06/06/2025
⚠️ Cause of Battery Expansion (Swelling)
The battery swelled due to overcharging and overdischarging, which occurred because the inverter was using incorrect user-defined settings and had no communication with the battery’s BMS. Without proper voltage control, the system allowed:
Charging above the max limit (53.5V)
Discharging below the safe limit (46V)
This caused internal chemical damage, leading to gas buildup and swelling of the lithium cells.
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✅ Recommendations to Prevent Future Damage
1. Use Inverters and Batteries with Communication Protocols (RS485/CAN):
Ensures real-time data exchange between inverter and BMS for safe charging/discharging.
2. Avoid Deep Discharges:
Never discharge below 20% State of Charge (SoC). Staying above 46V protects battery lifespan and safety.
3. Manually Configure Inverter Carefully (if no communication):
Max Charge Voltage: 53.5V
Low Voltage Cutoff: 46V
Float Voltage: 52V or disabled
Max Charge Current: ≤ 0.5C (e.g., 50A for 100Ah battery)
4. Add a Battery Monitor:
Tools like a Victron SmartShunt or JBD display help track real SoC and voltage.
5. Protect with Breakers or Relays:
Use automatic cutoff if voltage goes outside safe range.
