Operations Manual | 25
Troubleshooting
Critical Alarms:
•
Battery Pack Overvoltage - BMS failure to stop during normal charging sequence. Call Service Technician for
BMS evaluation.
•
Battery Pack Undervoltage – On discharge the breaker will open when reaching the operational limits. Critical
Alarm level will only be reached if multiple battery failures occur. Call Service technician for evaluation and
replacement of bad batteries.
•
Single Battery Overvoltage / Undervoltage – This will only be reached if the BMS fails to stop a charge or
discharge. Portions of the BMS Main or Secondary Processor Units may need to be replaced.
•
Over temperature when charging or discharging – Battery should be inspected to see if there is a problem on
any charge or discharge where it reaches the Critical Alarm temperature. It will likely need to be replaced.
•
Over-Current on Charge – Max current should not exceed 160Amps from the battery charger. The BMS will
open contactor and not allow charging when greater than this.
•
Over-Current on Discharge – The Battery Cabinet will open the breaker if current exceeds 800Amps for more
than 2 seconds. A critical Alarm will occur if the cabinet every sees greater than 880Amps. Reduce the load to
resolve exceeding the discharge current limits.
•
Monoblock Voltage Differential – No battery in the system should differ from the remainder of the batteries
by 1.2V. If they do then that battery has lost a cell and will need to be replaced for the system to function
properly.
Discharge ended earlier than expected with a Over Temperature Critical Alarm: Battery Unit temperature too high
– A battery exceeded 75°C
•
This means 3 batteries reached 75°C (or higher) on the Positive Terminal Post during the discharge. The
system historical data will need to be evaluated during the failed discharge to determine which batteries
reached >75°C. Any battery that exceeded >85°C should be replaced for optimum system performance.
System is not going into Charge state (SOC < 90% and all batteries between 15°C – 40°C) – Contactor Control
Power Status is Red.
•
Open and close the breaker and the state should be reset.
Battery voltage or temperature is not reading correctly:
•
Check for lose or poor connections on the spade/quick
connect terminals on the battery terminals.
•
Check for connection issues like shown in the picture
where the Quick Connect is not attached correctly (did
not go over the QC correctly). Also the Torque Seal is
broken here, so this bolt should be re-torqued.
Multiple Power Outages Occurrence
•
If the battery cabinet has a FULL discharge and opens the breaker it WILL NOT be available for any
subsequent discharges until the breaker is manually closed.
During a charge or discharge the battery voltages are not aligned.
•
Generally all the batteries will be /-0.3V of one another. If that is not the case there maybe a short to
chassis ground or problem with the harness.
•
Check to see which Secondary Processing Unit batteries have the issue and inspect connections and measure
voltages around those batteries. Try to plug and re-plug the SPU connections near batteries and in the BMS
box.
