SECTION 3 - TROUBLESHOOTING AND FAULT CODES
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2.
DMCC (A): It is the current by the BMS from the
battery charger. It depends on the cells and
charging status.
When machine is not under charge, the current
required by BMS is always maximum. The
required current detail is listed in below table.
In the beginning of the charging process, BMS
requires the maximum current to the battery
charger, independently from the cells voltage.
After some time if a cell voltage is already 3630
mV, the current required is reduces according
with a series of parameters (state of the other
cells, temperature, current absorbed etc).
In the last charging steps (equalization phase),
the current required to the battery charger
should be reduced.
When the battery pack is completely charged
and Equalized, 1st generation BMS requires a
current of around 4-5 ampere for initial few sec-
onds, then requires zero ampere for next few
seconds. The 2nd generation BMS requires a
fixed current of around 0.5-1 Ampere.
3.
SOC (%): It is the level of battery pack charge and
corresponds to the value showed by the remote
control display.
If the SOC value is not 100% and the current
required is not maximum, there is a problem
with one cell.
The cells maximum level is100% and minimum
level is 0%. However the value 0% is not the
complete cells discharge point, there is some
residue cells power to avoid the excessive low
voltage od cells. SOC (%) depends on the status
of all the cells.
4.
Current (A): It is the value of the current mea-
sured by the LEM sensor. With sign “-” the cur-
rent is going out from the battery pack
(discharge). If there is no sign, the current is
going inside the pack (charge).
During charge, if the machine is not moving,
Current (A) value should be close to the DMCC
(A) value, as the current required to the battery
charger is almost the same as the current going
inside the battery pack.
For example, if DMCC (A) value is 25 Amp, and
the Current (A) value is -1.5 Amp, the battery
charger is disconnected, or one contactor is
open.
If the main key is on with machine not under
charge, Current (A) value should be around -1.5
to 2 Amp, that is the current absorbed from all
the ECM and the remote control.
In the same condition, if the Lead-acid battery
level is low, the Current (A) negative value
increases because the system also has to
recharge the Lead-acid battery.
5.
Rem. Energy (kWh) (1st and 2nd Generation):
Power still available in the battery pack
6.
Rem. Capacity (Ah): Capacity still available in the
battery pack
7.
SOH (%): State of health (SOH) of the battery
pack shows how good the battery pack perfor-
mance is as compared to when the pack was
new.
When the battery pack is new, this value should
be 100. Cycles of charges and discharges, tem-
peratures and other elements effect SOH.
SOH (%)= “0” means the pack still has 80% of the
capacity compared with a new battery pack. For
example when we read SOH (%) value as 1%, it
means that the performance of this battery pack
is approximately 80% as compared to a new bat-
tery pack.
NOTE:
SOH (%), Rem. Energy (KWh) and Rem. Capacity
(Ah) are the same data showed in different ways.
Table 3-7. BMS Current Requirement
Battery Pack
CE Machines
ANSI Machines
38V Battery Pack
18A
18A
48V Battery Pack
25A
18A
72V Battery Pack
30A
13A
76V Battery Pack
30A
13A
83V Battery Pack
30A
13A
MAF12250
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