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Analysis of common faults of lithium ion battery BMS

1. the whole system does not work after power supply

Possible causes

The power supply is abnormal, the harness is short circuited or open circuited, and DCDC has no voltage output.

Troubleshooting

Check whether the external power supply of the management system is normal, whether it can meet the minimum working voltage required by the management system, and whether the external power supply is set with limited current, resulting in insufficient power supply of the management system; The external power supply can be adjusted according to the power requirements of the management system; Check whether the harness of the management system is short circuited or damaged, and modify the harness to make it work normally; If the external power supply and harness are normal, check whether the DCDC in the power supply management system of the whole system has voltage output; You can replace the damaged DCDC module under any abnormal condition.

2. BMS cannot communicate with ECU

Possible causes

BMU (main control module) does not work, but the signal line is broken

Troubleshooting

Check whether the BMU power supply is normal at 12v/24v; Check whether the can signal transmission line is plugged; Listen to can port data to see if BMS or ECU packets can be received.

3. The communication between BMS and ECU is unstable

Possible causes

Poor matching of external can bus, bus branch too long

Troubleshooting

Check whether the bus matching resistance is correct; Whether the matching position is correct and whether the branch is too long.

4.bms internal communication is unstable

Possible causes

The communication line plug is loose, the can wiring is not standard, and the BSU address is repeated.

Troubleshooting

Check whether the wiring is loose; Check whether the bus matching resistance is correct, whether the matching position is correct, and whether the branch is too long; Check for duplicate BSU addresses.

5. insulation detection and alarm

Possible causes

Battery or drive leaks. Insulation module connection failure.

Troubleshooting

Use BDU display module to check insulation test data, and check whether battery bus voltage and negative bus voltage to ground are normal; The insulation resistance of bus and driver to ground is measured by insulation meter.

6. the main relay does not close after the power is turned on

Possible causes

The load detection line is not connected, the pre fill relay is open, and the pre fill resistance is open.

Troubleshooting

Use the BDU display module to check the bus voltage data, check whether the battery bus voltage and load bus voltage are normal; Check whether the load bus voltage rises during precharge.

7. the data of the acquisition module is 0

Possible causes

The acquisition line of the acquisition module is disconnected and the acquisition module is damaged.

Troubleshooting

Unplug the module again, and measure whether the battery voltage at the connection of the acquisition line is normal, and whether the resistance value at the connection of the temperature sensor line is normal.

8. battery current data error

Possible causes

The hall signal wire plug is loose, the hall sensor is damaged, and the acquisition module is damaged.

Troubleshooting

Unplug the current Hall sensor signal wire again; Check whether the hall sensor power supply is normal and whether the signal output is normal; Replace the acquisition module.

9. the battery temperature difference is too large

Possible causes

The cooling fan plug is loose and the cooling fan fails.

Troubleshooting

Unplug the fan plug cable again; Respectively power on the fan and check whether the fan works normally.

10. the battery temperature is too high or too low

Possible causes

The cooling fan plug is loose, the cooling fan is invalid, and the temperature probe is damaged.

Troubleshooting

Unplug the fan plug cable again; Respectively power on the fan and check whether the fan is normal; Check whether the actual temperature of the battery is too high or too low; Measure the internal resistance of the temperature probe.

11. system error report after relay operation

Possible causes

Relay auxiliary contact is disconnected and relay contact is stuck

Troubleshooting

Re unplug harness; Use a multimeter to measure whether the on-off state of the auxiliary contact is correct.

12. do not charge with charger

Possible causes

Abnormal communication between charger and BMS

Troubleshooting

Replace the charger or BMS, and confirm whether it is BMS fault or charger fault; Check whether the matching resistance of BMS charging port is normal.

13. no BMS data display for airborne instruments

Possible causes

Abnormal connection of main control module harness

Troubleshooting

Check whether the harness of the main control module is fully connected, whether the low-voltage working voltage of the vehicle is normal, and whether the module works normally

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