Troubleshooting and repair of a Li-ion battery, pitfalls to avoid. From the book "Li-ion Batteries and Applications" by Davide Andrea

1. Li-ion batteries
and applications
Baterías de iones de litio
y aplicaciones
Davide Andrea
Elithion Inc.
Volume 1: Batteries
Ch 9: Dysfunctions
Volúmen 1: Baterias
Cap. 9: disfunciones

2. Chapter 9.1
Dysfunctions - Introduction
Ch 9.1: Dysfunctions - Introduction
Disfunciones - Introducción

3. Ch 9.1: Dysfunctions - Introduction
Troubleshooting and repair
Diagnóstico y reparación

Troubleshooting and repair
1)Troubleshooting comes first
2)Repair comes second

Resources

4. Chapter 9.2
Dysfunctions - Cell and battery
damage
Ch 9.2: Dysfunctions - Cell and battery damage
Disfunciones - Daños a celdas y baterías.

5. Ch 9.1: Dysfunctions - Introduction
Cell damage
Daño a las celdas

No BMS

Thermal runaway

Mechanical abuse

Degradation

6. Ch 9.: Dysfunctions - Cell and battery damage
Disconnected cells and taps
Celdas y grifos desconectados

7. Chapter 9.3
Dysfunctions - BMS damage
Ch 9.3: Dysfunctions - BMS damage
Disfunciones - Daño al BMS

8. Ch 9.3: Dysfunctions - BMS damage
Miswired cell voltage sensing
Grifos de celda mal conectados

9. Ch 9.3: Dysfunctions - BMS damage
Battery is connected, working on BMS
Batería conectada mientras se trabaja en BMS

10. Ch 9.3: Dysfunctions - BMS damage
A fuse installed in the middle of a bank
Un fusible instalado en medio de un banco

11. Ch 9.3: Dysfunctions - BMS damage
Placement of component that may open
Colocación de un componente que puede abrirse

12. Ch 9.3: Dysfunctions - BMS damage
Radiated noise pick-up
Captación de ruido radiado

13. Ch 9.3: Dysfunctions - BMS damage
Power connection with high impedance
Conexión de potencia con alta impedancia

14. Ch 9.3: Dysfunctions - BMS damage
Uncontrolled devices
Dispositivos no controlados

15. Ch 9.3: Dysfunctions - BMS damage
Short circuit current path
Trayectoria de la corriente de cortocircuito

16. Ch 9.3: Dysfunctions - BMS damage
Damaged assemblies
Ensamblajes dañados

17. Ch 9.3: Dysfunctions - BMS damage
Other BMS damage
Otros daños al BMS

Power supply inputs and output

Driver outputs

Communication ports

Signal inputs

18. Chapter 9.4
Dysfunctions - Protector switch
damage
Ch 9.4: Dysfunctions - Protector switch damage
Disfunciones - Daño al interruptor de
protección

19. Ch 9.4: Dysfunctions - Protector switch damage
Protector switch damage
Daño al interruptor de protección

High MOSFET temperature

Multiple batteries in series

Shorted charging port in a dual port
battery

Contactor

Precharge resistor

20. Ch 9.4: Dysfunctions - Protector switch damage
Damaged components
Componentes dañados

21. Chapter 9.5
Dysfunctions - Power up
troubleshooting
Ch 9.5: Dysfunctions - Power up troubleshooting
Disfunciones - Diagnóstico de problemas de
encendido

22. Ch 9.5: Dysfunctions - Power up troubleshooting
Power up troubleshooting
Diagnóstico de problemas de encendido

No BMS power

BMS power cycles constantly

Warnings and faults troubleshooting

Current limits troubleshooting

23. Chapter 9.6
Dysfunctions - Measurements
troubleshooting
Ch 9.6: Dysfunctions - Measurements
Disfunciones - Diagnóstico de problemas de
mediciones

