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1、 Voltage related faults

1. High battery voltage: After being fully charged and idle, the voltage of a single or several battery strings is significantly higher, while other individual cells are normal.

Reason for malfunction: ① Collection error; ② LMU balance function is poor or ineffective; ③ The battery cell has a low capacity and the voltage rises rapidly during charging.

Solution: ① If the displayed voltage of a single unit is higher than that of other units, measure the actual voltage value of the unit for comparison. If the actual value is lower than the displayed value and is the same as the voltage of other units, calibrate the LMU unit voltage based on the actual value; If the measured value matches the displayed value, manually perform discharge balancing on the individual battery cells Check if the voltage sampling line is broken or virtual connected; ③ Replace LMU.

2. Low battery voltage: After being fully charged and left to stand, the voltage of one or several individual cells of the battery is significantly lower, while the other cells are normal.

Reason for malfunction: ① Collection error; ② LMU balance function is poor or ineffective; ③ High self discharge rate of battery cells; ④ The battery cell has low capacity and the voltage drops rapidly during discharge.

Solution: ① If the displayed voltage of a single unit is lower than that of other units, measure the actual voltage value of the unit for comparison. If the actual value is higher than the displayed value and is the same as the voltage of other units, calibrate the LMU unit voltage based on the actual value; If the measured value matches the displayed value, manually charge and balance the individual battery cells Check if the voltage sampling line is broken or virtual connected; ③ Replace LMU; ④ Replace the faulty battery pack.

3. Pressure difference: dynamic pressure difference/static pressure difference. When charging, the single cell voltage quickly reaches the full charge cut-off voltage and the gun jumps; When stepping on the accelerator, the voltage of a single unit drops faster than other series; When the brake is applied, the voltage of a single unit rises faster than other series.

Fault cause: ① Loose fastening nut of the copper plate connecting the battery; ② There is dirt on the connecting surface; ③ High self discharge rate of battery cells; ④ The copper plate of the battery cell welding connection is open (causing low capacity of the individual cells in the string); ⑤ Some individual battery cells are leaking.

Solution: ① Tighten the nut; ② Remove foreign objects from the connection surface; ③ Charge/discharge balancing of single string batteries; ④ Replace the problematic battery pack.

4. Voltage jump: When the vehicle is running or charging, the voltage of a single unit jumps.

Fault cause: ① Loose connection point of voltage acquisition line; ② LUM malfunction.

Solution: ① Tighten the connection points; ② Replace LMU.

2、 Temperature related faults

1. Thermal management failure;

① Heating malfunction (heating element); When the temperature is below a certain value, heating will not be turned on during charging.

Reason for malfunction: ① Heating relay or BMU malfunction; ② The heating element or relay power supply circuit is abnormal.

Solution: ① Repair or replace the heating relay or BMU; ② Check and repair the power supply circuit.

② Cooling failure (fan); After the temperature exceeds a certain value, the fan does not work.

Reason for malfunction: ① Fan relay or BMU malfunction; ② Fan or relay power supply circuit abnormality.

Solution: ① Repair or replace fan relay or BMU malfunction; ② Check and repair any abnormalities in the power supply circuit.

2. High temperature: One or several temperature points in the battery system are too high, reaching the alarm threshold during operation or charging.

Reason for malfunction: ① Temperature sensor malfunction; ② LMU malfunction; ③ Abnormal electrical connection and local heating; ④ Fan not turned on, poor heat dissipation; ⑤ Close to heat sources such as motors; ⑥ Overcharging.

Solution: ① Compare the resistance value of the temperature sensor with the displayed value. If the actual value is lower than the displayed value and is the same as other temperature values, calibrate the LMU temperature value based on the actual value. ② Tighten the electrical connection points and remove any foreign objects from the connection points; ③ Ensure that the fan is turned on; ④ Increase insulation materials to isolate from heat sources; ⑤ Suspend operation for heat dissipation; ⑥ Immediately stop charging; ⑦ Replace LMU.

3. Low temperature: One or several temperature points in the battery system are too low, reaching the alarm threshold during operation or charging.

Reason for malfunction: ① Temperature sensor malfunction; ② LMU malfunction; ③ Local heating element abnormality.

Solution: ① Compare the resistance value of the temperature sensor with the displayed value. If the actual value is higher than the displayed value and is the same as other temperature values, calibrate the LMU temperature value based on the actual value. ② Check and repair the heating element; ③ Replace LMU.

4. Temperature difference; Refer to the high and low temperature troubleshooting methods. Differential heating of battery cells.

3、 Charging malfunction

1. DC charging fault; GB/T27930-2015 Charging cannot start, charging jumps, SOC does not reset after charging is completed.

Reason for malfunction:

① Battery malfunction (abnormal voltage, temperature, insulation, etc.)

② BMU malfunction (abnormal charging module or charging CAN)

③ Abnormal main negative and charging relay

④ CC1 ground resistance and CC2 ground voltage are abnormal

⑤ PE ground anomaly

Handling method:

① Troubleshooting battery issues

② Repair/replace faulty components

③ Capture charging messages and analyze the cause of the malfunction.

2. Communication charging failure;

Reason for malfunction:

① Battery malfunction (abnormal voltage, temperature, insulation, etc.)

② BMU malfunction (abnormal charging module or charging CAN)

③ Abnormal main negative and charging relay

④ CC ground resistance and CP ground voltage are abnormal

⑤ PE ground anomaly

Handling method:

① Troubleshooting battery issues

② Repair/replace faulty components

③ Capture charging messages and analyze the cause of the malfunction.

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