Procedure for unbricking a battery module with 'Unbricking tool' and 'Module Upgrade Tool' (Gen 2 & Gen 3)

This procedure will guide you through the process of unbricking an unresponsive battery module using an ‘Unbricking Tool’ and the ‘Module Upgrade.

A ‘bricked’ battery module is an unresponsive battery module that is not detectable by the BMS, may. Display an internal communication fault (error 20), may display null value firmware (0000), or may exhibit any one of the following: 

• The module switch is in the ON position, but the green light indicator near the switch does not turn ON.
• The module switch is in the OFF position, but the green light indicator near the switch remains turned ON.
• The module switch is in the ON position, but there is a red-light indicator turned ON near the switch.
• Another good way to know if a module is dead is if the voltage is below 43V.

Requirements:

-Computer with Windows OS (not compatible with Mac OS)

- TeamViewer (if necessary, for HomeGrid Support to provide remote assistance).

Please provide HomeGrid Support with the following:

• ‘Your ID’
• ‘Password’ if you have one.

Setting Up

Once you have acquired the ‘unbricking tool’, proceed with downloading and installing the necessary software/drivers to perform the unbricking procedure.

Download the ‘HomeGrid Firmware Tools’ folder (~480MB) from the provided link below as it contains all necessary software and drivers (EMS Tools, Upgrade Tools, drivers & firmware).

• homegridenergy.com/downloads

Tip: If you already have downloaded and installed the necessary software/drivers on your computer, you can download the ‘Latest Firmware’ folder to download just the latest firmware. 

Unbricking Procedure:

STEP 1: Isolate the unresponsive/bricked battery module.

You will need to isolate the unresponsive battery module(s) by completely disconnecting it from the rest of the stack, as shown in the image below. Depending on the location of the unresponsive module, you may need to remove modules. 

Note: Failure to isolate the battery module will result in failed attempts in ‘unbricking’ an unresponsive battery module.

STEP 2: Set the ‘Address Set’ dip switches.

After isolating the unresponsive battery module, leave the dip switches in the position that they are in, there is no need to change them.

Note: Only 1 battery module can be ‘unbricked’ at a time. 

STEP 3: Connect the ‘Unbricking’ cable to the computer.

 Connect the ‘unbricking’ cable to the computer. The ‘unbricking’ tool is comprised of two cables connected.

▪ USB to Serial (DB9) converter cable (RS485).

▪ Custom serial (DB9) to battery module connector

Do not connect the end with the battery module connector until directed in later steps. Connecting to the battery module is the last step.

STEP 4: Setting up the application settings for the unbricking procedure.

Step 5: Selecting the COM Port for 'Unbricking' Tool

1. In the application's window, locate the dropdown 'COM port' selector on the upper right side.
2. From the dropdown, select the COM port that corresponds to the 'unbricking' tool.
3. On the upper left side of the application's window, select the 'Open COM' button.

Tip: To make the identification of the COM port easier, disconnect any other unused USB cables connected to the computer. Following these steps will help you correctly select the COM port for the 'unbricking' tool.

Note: If the driver (RS485) for the 'unbricking tool' was correctly set up, you should see the message 'Open serial port successfully'

Step 6: Uploading Firmware File

1. In the gray box at the far right, select it to choose and upload a firmware file.
2. Locate and select the appropriate firmware file for the battery module you're updating:
   • Navigate to the location where you have the necessary firmware file.
   • Choose the required firmware file based on the battery module type:
     • For Gen 2 battery modules, select the 'FS-48-100-15-V2.056.bin' file.
     • For Gen 3 battery modules, select the 'FS-48-100-15-V3.044.bin' file.
3. Confirm your selection by selecting the '??(O)' button.

STEP 7: Positioning the Unbricking Tool Connector (Do not fully insert)

1. Position the unbricking tool connector, but do not fully insert it at this stage.

Tip: Ensure that the cable connector on the unbricking tool does not contact the top port of the unresponsive battery module. You should not fully insert it until directed to do so in the next step. To avoid accidental contact, position the connector at an angle until you are ready to fully insert it.

STEP 8: Initiating the 'Upgrade'

1. Ensure that 'Open COM' has been selected, and that you have established a successful COM connection before proceeding.
   • A message confirming 'Open serial port successfully' should appear.
2. Select the 'Upgrade' button. Immediately follow this by inserting the unbricking tool connector into the top connector port of the unresponsive battery module.
   • If done correctly, you should observe the progress bar and byte counter incrementing, indicating that the firmware is actively being pushed to the unresponsive module.

.

Once the update is complete, you should see a message 'module1: Download Successful!', confirming that the module has been successfully updated.

Note: If the procedure was not successful, and you see a 'failed' message, remove the unbricking tool's connector from the battery module's top port, and start again from STEP 8.

Tip: To re-enable the 'Upgrade' button, press the 'Close COM' button, then press the 'Open COM' button.

Post-Update Testing:

1. With the unbricking tool still attached to the top port on the Battery Module, turn the battery on, and if the light turns on, it indicates a successful update.
2. Perform an additional test by placing the updated battery back on the stack. You can either put another battery on top of it or the BMS. If it turns back on, the update has worked.
3. If you completed the entire update process, and it worked correctly, but after putting the battery back on the stack with another battery on top or the BMS, it does not turn on, you may need to consider replacing the battery.

In case of any issues or uncertainties, please reach out to us for further assistance.