Showing 10 of 10 articles
Troubleshooting & Maintenance
Lithium batteries are often sold as "Maintenance Free," but that is a myth. Thermal expansion loosens bolts, dust creates conductive paths, and cells drift over time. This semi-annual engineering checklist ensures your system remains safe and efficient through the changing seasons.
Troubleshooting & Maintenance
Your battery was full when you parked the RV in November, but it is dead flat in March. What happened? In this diagnostic guide, we expose the "Vampire Loads" hiding in your BMS, buck converters, and inverters, and teach you how to use a multimeter to measure milliamp-level leaks that kill batteries over time.
Troubleshooting & Maintenance
When a BMS fails to keep a pack in sync, one group often drifts lower than the others, crippling the entire battery. In this repair guide, we show you how to bypass the slow BMS balancers and use a lab power supply to surgically recharge a single series group, restoring balance and capacity to your pack.
Troubleshooting & Maintenance
Your e-bike range has dropped, or your solar bank runs dry by 2 AM. Is the battery dying, or is it just the weather? In this comprehensive diagnostic guide, we detail the equipment and protocols for performing a true Discharge Capacity Test, calculating SOH percentages, and deciding when to retire a lithium battery bank.
Troubleshooting & Maintenance
Galvanic corrosion is the silent killer of high-current systems. In this materials science guide, we explain why placing a stainless washer between a copper lug and an aluminum terminal creates a resistor, how to chemically neutralize acid/alkali leaks, and the proper torque and grease protocols to ensure a gas-tight, oxide-free connection.
Troubleshooting & Maintenance
A dead BMS is the most common failure point in DIY packs. Swapping it out is dangerous because you cannot turn the battery off. In this safety-critical guide, we detail the strict disconnection and reconnection sequence required to prevent short circuits and explain why pinout verification is mandatory even if the plug looks the same.
Troubleshooting & Maintenance
Your blue prismatic cells are bulging. Is it a dangerous gas buildup, or just normal mechanical expansion? In this safety analysis, we distinguish between intercalation swelling and electrolyte decomposition, define the safe limits of deformation, and explain how proper compression fixtures prevent your battery from destroying itself.
Troubleshooting & Maintenance
Your BMS constantly struggles to balance one specific group. You charge it, and two days later, it is low again. This is the hallmark of a "Self-Discharge" failure. In this repair guide, we detail the surgical process of isolating a bad parallel block, identifying the specific "leaker" cell, and replacing it without destroying the rest of the pack.
Troubleshooting & Maintenance
You found an old tool battery reading 0V. Can you save it? Maybe. Should you? That depends on the copper shunts growing inside. In this safety guide, we distinguish between a "sleeping" BMS and a chemically "dead" cell, and outline the strict low-current protocol for attempting a resurrection without causing a fire.
Troubleshooting & Maintenance
Your battery reads 54V, but cuts out the moment you hit the throttle. Why? Voltage Sag is the difference between resting voltage and load voltage, and it is caused by resistance hiding somewhere in your system. In this diagnostic guide, we use Ohm's Law to track down weak cells, bad spot welds, and undersized wiring to restore your pack's punch.
