Energy Storage System Caterpillar

System Level Faults

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Table 1
Fault Name	Description	Troubleshooting Steps
Bus current sensor - out of calibration at idle	At idle, bus current is between 0A and 4A.	1. Verify communication parameter #50 is set to the value of 1.
Bus current sensor - out of calibration at idle	At idle, bus current is between 0A and 4A.	2. If fault persists, contact product support.

Cabinet Fan - All Fans Failed Cabinet Fan - Fan Open Circuit Cabinet Fan - Fan Short Circuit Parallel System - Cabinet Fan Fault	There are several different faults indicating one or more of the cabinet fans have failed due to an open or short circuit.	1. Check output voltage of communication control board at fan connector. Normal voltage range is 52 V to 56 V.
		2. If no voltage is present, check fuses for the fans on communication control board. If any fuses are found open, check fans and harnessing for signs of short circuit.
		3. Check for loose/broken and/or shorted wires at all connection points of the cabinet fan harness.
		4. Do a slight pull test on the wires at the connectors. The pull test is to verify that there are no loose pins that could cause an intermittent open/short circuit.
		5. Check for obstructions in the fan that may prevent the fan from spinning.
		6. Check for any source of contamination. Be sure to address the source of contamination before replacing any components.
		7. If voltage is present at the communication control and at the enclosure fan connector, the fan will need to be replaced.
		8. The system must be shut down prior to fan replacement. Enclosure fans must be connected while the system is shut down.

Communication Control - System Offline for 24 Hours	The system has not reported into the Back Office server for 24 hours	1. Check the SIM card balance and expiration date.
		2. Check for local network outage affecting communication at the site.
		3. Check the network configuration settings in the FST to ensure that APN, user name, password, and band are correct.
		4. Check the transmission equipment at the installation site.
		5. Test the SIM card in mobile phone.
		6. Test an alternate SIM card.
		7. Check the HB LED and HKPS LED on the communication control board. a. If no status LED lights are on, verify that there is DC power to the battery terminals. Check to ensure that the DC circuit breaker, that provides power to the system, is closed. b. If power is present, turn off the communication control board for 10 seconds. Turn the power back on for the communication control board. c. If no HB and HKPS LED lights are on communication control board after reset, replace communication control board.
		8. If the HB and HKPS LED lights are on, check modem power and signal cable from communication control. Modem LED will be red and/or green blinking if power present. a. If modem power is present and no LED lights are on, replace the modem.
		9. If a unit is foundto have repeatednetwork connectivity issues that are a result of site equipment or transmission issues, an SMS Server can be set up in the region that would maintain a "pulse" from the system until connectivity is restored. Contact product support.

Diesel Generator - Diesel Generator Fail	The system has received a fail signal from the diesel generator. The fault can be due to low fuel, oil pressure, over-heating, and several other possible issues with the diesel generator. The DG run signal will likely be deactivated as well.	1. Check the condition of the diesel generator including active and historical alarms for low fuel level, oil pressure, and temperature.

Diesel Generator - Diesel Run Signal Lost	The DG run signal was interrupted, but no fail signal was received possibly indicating an issue with the DG run signal wiring.	1. Check the DG run signal wiring for signs of an open circuit.
Diesel Generator - Diesel Run Signal Lost		2. Check the condition of the diesel generator including active and historical alarms.

Diesel Generator - Diesel Start Time out	The message signifies that the system has commanded the diesel generator to start. However, the DG run signal was not received from the diesel generator in the allotted time of 10 minutes.	1. Check the condition of the diesel generator including active and historical alarms, and fuel
Diesel Generator - Diesel Start Time out		2. Check the DG start and DG run wiring for signs of an open or short circuit.

Door Sensor - Door Open Detected	One or more of the doors in the system is open.	1. Verify if any service visits are scheduled for the site and contact the field technician to verify the doors.
		2. If there is no visit scheduled and/or no technician authorized at the site, contact the site owner. Confirm if there are any authorized people at the site.
		3. If no one is authorized at the site, the site must be visited by a dealership representative, client representative and/or police to investigate vandalism.
		4. Caution must be taken entering the site as there may be unauthorized people at the site performing illegal activity. Notify the local authorities.
		5. If a false door alarm is determined to be the problem, follow the steps below.
		Diagnose A False Alarm
		1. Verify that the wires at communication control terminal block are installed correctly.
		2. At the terminal block, verify that there is 5 VDC present with the doors open.
		3. Install a two conductor cable that is long enough to reach outside the door with the door closed. Verify that there is 0 VDC with the doors closed.
		4. If the communication control board is functioning normally and the LED lights are on, there may be an open circuit in the harness. There may be a broken component in the door sensor system.
		5. Check for loose or broken wires at all connection points of the door sensor harness. Perform a slight pull test on the wires to verify that there are no loose pins that could cause an open circuit.
		6. Verify alignment of door sensor and magnet. Remove the Door Sensor Plug from the harness and close and lock the door.
		7. Check for continuity of all sensors at all doors when the doors are closed.

