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Batteries not fully charging

Kimby68

New Member
Joined
Sep 13, 2022
Messages
6
I have 2 LifePO4 batteries and a EG4 6000EX inverter...our batteries aren't fully charging (panels OR generator) but inverter says they are fully charged. PLEASE HELP, I can not find anything in my manual and don't want to screw anything up. Picture below shows the 3 lights on top and 2 on bottom, instead of the usual 4 on each.
Thank you
 

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I'm guessing you're running open loop?
Ignore the SOC on the inverter, it's useless for LiFePO4.
What voltage are you charging to?
Do you have a shunt? Get one if not.
Have you connected to the batteries with a PC to see what the individual cell voltages look like / make sure they are balanced?
 
I'm guessing you're running open loop?
Ignore the SOC on the inverter, it's useless for LiFePO4.
What voltage are you charging to?
Do you have a shunt? Get one if not.
Have you connected to the batteries with a PC to see what the individual cell voltages look like / make sure they are balanced?
And if you are running them closed loop (communication to the eg4 batteries with a cable) upgrade the batteries firmware. They I believe have a number of fixes to make the batteries behave better. Other BMS'es have also fixed similar defects.
 
Setup the windows software to read the packs.

If Unbalanced and a cell is triggering OV and stopping the process. You have to get the packs updated with latest software, balanced, and hold at 56.6V to reset the BMS to 100% SOC. If it fights you and alarms out then you may have to actively balance them.

Been there, done that, and now writing the book ;)
 
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The LP4V1 are notorious about getting completely out of unbalanced. We have now learned how to fix it. I'll keep it simple for now. Update software, charge, discarge, and repeate. That is the MFG answer. If that doesn't work for you we will take you to the Active Top Balancer method but you will need to buy this

Below is the advice I was given. This will take you a long time.

--------------------------------------

EG4 Support <support@eg4electronics.com>

Hello Robert,

The only way to balance the batteries is to deep cycle as much as you can over 7-10days 100% to 20%. If you are still having issues you might want to run a bms test of the batteries to see the individual cells and state of health on the batteries.

Thank you,

---------------------------

<tech@signaturesolar.com>
As for the batteries having issues. I do see they only have three cycles on them and are a little out of balance. I would recommend cycling them between 100% and 20% or 46v and 55v 5 to 10 times to get a few cycles on them and get them balanced out.

---------------------------
 
The LP4V1 are notorious about getting completely out of unbalanced. We have now learned how to fix it. I'll keep it simple for now. Update software, charge, discarge, and repeate. That is the MFG answer. If that doesn't work for you we will take you to the Active Top Balancer method but you will need to buy this

Below is the advice I was given. This will take you a long time.

--------------------------------------

EG4 Support <support@eg4electronics.com>

Hello Robert,

The only way to balance the batteries is to deep cycle as much as you can over 7-10days 100% to 20%. If you are still having issues you might want to run a bms test of the batteries to see the individual cells and state of health on the batteries.

Thank you,

---------------------------

<tech@signaturesolar.com>
As for the batteries having issues. I do see they only have three cycles on them and are a little out of balance. I would recommend cycling them between 100% and 20% or 46v and 55v 5 to 10 times to get a few cycles on them and get them balanced out.

---------------------------

That's just bizzarre. It implies that they will balance in the operating range, where cell voltages are typically so tight, balance can't happen.
 
This isn't that difficult a concept to understand ... the balancers need time to work. If the batteries don't spend very much time in the upper voltage range when the balancers are on, they won't balance.

Ever notice how cell phones charge up to 80% capacity fairly quickly, then take a long time to get from 80% to 100%. You need to do the same thing with these batteries. I see no reason to discharge them all the way down ... just down to the point where the balancers come on.
 
Several items from the picture. You do not have the batteries daisy chained to each other with the supplied short cat5 cable connecting each battery via one of the batteries RJ45 jacks. One battery should to be set as "Master" (address 0) if you are using closed loop. Having one battery set as "Master" is not required if you are not using closed loop however having a "Master" with open loop is not an issue, the "Master" BMS does not care.

In addition, if you do daisy chain all the batteries then you can monitor them all with a single RS485 to USB converter installed in an open RJ45 jack.
Download the "BMS_Tests" software from the EG4 website (Ensure you select the EG4 LifePower4 V1 battery and not the V2). In addition you can download the latest firmware which is v3.40. The "BMS_Test" software is required for the firmware upgrade.