24. Ch 9.6: Dysfunctions - Measurements
Measurements troubleshooting
Diagnóstico de problemas de mediciones

Cell voltage troubleshooting

Wired BMS troubleshooting

Distributed BMS troubleshooting

Battery voltage troubleshooting

Temperature troubleshooting

Current troubleshooting

25. Chapter 9.7
Dysfunctions - Mismatched cell
voltages troubleshooting
Ch 9.7: Dysfunctions - Mismatched cell voltages
Disfunciones - Diagnóstico de problemas de
voltajes de celda no coincidentes

26. Ch 9.7: Dysfunctions - Mismatched cell voltages
Mismatched cell voltage identification
Identificación del problema de voltajes no coincidentes

27. Chapter 9.8
Dysfunctions - Data evaluation
troubleshooting
Ch 9.8: Dysfunctions - Data evaluation
Disfunciones - Diagnóstico de problemas de
evaluación de datos

28. Ch 9.8: Dysfunctions - Data evaluation
Data evaluation troubleshooting
Diagnóstico de problemas de evaluación de datos

State of Charge troubleshooting

Actual capacity troubleshooting

Actual resistance troubleshooting

State of Health troubleshooting

29. Chapter 9.9
Dysfunctions - CAN bus
troubleshooting
Ch 9.9: Dysfunctions - CAN bus
Disfunciones - Diagnóstico de problemas de
bus CAN

30. Ch 9.9: Dysfunctions - CAN bus
CAN bus troubleshooting
Diagnóstico de problemas de bus CAN

No communications

Poor noise immunity

Poor data throughput

31. Chapter 9.10
Dysfunctions - Troubleshooting other
communications
Ch 9.10: Dysfunctions - Other communications
Disfunciones - Diagnóstico de problemas de
otras comunicaciones

32. Ch 9.10: Dysfunctions - Other communications
Troubleshooting other communications
Diagnóstico de problemas de otras comunicaciones

Windows GUI troubleshooting

Command line terminal

Slave communications

33. Chapter 9.11
Dysfunctions - Ground faults
troubleshooting
Ch 9.11: Dysfunctions - Ground faults
Disfunciones - Diagnóstico de problemas de
fallas a tierra

34. Ch 9.11: Dysfunctions - Ground faults
Ground faults troubleshooting
Diagnóstico de problemas de fallas a tierra

False positive

False negative

35. Chapter 9.12
Dysfunctions - Troubleshooting
inputs and outputs
Ch 9.12: Dysfunctions - Inputs and outputs
Disfunciones - Diagnóstico de problemas de
entradas y salidas

36. Ch 9.11: Dysfunctions - Ground faults
Troubleshooting inputs and outputs
Diagnóstico de problemas de entradas y salidas

Digital inputs

Analog inputs

Logic outputs

Relay outputs

Analog outputs

Open drain drivers

37. Ch 9.12: Dysfunctions - Inputs and outputs
Open drain output measurement
Medición de una salida de drenaje abierto

38. Chapter 9.13
Dysfunctions - Troubleshooting
power circuits
Ch 9.13: Dysfunctions - Power circuits
Disfunciones - Diagnóstico de problemas en
los circuitos de potencia

39. Ch 9.1: Dysfunctions - Introduction
Troubleshooting power circuits
Diagnóstico de problemas en los circuitos de potencia

Contactors troubleshooting

Precharge troubleshooting

40. Chapter 9.14
Dysfunctions - Troubleshooting fault
messages
Ch 9.14: Dysfunctions - Fault messages
Disfunciones - Diagnóstico de problemas de
mensajes de fallo

41. Ch 9.14: Dysfunctions - Fault messages
Troubleshooting fault messages
Diagnóstico de problemas de mensajes de fallo

Killing the messenger

Battery shutdown, high cell voltage

Battery shutdown, low cell voltage

Vehicle, high acceleration, up a long hill

Stationary, battery is empty

Battery shutdown, charge over-current

Battery shutdown, discharge over-current

Isolation fault

42. Chapter 9.15
Dysfunctions - Repair
Ch 9.15: Dysfunctions - Repair
Disfunciones - Reparaciones

43. Ch 9.15: Dysfunctions - Repair
Repair
Reparaciones

Safety procedures

Cell replacement

Gross balancing in the field

BMS repair