Forklift lithium battery pack, if the battery core material selection, PACK process, charger, protection board problems, line connection, and improper use, and other problems may cause the battery pack serious hidden danger.
1. Battery Pack Can Not Be Charged
The battery pack can not be charged when charging, which can be divided into the following reasons: reverse connection of the charger or charger failure; Protection board‘s function is not restored or protection board failure; Battery pack and electrical appliances are externally disconnected.
For the above problem, check these parts in turn: whether the charger is connected to the reverse, whether the battery pack charging positive and negative plug is connected to the reverse; Restart the appliance to disable the protection function of the protection board and measure whether the MOS tube of the protection board has driving voltage; Find whether the connection is loose and disconnected.
2. Battery Pack Can Not Discharge
There are several reasons why the battery pack can not discharge normally when it is in use: When the battery pack voltage is low, protection board's or controller's protection function enabled; Protection board or controller damage; The positive and negative electrodes of discharge are connected in reverse; The line is disconnected, or the switch is not turned to “On.”
These problems can be solved by charging the battery pack, checking the protection board or wiring problems.
3. Battery Pack Is Not Fully Charged
During the cycle use of the battery pack, the charging mode stops before reaching the cut-off voltage of the battery pack as a whole. This situation is due to the battery pack single string of power or capacity is not consistent, high power or low capacity first charge saturated, then the protection function of the protection board starts, which makes other batteries stop charging when they are not fully charged.
In this case, an equalizing charger can be used to recharge the battery pack so that the voltage of each battery is the same, but if the capacity difference is large, the battery must be replaced. It is important to test the capacity of the battery cell before the battery pack is assembled. Otherwise, when the single battery is inconsistent, it needs to be disassembled again, which is very troublesome.
4. Short Range
The battery pack runs out of power quickly. This can happen because the battery is not fully charged； The voltage capacity of single series is different greatly in a Micro short circuit or a large self-discharge of the battery pack will cause the battery pack to be fully charged and quickly depleted.
For the above problems can be used to recharge the battery pack or replace the defective cell to solve these problems.
5. Low Voltage
The voltage of the whole battery pack is only half of the nominal voltage or negative voltage. This situation generally occurs when the battery pack is just assembled; this may cause by the battery pack is misconnected; Inverse connection between positive and negative or individual batteries are not fully connected. If the battery pack is fully charged after normal but standing or use for a period of time immediately occur the low voltage situation, it is likely to be the battery‘s large self-discharge or the battery pack has a micro short circuit.
Correct wiring must be done when the nominal voltage is low or negative. When the voltage becomes low immediately after being fully charged, the defective battery needs to be replaced.
6. High Temperature
The temperature of the battery pack is abnormally high and hot when it is charged or discharged. This situation may be due to the high internal resistance of the battery pack or the micro-short circuit, which leads to the temperature rise when the battery pack is charged and discharged.
It is very dangerous for the battery pack to work at a high temperature for a long time. In this case, it is necessary to replace the defective battery or check the circuit to fix the problem of the micro-short circuit.
7. Short Cycle Life
The cycle life of the battery pack ends within the promised service time. This situation is due to the poor consistency of the battery pack or the poor performance of the battery pack in series, which makes the battery pack not fully charged when charging and not fully discharged when discharging. In this case, only can replace the defective cell to solve this problem.
8. Stops Working Suddenly While In Use
The battery pack stops working suddenly when in use. The reason may be that the battery has finished discharging and reaches the lowest lower limit voltage of the protection board or controller, then the protection board or controller stops working. Or the continuous working current is too large (such as when the electric vehicle starts with a load or climbs a hill), which exceeds the designed protection current of the protection board； Also maybe the continuous current of the controller makes the protection board or controller stop working, which will cause the battery pack to stop working suddenly.
This can be solved by charging the battery pack, rebooting appliances, resetting parameters, or replacing the protection plate or controller.
9. Battery Leakage, Catch Fire
The battery pack may spill liquid or suddenly catch fire during use. This is rare but very dangerous. Leakages can cause fires and explosions because the spilled electrolyte lithium hexafluorophosphate is an organic solvent with a very low ignition point. The reason for this situation is that the moisture of the cell is not completely dried, resulting in the effects inside the cell, producing gas to burst the safety valve, or the cell cap sealing is bad and poor protection. The cause of the fire may be the battery internal or external circuit break, leakage, battery pack close to the fire source and the packaging material is not fireproof.
If the battery only leaks liquid, just replace the leaky battery. If the battery pack catches fire, it must be covered with a fire extinguisher or fire sand, etc., and cannot be extinguished with water or clothes, because water is the conductor and clothes are flammable.
10. Battery explosion
Battery packs exploding are as rare as battery pack fires, but more serious. The reason is also because of external or internal long time short circuit caused. The external short circuit is equivalent to the instantaneous superlarge current discharge, exceeding the limit of the core protection board, the gas generated inside the instantaneous ejection, very dangerous. An internal short circuit and a poor sealing effect of the diaphragm can also cause an explosion.
For the prevention of external short circuit can be used to avoid the protection board, the protection board has a short circuit and overcurrent protection function can completely eliminate this risk. But to solve the battery internal short circuit problem must use qualified cells from regular manufacturers.
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