The "BMS_Test" software is an invaluable tool for monitoring and diagnosing any issues with your batteries, particularly during charging. You will be able to monitor all batteries during a charge and determine if the charge is being cut short due to a "runner" cell charging to Cell Over Voltage Protection which then causes the BMS to stop further charging. If this is happening then the BMS will never get the battery charged to the point where the BMS resets SOC to 100%. Clearly by the picture the batteries are not getting a complete and full charge.

The EG4 LifePower4 V1 batteries implement two RS485 busses in the RJ45 jacks. Pins 7&8 are used by the "Master" to communicate with the other batteries (Can be used by monitoring software if there is no "Master") and pins 1&2 for monitoring software such as "BMS_Test" or Solar Assistant.
The "BMS_Test" needs to use the pins 1&2 RS485 bus for firmware updates so in any case this is the bus you should connect to.

EG4 and your source for the batteries should be able to provide you with the correct communications cable or you can build your own.

See these two threads on how to build your own cable:

 
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You cannot get it to top balance because the BMS will over voltage way before you are able to get there.

After exhausting all other methods and spending weeks trying everything. If no one else can help, and if you can find it.



Use the Barracuda Bob Top Balance Method (BBTBM)

Warning: For advanced users! Use all possible safety equipment.


Make sure you update your battery firmware and have a good monitoring software running.

Charge the battery up to 54.6V normally and hold it for over an hour or when it quits taking current.

Turn the BMS off

Open the battery pack.

Put an active balancer on all the cells and set it for 3.420V to active balancer.

Put a low current power supply (1-4A) and set it for constant current of 1-3.5 Amps at 58.4V (16 Cell @ 3.650V/each) up slowly until you get all the cells to 3.650V and let it sit for as long as can.

After top balancing every cell for a couple of hours turn it off and let them settle down.

Turn battery on and monitor with software/Bluetooth.

Discharge it as low as it will go.

Charge it up at 25-50% C rate at the BMS 100% SOC limit (EG4 LifePower4 V1 with latest software is 56.6V, ECO-WORTHY Rack Battery is 56.8V)

Check the status to see if it is properly balanced. If not do the procedure over.

If your cells are in decent shape, you should be good to go. If after doing this procedure multiple times and still having issues permanently install active balancer inside battery pack.

I made this into a resource because it keeps coming up. I personally found this a HUDGE time saver. I am open for changes and comments. I truly believe it can help a lot of people with this issue.
 

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Several items from the picture. You do not have the batteries daisy chained to each other with the supplied short cat5 cable connecting each battery via one of the batteries RJ45 jacks. One battery should to be set as "Master" (address 0) if you are using closed loop. Having one battery set as "Master" is not required if you are not using closed loop however having a "Master" with open loop is not an issue, the "Master" BMS does not care.

In addition, if you do daisy chain all the batteries then you can monitor them all with a single RS485 to USB converter installed in an open RJ45 jack.
Download the "BMS_Tools" software from the EG4 website (Ensure you select the EG4 LifePower4 V1 battery and not the V2). In addition you can download the latest firmware which is v3.40. The "BMS_Tools" software is required for the firmware upgrade.

The "BMS_Tools" software is an invaluable tool for monitoring and diagnosing any issues with your batteries, particularly during charging. You will be able to monitor all batteries during a charge and determine if the charge is being cut short due to a "runner" cell charging to Cell Over Voltage Protection which then causes the BMS to stop further charging. If this is happening then the BMS will never get the battery charged to the point where the BMS resets SOC to 100%. Clearly by the picture the batteries are not getting a complete and full charge.

The EG4 LifePower4 V1 batteries implement two RS485 busses in the RJ45 jacks. Pins 7&8 are used by the "Master" to communicate with the other batteries (Can be used by monitoring software if there is no "Master") and pins 1&2 for monitoring software such as "BMS_Tools" or Solar Assistant.
The "BMS_Tools" needs to use the pins 1&2 RS485 bus for firmware updates so in any case this is the bus you should connect to.

EG4 and your source for the batteries should be able to provide you with the correct communications cable or you can build your own.

See these two threads on how to build your own cable:

Ok I am getting so many different suggestions and I don't want to fry my system....the batteries are in a box with bus bars and then running cables? Pics or a video would b helpful-tech guy suggested a battery charger-remove battery and charge up with a charger and put back inside box?
 
You cannot get it to top balance because the BMS will over voltage way before you are able to get there.