Enclosure Temperature Sensor - Temperature High	The temperature sensor in the system is reading greater than 70° C (158° F)	1. Inspect the system for any heat sources or signs of fire or smoke damage.
Enclosure Temperature Sensor - Temperature High		2. If any fire or smoke damage, investigate root cause and repair components as necessary ensuring cause of high temperature is resolved.

Module State - Module State Mismatch	The modules in the system do not have the same state of "Grid-on" or "Grid-off".	1. Verify that the module bus voltage is within the normal range for Grid-on. Grid-on voltage is greater than 52 VDC. Grid-off voltage is less than 52 VDC. If any of the modules are out of range, there is likely a measurement issue on the board.
Module State - Module State Mismatch		2. Replace the component and observe if the fault is still active.

Parallel System - Bus Voltage Out of Range	The fault is set when the bus voltage of cabinet 1 is different from the bus voltage of cabinet 2 by 1 V or more.	1. Check power cabling and connections. Check for signs of high impedance and torque all connections again.
Parallel System - Bus Voltage Out of Range		2. Measure the bus voltage on cabinet 1 and cabinet 2. Ensure that the measured value matches the value shown by the FST. If the measured value is greater than 0.25 V difference from the FST reading, replace the communication control board.

Parallel System - Configuration Mismatch	The number of configured modules does not match the number of reporting modules in cabinet 2.	1. Verify configuration for number of modules in cabinet 2 matches the number of installed modules. Correct as necessary.
Parallel System - Configuration Mismatch		2. If configuration matches number of installed modules, contact Product Support.

Parallel System - No CAN Data to Main Comm	There is no CAN communication from cabinet 2 to cabinet 1.	1. Verify that the system is configured correctly. If not a parallel system configuration, adjust the configuration accordingly.
		2. Check the CAN harness from cabinet 1 to cabinet 2 for signs of open or short circuit. Replace the harness if necessary.
		3. Check the CAN harness connection to communication control on cabinet 1 and 2.

SD Card - Free Space Low	The available space on the SD card is low. Oldest data will be deleted to make room for new data.	1. No action is required unless data is needed from the SD card.
SD Card - Free Space Low		2. Be sure to remove and store any needed data from the SD card before any data is deleted from the SD card.

System Software - Software Version Mismatch	The software version reported on the system does not match the required versions for the hardware installed.	1. Update software to the latest versions as required for the hardware installed on the system.

System State - Low Charge Voltage	The system is in a "Grid-Off" state. The bus voltage and load on the system indicates that the system should be in "grid-on". The error may indicate that the system is "disconnected" from the DC bus of the rectifier. The fault would indicate possible vandalism or an open circuit breaker.	1. Verify the rectifier "grid-on" voltage is set to 54.5 V.
		2. Verify the DC circuit breaker for the energy system is closed and that there is bus voltage at the battery terminals.
		3. Inspect the DC power cables from the rectifier to the system do not have an open circuit. The open circuit can occur as a result of vandalism when power cables are stolen.
		4. Verify ample rectifier module capacity per system sizing and Installation settings manual.

System State - System State Oscillating	The system state is oscillating.	1. Check the status of the AC power at the site. A brownout condition or low AC power input could cause the system to oscillate between charge and discharge.
		2. Check the rectifier parameters to ensure that it is configured to allow the proper amount of current to charge the ESS.
		3. Check the generator control cabling for an open or short circuit. An open or short circuit may cause a false command signal to turn the generator on and off.

System State - System State Stuck in Discharge	The system state is in "Grid-Off" when the system should be in the "Grid-On" status.	1. Verify that the DC circuit breaker for the ESS is closed and that there is bus voltage at the battery terminals.
System State - System State Stuck in Discharge		2. Inspect the DC power cables from the rectifier to the system do not have an open circuit. The error can occur as a result of vandalism when power cables are stolen.

System State - System/Module State Mismatch	The system and module states do not match. The system is in one of the following conditions: 1) The system is in "Grid-On" status and the modules are in "Grid-Off" status. 2) The system is in "Grid-Off" status and the modules are in "Grid-On" status.	1. Contact the technical communicator at the dealership.

System Time - System Time Error	The system time has failed synchronization with the Back Office server. The system time is offset from the server time by one or more hours. The time can be behind or ahead of the server.	1. Check the voltage of the battery that is on the communication control board.⁽¹⁾ Ensure that the system is turned off and safety procedures are followed. Switch off the power to the board, remove the battery, and measure the voltage of the battery. If voltage is less than 2.75 volts (DC), replace the communication control board battery.
		2. Attempt a reset of the communication control board. Power off the communication control board for 10 seconds. Power on and allow 10 minutes for the system to synchronize with the server.
		3. If problem persists, contact your technical communicator.