Lithium battery packs have become essential in portable electronics, electric vehicles, solar systems, and backup power. While they offer high energy density and long service life, they’re not immune to failure. Whether you're a general user or an engineer, this guide helps identify and troubleshoot common battery pack problems.
- Shortened operating time
- Battery percentage drops rapidly under load
- Frequent deep discharges or overcharging habits
- Improper storage (e.g., in hot environments)
- Battery cell aging or imbalance
- Charge before dropping below 20% to extend lifespan
- Store batteries in cool, dry places
- Use diagnostic tools to check IR (internal resistance)
- Balance the battery pack with active/passive equalization
- Battery remains at 0% or shows no charging indicator
- Charger light blinks or stays off
- BMS protection lockout due to undervoltage or overdischarge
- Charger mismatch or failure
- Loose terminals or corroded connectors
- Try a different certified charger
- Disconnect and reconnect battery to reset BMS
- Clean terminals and inspect cable continuity
Some smart BMS units may require communication with a PC or app to reset protections. Please refer to the BMS protocol or consult the manufacturer.
- Overcharge, overdischarge, overcurrent, or short-circuit protection triggered
- Temperature sensor alarm (too hot or cold)
- Let the battery cool down and try again
- Ensure the load is within rated specs
- If equipped, press a reset switch or use diagnostic software
Check cell voltage imbalance using the BMS dashboard. Cells more than ±0.1V apart may require rebalancing.
- Battery drops from 30% to 0% instantly under high load
- Voltage sag causes device reset or crash
- High internal resistance due to degraded cells
- Discharge rate exceeds design capacity (C-rate too high)
- Load specifications vs battery datasheet
- Battery health report (IR values and cell balance)
If your lithium battery shows signs of bulging, leaking fluid, or abnormal heat — stop using it immediately and isolate the unit in a fire-safe area.
- Physical damage or puncture
- Internal short-circuit from manufacturing defect
- Overcharge without proper BMS protection
This is a critical safety hazard. Never attempt to puncture or repair a swollen lithium cell yourself.
For persistent or serious issues, it is best to contact your battery provider. Huawen New Power provides full technical support for all of our lithium battery products.
We offer customized lithium battery pack solutions, advanced BMS configurations, and long-term OEM/ODM services for clients in over 30 countries.
Visit our official site: www.huawennewpower.com or email our support team at sales@huawennewpower.com
Stay safe, power smart — with Huawen New Power.
