DVS 400 Fast Charging System Operation and Maintenance Manual
09190-W-03-01 Page 25 of 27 Webasto Charging Systems, Inc.
path for shorts or opens. Check the battery for defective or damaged cells. If no problems are found replace
the BMID.
M) This fault is usually the result of an un-programmed BMID or an improperly programmed BMID. Using the
BMID Configuration menu verify that the BMID installed on the pack has the correct battery manufacturer
type-code, the correct capacity of the cells, and the correct number of cells input.
N) Refer to the Installation Manual for correct cable and connector sizing. Check the crimp or solder joint
between the cable and the connector pins to ensure good electrical contact. Replace the connector if the
case is damaged.
O) The equalization schedule is very important to the life of the batteries. If the batteries are being equalized
too infrequently, or the equalization is interrupted too often, the capacity will start to degrade. If the batteries
are being equalized too often, there will be excessive water loss requiring higher maintenance. Adjust the
equalization schedule for the batteries based on the use level. See the “BMID Programming and Advanced
Features Manual” for reprogramming instructions.
P) Flooded lead acid batteries must be watered as part of a regular maintenance schedule. Insufficient
watering will result in reduced capacity, overheating and reduced life. Consult your battery manufacturer’s
guidelines for a watering schedule and proper procedures.
Q) Loose battery interconnects or power cables increase the resistance of the pack and can cause overheating
and/or slow charging. Using insulated gloves and tools, check the torque on all bolted interconnects and
power cables, and verify that welded interconnects have not loosened.
R) Tighten all screws and fasteners as needed.
S) Check for opens in the charge path (contactors, output cables). Check DVS 400 Control Board connectors
P12 (Output Voltage Sense) and P15 (To Contactors). Check that all wire crimps are secure.
T) Shut down the unit and check for shorts or problems in the output cable. Check current sensors and check
their harnesses P11/P12 for continuity.
U) Undercurrent faults may be caused by a loose connection or faulty contactor in the high current path. The
fault indicates a 15A discrepancy between the current requested and the current delivered. Check the DVS
400 current sensors, verify that the DVS 400 contactors are closing and check for loose connections. If the
DVS 400 contactors are not closing check/replace relays K1 to K4 on the control board or the drivers U10
and U71. Replace the control board if required.
V) Indicates that the 150V DC Buss dropped below 100V or exceeded 200V. Check the utility power for spikes
and periodic phase drops. Transistor faults may be caused by excessive heat.
W) Current sensor faults may be caused by a poor connection or faulty cable. Check all connections to current
sensor carefully before replacing a current sensor.
X) Indicates that the 150V DC Buss dropped below 110V or rose above 170V creating a continuous error for 10
seconds.
Y) If there is no sign of excessive heat, a temperature fault may indicate a faulty temperature switch. In this
case, check for normal operation of temperature switches.
Z) Check to make sure that your battery pack is properly wired to the output connector, and that there are no
shorted or damaged cells. Check that connector P12 on the DVS 400 control board is properly seated and
that all pins are making contact. A low Vdc fault indicates the charger has sensed less than 10V. A High
Vdc fault indicates greater than 150V has been sensed by the charger.
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