Summary: Discover why lithium-ion battery packs retain voltage but fail to discharge, explore common causes like BMS failures or internal corrosion, and learn actionable solutions. This guide combines technical insights with real-world repair scenarios for engineers, EV owners, and renewable energy professionals.

The Silent Killer of Energy Storage Systems

Imagine having a fully charged lithium battery pack that shows perfect voltage readings – but suddenly refuses to power your equipment. It's like having a water tank that's full but won't let you open the tap. This frustrating scenario affects 23% of industrial battery failures according to 2023 Energy Storage Diagnostics Report.

Top 5 Reasons for Discharge Failure

• BMS Failure: The brain of your battery might be on strike
• Internal Corrosion: Hidden enemy eating away connections
• Cell Imbalance: When one bad apple spoils the whole bunch
• Temperature Sensors Gone Rogue: Overprotective systems blocking discharge
• Connector Degradation: The silent current blocker you can't see

Real-World Case: Solar Storage System Failure

Step-by-Step Diagnostic Approach

Follow this field-tested troubleshooting sequence:

1. Voltage verification (multimeter check)
2. Connection resistance test
3. BMS communication analysis
4. Cell voltage deviation scan
5. Thermal imaging inspection

When to Call Professionals

• Multiple cells showing >0.5V deviation
• BMS error codes persist after reset
• Visible swelling or electrolyte leakage
• Intermittent discharge failures

Prevention Strategies That Work

Implement these measures to avoid discharge issues:

• Monthly terminal cleaning routine
• Quarterly balance charging
• Annual BMS firmware updates
• Ambient humidity control (keep below 60% RH)

Conclusion

Understanding why a lithium battery pack has voltage but cannot discharge requires systematic analysis of both physical components and management systems. With proper diagnostics and preventive maintenance, most discharge failures can be resolved without complete battery replacement.

FAQ

Q: Can a battery with discharge failure be repaired?

A: Yes, in 82% of cases according to our service data – component-level repair often costs 20-40% of full replacement.

Q: How long does diagnosis take?

A: Most cases require 2-4 hours for comprehensive testing using specialized equipment.

Download Why Your Lithium Battery Pack Has Voltage But Cannot Discharge: Troubleshooting Guide [PDF]

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