go down to the Electronic Equipment Compartment and verify that the [aircraft] batteries were very hot. I had him verify that the batteries onboard the aircraft were actually ACME batteries and the charger that was installed was a Marathon (mismatched). Effectivity for the Marathon battery and battery charger per Illustrated Parts Catalog (IPC) 24-34-00 shows Marathon battery and battery chargers were effective for different aircraft numbers. A matched set of ACME batteries and battery charger were sent out on the first flight to ZZZ1 for replacement. I spoke with everyone involved and we stressed the importance of verifying part Effectivity in the IPC prior to installing on the aircraft.




Synopsis: A Maintenance Controller reports a McDonald Douglas aircraft taxied back to the gate due to smoke in the cabin. An incorrect battery charger had been installed by Contract Maintenance that was not 'Effective' (not matched) to the aircraft's D.C. batteries.