TROUBLESHOOTING


Eltek charger isn’t charging, but should be (for standard Orion BMS)



Start with your system set up such that the charger should be charging the batteries.

Step 1. Open the BMS utility and select File -> Connect to the BMS.

If you are unable to connect to the BMS, see the Troubleshooting Guide at http://orionbms.com/troubleshooting/ for help connecting to the BMS. If unable to communicate with the BMS only when the charger is connected or only when the charger is powered, it is possible that the baud rate of the BMS and charger are different or that the CAN wiring to the charger is causing communication problems. If this happens, ensure that CAN High and CAN Low are not backwards and that the BMS and the charger are operating at the same baud rate (usually 500kBps for Eltek chargers.)

Step 2. Select the “Live Text Data” tab at the top of the screen.

Step 3. Near the bottom of the screen where it says “Selected Parameter Group”, select “Advanced Parameters”

Step 4. Look for the parameter called “Is-Charging” power status. This should read ON.

If this reads OFF, then charge power is not applied to the BMS. Apply charge power to the BMS to correct this issue.

Step 5. Look for the parameter called “Charger-Safety Output Active”. This should read ON, indicating that the BMS is in fact calling for charge.

If this reads OFF, then the BMS is not allowing charge for some reason. If that is the case, proceed to step 5a and continue diagnosing until “Charger-Safety Output Active” reads ON; otherwise proceed to step 6.

Step 5a. At the bottom of the screen where it says “Selected Parameter Group”, select “Current”.

Step 5b. Look for the parameter called “CCL Zero Because Charge Complete”.

If this says “YES”, it means that the BMS tried to charge the pack and stopped because a battery exceeded the maximum voltage. You can select “Restart the BMS” from the File menu and the BMS will attempt to charge again to closely watch what is happening. If the charger turns off very rapidly, it may be necessary to use the graphing screen to graph the highest cell voltage look for rapid spikes in voltage. Rapid spikes in voltage may indicate a problem with a cell or loose busbar / connection and may require diagnostics on the cell causing the issue.

Step 5c. Look for the parameters called “Reduced Due to Voltage Failsafe”and “Multi-Unit Comm Failsafe”.

If either of these parameters read YES, the BMS is prohibiting charge due to a critical failure. Look at the “Diagnostic Trouble Codes” page for fault codes and diagnose these codes. Note that only certain codes are critical and prevent charging or discharging. Charging will be prohibited if the charge current limit (CCL) is zero amps for any reason.

Step 5d. Ensure that the profile on the BMS has been setup and that the charger safety relay has been enabled.

If the profile has never been setup, run through the profile setup wizard in the utility if using a battery type in the database; otherwise, ensure that the profile has been setup manually. The BMS will not allow charging or discharging if the profile has not been setup or if the charger safety relay is not enabled.

Step 6. Download the current profile from the BMS to ensure proper CANBUS configuration for the Eltek charger.

Switch to the “Battery Profile” tab at the top. Select “Receive Current Profile From BMS”.

Step 7. Click on the “3rd Party Devices” tab (under the Battery Profile tab). Ensure that there is a checkbox next to the “Eltek Valere Charger” line.

In versions of the utility newer than 1.8, this can be found under the “CANBUS settings” tab.  If this is not checked, place a check next to it, follow the instructions and upload the updated profile to the BMS. This box can be un-checked and re-checked in order to ensure that the proper Eltek charger has been selected (this is important as selecting the wrong charger will transmit the wrong information and will likely result in the charger not operating.)

Step 8. Click on the CANBUS settings tab (if you are not already there) and check to ensure that the CANBUS which the Eltek charger is connected to is operating at 500kBps.

Please note that the BMS must be fully power cycled with all power removed after a CANBUS baud rate change has occured.

Step 9. Attempt to communicate with the charger.

For this step, it works best with the CANdapter connected to the same CAN interface that the Eltek charger is located on, though limited data should be available even if located on the other CAN interface. Go to the “3rd Party Data” tab at the top of the screen and select the “Eltek Charger” under “Selected Third Party Device.”

Step 10. Under “Device Parameters”, there should be some information from the Eltek charger. If all of the lines starting with “Eltek” read “Not Available”, the BMS utility is unable to establish communication with the Eltek chrager.

Troubleshoot this by ensuring that the charger is powered and that the CANBUS connection to the BMS is good. CAN wires MUST be twisted pair wire and MUST be properly terminated to operate correctly. Ensure that CAN High and CAN Low wires are not reversed.

Step 11. If “Eltek Errors Present” says “YES”, this indicates an issue with the Eltek charger.

If connected to the same CAN interface as the charger, the rest of the data can be used to diagnose the issue. Ensure that the Eltek charger is properly connected to the battery pack and that the polarity of the battery connection is correct. If the charger was connected in the reverse polarity, the charger may be damaged and require repairs.

Note: Eltek chargers have a primary charging voltage range and a maximum charging voltage range. The charger will not operate outside of the maximum defined range. Outside of the primary charging voltage range, but still inside the maximum defined voltage range, the charger will operate at a fixed current and may have erratic behavior, especially when used with long extension cords. For best results, always use the charger within the primary charging voltage range only.

Note: Eltek chargers will enter an undefined state if they are told to charge at a higher amperage than their maximum possible amperage. This will prevent them from charging. When setup using the profile setup wizard, the BMS will not transmit a charge current limit higher than the maximum allowable for that charger. If setting up manually, ensure that the “Maximum Amperage While Charging” variable is set at or below the theoretical maximum possible DC amperage for the specific model of charger being used.

Copyright (C) 2015 Ewert Energy Systems




Ewert Energy Systems, Inc
161 East St. Charles Rd
Carol Stream, IL 60188

Phone: (630) 868-3173
Fax: (866) 657-5667

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