Unequal charge after adding LiFePo batteries

[GSmith]

About 1 month after installing the initial 4 Pytes V16 batteries, my installer delivered the final 2. When the 2 new ones were connected I noticed that, using the built in State of Charge bar on the face of each battery, they were significantly higher charged than the "old" batteries. I questioned the installer about this and he said not to worry. Now the system stops charging at a voltage of 53.3V which a Pytes chart corresponds to 90% but the older batteries still show a lot less charge. The charge bar on the new batteries shows 4 lit segments where on the old batteries it shows 3. This situation means I actually was better off before I added the last two batteries. These batteries are being charged by 3 Outback FM100 300VDC charge controllers with a GS8048 Inverter. There's also a "BMS Battery Energy Cell 5" shown on my device map which no one seems to be able to identify. Are my suspicions likely? How can I equalize the charge on the batteries? Any help would be appreciated. Thanks in advance.

[GSmith]

Update to my own post:

Specialist enlightened me about the Energy Cell 5 that appeared on my OpticsRE Device Map when my new batteries were first installed. I note that all of the settings on the Energy Cell 5 are zero in my system (see attachment.) Can this explain my charging problems? Can anyone tell me where to find the settings I need? Thanks!

[raysun]

What firmware version is installed in the Mate3S.

The non-existent Port 15 populated with Energycell 5 is Outback's sloppy programming for their own "closed loop" battery system spilling into user's device maps. IDK if it affects "normal" battery operations.

With your Pytes battery, adding the new monoblocs to the existing four is fine, however the method of slapping them in without properly commissioning it likely not. I'd suggest some remedial activity.
At the very least, all monoblocks should be at the same state of charge / voltage prior to combining. For this step I suggest burning some diesel. (Of course solar is fine for charging, but the battery stays under load while doing so, partly defeating the end state desired. Disable it for the following steps.) On generator, loads and charging are handled by the generator/Radian leaving the battery in an idle state. Disconnect (turn off) the new monoblocs and fully charge the original four. Next, connect the two new monoblocs and disconnect the original four. Adjust Radian charge rate and charge the new monoblocs. When fully charged, combine the new and original monoblocs, readjust the Radian charge rate and run another charge cycle, it will be short.
Now the battery will at least start with all the monoblocs within "ballpark" voltage of each other. However, commissioning work is not likely complete.
IDK about Pytes, but most all chinese LFP are delivered with cells sorely out of balance. The standard prescription is to "Charge them for many cycles to reach full capacity." Though the new and old monoblocs have been charged to their individual "full capacity" that actual number likely does not agree. What is likely to be seen is during normal charging, the new monoblocs will throw a high cell voltage error and disconnect while the old ones are still accepting charge.
The remedial step is to lower the charge (Absorb) voltage, to give the individual monoblocs more time to balance cells internally. If using 56V Absorb, lower it on all chargers to 55.6V for now. Drop float from 55.6V to 55.2V. Run a dozen or so charge cycles at the lower voltage then eventually reset to the higher settings.

[GSmith]

Thank you for the detailed reply. I will be trying your scheme for equalizing the batteries after getting an OK from the salesman/installer (to make sure I don't jeopardize my warranty.)

To answer your question, the Mate3S is at firmware version 1.4.7.

Thanks again,

Gerry Smith

[raysun]

Thank you for the detailed reply. I will be trying your scheme for equalizing the batteries after getting an OK from the salesman/installer (to make sure I don't jeopardize my warranty.)

To answer your question, the Mate3S is at firmware version 1.4.7.

Thanks again,

Gerry Smith

To put it in simple language:
Step 1: Charge new batteries and existing batteries separately to full charge.
Step 2: Combine new batteries with old batteries.
Step 3: Temporarily lower charge voltage to 55.6V in order to allow new batteries more opportunity to top balance.

The only step they may question is #3. However, they shouldn't.