OPERATION & MAINTENANCE
NOTICE |
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DAMAGE DUE TO IMPROPER MAINTENANCE Proper maintenance is essential for ensuring system reliability and longevity. The 805-0094 Maintenance Guide provides detailed instructions on maintenance procedures and best practices. Failure to follow these instructions may result in equipment damage. |
System Alarms (Cause & Troubleshooting)
Alarm | Cause | Troubleshooting/Resolution |
Abnormal Cell Voltage Low | Cell voltage too low due to imbalance or poor connections. | Adjust the charging system’s CV setpoint, track cell voltage, and discharge slowly. Replace the battery pack if necessary. |
Abnormal Cell Voltage High | Cell voltage exceeds safe limits due to imbalance. | Adjust the charging system’s CV setpoint, track cell voltage, and initiate slow balancing. Replace the battery pack if needed. |
Abnormally High Temperature | Temperature exceeds safe limits (>60°C). Possible TMS or battery pack issue. | Inspect TMS operation, check airflow and vents, ensure proper coolant circulation. Disconnect charger or load, and monitor system behavior. Replace TMS or battery pack if necessary. |
Battery Pack Disabled | BCU detects a misconfigured BMU or BMU issue. | Check BCU and BMU configurations, verify pack communication cables, and reconfigure the system. |
Battery Pack Offline | BMU missing or BMU-related issue detected. | Inspect MSD, verify BCU and BMU configurations, check pack communication cables, and reconfigure the system. |
BCU Abnormal Voltage Rise | Cell voltage increasing too quickly due to imbalance or connection issues. (System Shutdown) | Restart the system, verify all pack connections, identify the affected battery pack, and track voltage. Replace the battery pack if necessary. |
BCU Contactor Override | The contactor was manually overridden. | Return the system to auto-control mode and restart if necessary. |
BCU Voltage Detection Fault | Inaccurate or disconnected voltage detection in HV Box. (Prevents System Start) | Inspect the MSD fuse, check BCU configuration, and verify all voltage detection connections. Replace the BCU if necessary. |
Blown Fuse | HV Box fuse is open or blown due to overcurrent. (Prevents System Start) | Inspect fuse connections, check for continuity, and replace the fuse if needed. |
BMU Hardware Fault | BMU hardware failure or internal fault. (System Shutdown) | Inspect the affected battery pack, check all BMU and pack connections (internal/external), and replace the BMU if necessary. |
BMU Voltage Detection Fault | BMU voltage detection failure or disconnected voltage input. (System Shutdown) | Inspect the affected battery pack, verify internal BMU connections, test BMU operation, and replace the battery pack if needed. |
BMU Communication Fault | BMU communication is inconsistent or unresponsive. (System Shutdown) | Check BMU and pack connections (internal/external), inspect for bent or corroded pins, and replace BMU or connectors if needed. |
BMU Temperature Sensor Fault | BMU temperature detection failure. (System Shutdown) | Inspect internal BMU connections, verify BMU operation, and replace the affected battery pack if necessary. |
Current Shunt Fault | Faulty or loose current shunt connections affecting monitoring. (System Shutdown) | Inspect shunt connections, check for discoloration, and replace the shunt if necessary. |
EMS Communication Abnormal | Communication issue between BCU and EMS. | Restart LYNK, check connections, and restart the system. |
EMS Communication Fault | Communication failure between BCU and EMS. | Restart LYNK, check connections, and restart the system. |
EMS Contactor Override | The contactor was manually overridden by the user. | Return the system to auto-control mode and restart if necessary. |
E-Stop Initiated | Emergency stop button manually triggered. (System Shutdown) | Verify the status of the E-Stop button and reset it if necessary. |
LYNK Communication Abnormal | Communication issue between BCU and LYNK. | Restart LYNK, check connections, and restart the system. |
Negative Contactor Fault | HV Box negative contactor not closing or not detected as closed. (Prevents System Start) | Check the 24V control system, verify I/O input and contactor wiring, and replace the contactor if faulty. |
Pack High Delta Voltage | Excessive voltage difference between battery packs due to imbalance or poor connections. | Verify all pack connections, check MSD installation, and balance-charge packs individually. |
Pack Quantity Misconfigured | Incorrect number of BMUs detected. | Verify MSD installation, check BCU and BMU configurations, ensure proper pack communication, and reconfigure settings. |
Positive Contactor Fault | HV Box positive contactor not closing or not detected as closed. (Prevents System Start) | Inspect the 24V control system, verify I/O input and contactor wiring, and replace the contactor if needed. |
Precharge Fault | Precharge process failed due to an open disconnect or excessive precharge load. (Prevents System Start) | Verify system wiring, check if PCS disconnect is open, and inspect precharge resistance. Retry the precharge sequence; replace precharge system components if necessary. |