A step-by-step path from symptom to cause.
Symptoms and what they point to
Most ‘dead battery’ reports are a connection, a charger or a BMS cut-off — in that order.
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Using the BMS log and test data
The BMS records what the charger cannot see; read it before swapping hardware.
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Maintenance & testing questions
Short answers to the ones that come up most.
How do I test a battery?
Resting voltage first, then voltage under a known load, then internal resistance. A pack that reads full at rest and collapses under load has a weak cell group or a bad connection.
What maintenance does lithium need?
Terminals tight, enclosure ventilated, BMS log reviewed. No watering, no equalising.
Is a swollen battery dangerous?
Yes — stop using and charging it, isolate it, and replace it.
How should I store a pack?
About half charge, cool and dry, disconnected from loads.
When should I replace a battery?
When the delivered capacity no longer meets the job, not when the calendar says so.
