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Analysis by Marcus & Team

EG4 PowerPro Battery Smells Like Ozone During Charging

Troubleshoot ozone smell during EG4 PowerPro battery charging. Diagnose potential causes & safety measures for residential energy storage systems.

Frequently Asked Questions

•What are the NEC requirements for battery disconnects in residential solar installations?

NEC 690.13 and 690.15 outline the requirements for disconnects. A readily accessible DC disconnect must be provided to isolate the battery system from the PV array and the inverter.

•What is the recommended PPE for working on a battery system?

Insulated gloves rated for the DC voltage of the system, safety glasses, and flame-resistant clothing are recommended. A voltage tester and clamp meter are also essential.

•How often should I perform a visual inspection of my battery system?

A visual inspection should be performed at least annually, or more frequently if the system is subjected to harsh environmental conditions.

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Marcus leads the technical research department at Storage Faults. Together with a team of systems analysts, he specializes in translating complex solar storage error codes into actionable diagnostic steps for the US market.

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Critical Safety Precautions:

High DC voltage is present in the battery system, posing a significant electrical shock hazard. Do not attempt any repairs or modifications without proper training and personal protective equipment (PPE), including insulated gloves and safety glasses. Arc flash is a potential hazard when working with DC circuits. Ensure the system is properly disconnected and de-energized before performing any inspections or maintenance. Adhere to NEC rapid shutdown requirements. A qualified electrician is mandatory for any work involving live circuits or internal components.

Technical Background:

The EG4 PowerPro is a self-contained lithium iron phosphate (LFP) battery energy storage system (ESS). Bulk charging refers to the constant current (CC) phase where the battery voltage is brought up to its absorption voltage. Ozone (O3) production typically occurs due to high-voltage electrical arcing, which can result from faulty wiring, loose connections, or component failure within the battery system or connected charging infrastructure. Improper grounding can also contribute to stray currents and arcing. The BMS should regulate charging parameters; faults in the BMS can lead to overcharging and potential arcing. The system includes DC/DC conversion for battery charging and DC/AC conversion for inverter output. Communication issues within the system (e.g., CAN bus errors) can disrupt proper charging control.

Step-by-Step Fix:

1

Immediately disconnect the EG4 PowerPro battery from the PV array and the inverter using the DC disconnect switches.
2

Turn off the AC breaker feeding the inverter to isolate the system from the grid.
3

Ventilate the area thoroughly to dissipate any accumulated gases.
4

Inspect all DC wiring connections within the battery enclosure and at the inverter for looseness, corrosion, or damage. Use a multimeter to verify the absence of voltage on the disconnected DC conductors before touching them.
5

Using an IR thermometer, scan the battery enclosure for hot spots, which may indicate a failing cell or connection. Document any temperature anomalies.
6

Engage a qualified electrician to perform a megohmmeter test on the DC wiring to check for insulation breakdown (NEC 690.4).
7

Contact EG4 technical support for further diagnostics and potential RMA procedures.

Possible Causes:

Loose DC connections within the battery enclosure or at the inverter connection, leading to arcing.
Internal cell damage or degradation resulting in outgassing and potential arcing.
Failure of the Battery Management System (BMS) causing overcharging and cell voltage imbalance.
Defective wiring or insulation breakdown in the internal DC wiring harness.
Inadequate ventilation leading to a buildup of flammable gases produced during charging.
Faulty ground connection between the battery system and the building grounding electrode system.

Preventative Care:

Schedule annual inspections of the battery system, including visual checks of wiring connections and thermal scans with an IR thermometer.
Ensure proper ventilation around the battery unit to prevent gas buildup.
Regularly check for and apply any available firmware updates for the BMS to ensure proper charging control.
Conduct capacity tests every 2-3 years to monitor battery health and identify potential degradation.
Verify proper grounding of the system according to NEC 250.