After exhausting all other methods and spending weeks trying everything. If no one else can help, and if you can find it.



Use the Barracuda Bob Top Balance Method (BBTBM)

Warning: For advanced users! Use all possible safety equipment.


Make sure you update your battery firmware and have a good monitoring software running.

Charge the battery up to 54.6V normally and hold it for over an hour or when it quits taking current.

Turn the BMS off

Open the battery pack.

Put an active balancer on all the cells and set it for 3.420V to active balancer.

Put a low current power supply (1-4A) and set it for constant current of 1-3.5 Amps at 58.4V (16 Cell @ 3.650V/each) up slowly until you get all the cells to 3.650V and let it sit for as long as can.

After top balancing every cell for a couple of hours turn it off and let them settle down.

Turn battery on and monitor with software/Bluetooth.

Discharge it as low as it will go.

Charge it up at 25-50% C rate at the BMS 100% SOC limit (EG4 LifePower4 V1 with latest software is 56.6V, ECO-WORTHY Rack Battery is 56.8V)

Check the status to see if it is properly balanced. If not do the procedure over.

If your cells are in decent shape, you should be good to go. If after doing this procedure multiple times and still having issues permanently install active balancer inside battery pack.

I made this into a resource because it keeps coming up. I personally found this a HUDGE time saver. I am open for changes and comments. I truly believe it can help a lot of people with this issue.

This isn't that difficult a concept to understand ... the balancers need time to work. If the batteries don't spend very much time in the upper voltage range when the balancers are on, they won't balance.

Ever notice how cell phones charge up to 80% capacity fairly quickly, then take a long time to get from 80% to 100%. You need to do the same thing with these batteries. I see no reason to discharge them all the way down ... just down to the point where the balancers come on.
I tried that...drained batteries completely and charged back up...didn't change anything
 
I tried that...drained batteries completely and charged back up...didn't change anything
You are ready for an active balancer than.. Your family and friends will thank you. The amount of time and aggravation even your dog will be happier.

Just speaking from experience!

When done hit that top voltage at least once a week!
 
Ok I am getting so many different suggestions and I don't want to fry my system....the batteries are in a box with bus bars and then running cables? Pics or a video would b helpful-tech guy suggested a battery charger-remove battery and charge up with a charger and put back inside box?

You should before you do anything get the BMS_Test software (I incorrectly referred to it as "BMS_Tools" which is not for the EG4 LifePower4 V1)
It's free and this is one of the things it will show you.

Screenshot 2025-02-04 153005.jpg
 
If you drained the batteries completely, then no, you did not try that. Try going down only to 80%, then charging up as slowly as you can.
In theory, the BMS will cut it off at the 20% level I found on the lp4v1 it's usually about 18% or so

It will either do it by shunt current value or the lowest cell voltage triggering under voltage alarm?
 
Ok I found firmware on EG4 website for Lifepower 4 V2 and not any BMS info...still looking tho :)
Download the "FIRMWARE" and "SOFTWARE" links.

You want to download the "EG4 LifePower4 48V 100AH – Firmware – 3.4". You do not need the "EG4 Multipack Communication"

 
If you drained the batteries completely, then no, you did not try that. Try going down only to 80%, then charging up as slowly as you can.
I DID drain batteries until they alarmed...both blinking red, then charged them back up...not sure the percentage of them?
 
I DID drain batteries until they alarmed...both blinking red, then charged them back up...not sure the percentage of them?
OK, let's try again. You only need to discharge about 20% of the battery. So the battery will still contain 80% of it's charge when you start to recharge it. The balancers don't work much below that point anyway. And you need to charge it s-l-o-w-l-y to give the balancers time to work.
 
Ok I am getting so many different suggestions and I don't want to fry my system....the batteries are in a box with bus bars and then running cables? Pics or a video would b helpful-tech guy suggested a battery charger-remove battery and charge up with a charger and put back inside box?
lol, the only misinfo u got really was from eg4, saying to discharge down to 20% remaining soc. that does nothing to balance the cells.

only during charge above 3.45V will the default settings kick in the balancing circuitry.

everyone else is pretty much right.

ill add that you only need to move slowly ( lower current) when the cells start hitting 3.45V ea.
do whatever it takes to pump current at up to .5c into the cells and only incrementally lower the current while keeping a cell at least 3.450V.

depending on the state of imbalance, it may not be practical and u will have to take cover off to individually charge the low cells and/or discharge hi cells
 

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