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Tracking down critical faults
#1
For the last few weeks I've had a critical fault occurring once or twice per 24hr period. I'm certain it is not an actual cell problem (high or low voltage), I'm suspecting a bad reading from a cellmon or a shunt lockup. I've disabled everything on critical logic except cell lo and cell hi voltage to narrow it down.

When a critical fault occurs, is the cause logged anywhere in the daily snapshot? I couldn't find it in there last time I checked.
Current system: 9.6kWh wet Nicad batteries, 16S1P Calb LiFePo4 210aH, Batrium WM4, Outback vfx3048 inverter, mx60 mppt controller, flexware 500 mounting hardware, 2.4kW solar array, 6kW lister diesel genset. MY'13 Vauxhall Ampera
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#2
Please post your current version of the hardware. I know it's in your signature, but that can change over time. That way if anyone in the future has a similar problem with similar hardware/software/version, it could help them out Wink
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#3
Update: Looking at my daily history and the data extracted from that, It seems my ShuntV-min and CellV-min are always 0v - there's the problem.

What the heck would cause this I wonder?

I do a daily session reset, and it shows the correct CellV-min for about 10 seconds then something sends an update at 0V - it's obviously below the timeout threshold for critical stop (10 secs I think I set it to now) so it rarely drops out the contactor.



I know I should update firmware and software - but I'm loathed to change anything as up till now everything has worked sweetly since installation over a year ago
Current system: 9.6kWh wet Nicad batteries, 16S1P Calb LiFePo4 210aH, Batrium WM4, Outback vfx3048 inverter, mx60 mppt controller, flexware 500 mounting hardware, 2.4kW solar array, 6kW lister diesel genset. MY'13 Vauxhall Ampera
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#4
Almost sounds to me like a bad connection, or a loose solder connection somewhere. Either your work, or on the shunt or other device. Would be interesting to know what is causing it.

I'm sure you've already done it, but try going through all connections and verify their connections. This includes the connections on the longmons themselves. Make sure they are securely fastened. You could even try wiggling the connectors slightly and see if the WM will trigger an event. Even if the pins and connector are tight, the pins to the board could be loose or cracked solder (just a thought).
Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
Certified 18650 Cell Reclamation Technician

Please come join in general chit-chat and randomness at Discord Chat (channels: general, 3d-printing, linux&coding, 18650, humor, ...)
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#5
(07-08-2019, 01:09 PM)Korishan Wrote: Almost sounds to me like a bad connection, or a loose solder connection somewhere. Either your work, or on the shunt or other device.  Would be interesting to know what is causing it.

I'm sure you've already done it, but try going through all connections and verify their connections. This includes the connections on the longmons themselves. Make sure they are securely fastened. You could even try wiggling the connectors slightly and see if the WM will trigger an event. Even if the pins and connector are tight, the pins to the board could be loose or cracked solder (just a thought).

I had a shunt lockup for the first time a few weeks ago, that was caused by a bad 485/canbus connection on the plug from the shunt up to the WM4 - I will check that again, and as you say, check all the other connections on the mons.
Current system: 9.6kWh wet Nicad batteries, 16S1P Calb LiFePo4 210aH, Batrium WM4, Outback vfx3048 inverter, mx60 mppt controller, flexware 500 mounting hardware, 2.4kW solar array, 6kW lister diesel genset. MY'13 Vauxhall Ampera
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#6
That is an odd issue - I assume the shunt is reporting pack voltage correctly within the toolkit ?

Have you rebooted the WM whilst the shunt is unpowered (so main neg feed and low amp pos disconnected) - you are a little behind in terms of updates, but the only shunt related issue the newest version was supposed to cure was the shunt failing to report anything (lockup).

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#7
(07-08-2019, 01:22 PM)Sean Wrote: That is an odd issue - I assume the shunt is reporting pack voltage correctly within the toolkit ?

Have you rebooted the WM whilst the shunt is unpowered (so main neg feed and low amp pos disconnected) - you are a little behind in terms of updates, but the only shunt related issue the newest version was supposed to cure was the shunt failing to report anything (lockup).


I have never seen the shunt report anything but the correct voltage and current values - even when it locked up it just stopped reporting new values (didn't cause a critical event - I just thought it odd that it was 10pm and still showing 96%)

The WM4 has not been rebooted in over a year - I'll try a reboot later
Current system: 9.6kWh wet Nicad batteries, 16S1P Calb LiFePo4 210aH, Batrium WM4, Outback vfx3048 inverter, mx60 mppt controller, flexware 500 mounting hardware, 2.4kW solar array, 6kW lister diesel genset. MY'13 Vauxhall Ampera
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#8
I recently had a problem where the physical shunt was OK (you can check the leds) but I had set a value thru the Hardware -> Shunt page that the software didn't like. It worked fine for several weeks but then the shunt info froze software wise / shunt value went to 0. The diagnosis was to check the Comms Ticks: box ... and in my case it was 'stuck' (no TX/RX). So I changed settings and rebooted and its working again.

Not saying this is your case - just sharing that certain settings can cause 'partial' Batrium software freeze - maybe it will help you investigate or ask the right questions.
HughF likes this post
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#9
Just an update - a firmware reflash to fix this WM4 that eventually locked up/died completely has fixed the critical fault problem. It has been working perfectly for weeks now.
jdeadman likes this post
Current system: 9.6kWh wet Nicad batteries, 16S1P Calb LiFePo4 210aH, Batrium WM4, Outback vfx3048 inverter, mx60 mppt controller, flexware 500 mounting hardware, 2.4kW solar array, 6kW lister diesel genset. MY'13 Vauxhall Ampera
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