BATTERY PACK REPORT

GENERAL INFO

PROBLEM Battery pack - Isolation and ground issues

PRODUCT
PROBLEM ID RD-00141 LFP Battery pack
FAMILY
SOURCE R&D xelectrix Power GmbH PRODUCT CODE EJT65236EJ100-XXX

REFERENCE Shenzhen ELITE DATE RECEIVED 15.11.2021

QTY REPORTED 19.11.2021 QTY RETURNED

1 | TEAM FORMATION

MEMBER NAME DEPARTMENT / ROLE MEMBER NAME DEPARTMENT / ROLE

Robert Schmidleithner R&D / Head of R&D

Alexandr Korolchuk R&D / Research Engineer

Jan Guger Production / Electrician

Roland Kosina Production / Electrician

King Man Mak Production / Electrician

2 | PROBLEM DESCRIPTION

ASSIGNED TO
After completion of all electrical tests, there is a problem with grounding (isolation issues)
Alexandr Korolchuk
between positive node and universal ground (Figure1). The voltage is increasing on node after
each run (charge and discharge of battery), The voltage on node was measured when the battery DATE EFFECTIVE
was fully disconnected from all sources of energy. Thats means there is still connection which is
not managed by Master BMS well enough. When control cable (Figure 2) is disconnected from 10.11.2021
Master BMS, there is no voltage on the positive node. Cells are okay, Other components are also LEAD NOTIFIED?
okay in this case.
YES

3 | CONTAINMENT / IMMEDIATE ACTIONS

ASSIGNED TO

Jan Guger

DATE EFFECTIVE
Removal of batteries with isolation problem from production chain.
15.11.2021

LEAD NOTIFIED?

YES

4 | ROOT CAUSE ANALYSIS

ASSIGNED TO

Alexandr Korolchuk
xelectrix Power GmbH suspects there is isolation problem inside of battery pack, which makes
internal safety operating with faults due to Master BMS failure control, usage of unreliable cables DATE EFFECTIVE
and connections outside surface of contactors around Master BMS. Master BMS could also have
issues itself. On average each tested battery has 20V capacitive to ground in DC. The worst case 15.11.2021
was 200V capacitive to ground. LEAD NOTIFIED?
was 200V capacitive to ground.

YES

5 | VERIFIED AND PERMANENT CORRECTIVE ACTIONS

ASSIGNED TO

Jan Guger
xelectrix Power Gmbh changed the cables of Master Unit. The voltage dropped from 8V to 2,4V.
Then, change of rings and cables on contactors lead to voltage reduction from 2,4V to 1.3V. That DATE EFFECTIVE
means there is still internal isolation issue between ground and node which is still not managed by 15.11.2021
MASTER BMS, and the problem was not fully eliminated using of hardware efforts.
LEAD NOTIFIED?

YES

6 | TEST OF SYSTEM AFTER CORRECTIVE ACTIONS

ASSIGNED TO

Jan Guger

The system still has problems after all reparations done, All possible hardware repairments were DATE EFFECTIVE
done. Maybe redesign of safety construction can help to make system operate in the safe state. 15.11.2021

LEAD NOTIFIED?

YES

PREPARED BY Alexandr Korolchuk DATE 19.11.2021

VERSION 1.05 UPDATED 19.11.2021