DVS 400 Fast Charging System Operation and Maintenance Manual
09190-W-03-01
Page 24 of 27
Webasto Charging Systems, Inc.
6.2.6
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A)
Not field serviceable. Contact your Authorized DVS 400 Fast Charging System service provider.
B)
This component may be replaced by a qualified service technician. Refer to the section listed in the right
column for more information. Contact Customer Service for availability of spare parts.
C)
Disconnect AC power and check the 120VAC fuse behind the AC utility power access panel. A good fuse
should measure 0 Ohms across the fuse. If the fuse has blown, replace it with the same size and rating of
fuse.
D)
Check that the AC wiring is connected properly to a 3-phase circuit, the unit is grounded, and that the circuit
breaker is closed.
E)
Identify equipment that shares the same voltage supply line, and temporarily shut it down. If the charger
starts to respond normally, check the grounds on all of the installed equipment
F)
Check the output wiring of the BMID unit.
1.
Ensure that all of the power and signal connectors are completely mated, and that there is no physical
damage to the connector or pitting on the contact that could cause poor connections.
2.
Check that the communication and pilot wires are connected to the unit. Check that all pins are seated
correctly in each connector.
3.
Visually inspect the insulation on all of the wires and verify that there are no shorts or burnt spots on
any of the wires. Check the continuity between the wire and chassis ground using a multi-meter.
4.
Verify that the BMID is installed properly (Refer to BMID manual).
G)
Visually inspect the BMID and the thermistor. If the potting of the BMID looks cracked, or the thermistor
appears corroded, avoid erratic charging by replacing these components even if functional problems have
not yet occurred. Temporarily attach another BMID or thermistor to the pack. If the problem is resolved,
replace the bad component. If the problem persists, plug the vehicle into another charge port. If this
corrects the problem, check continuity on all BMID interfaces on the original charge port.
H)
The DVS 400 Fast Charging System contains built-in safety systems, which will fold back charge in response
to high battery temperatures, and stop charge completely if the batteries get above a manufacturer’s
specified threshold temperature. If the charger has stopped because of a false reading of a high battery
temperature, check the installation of the BMID and the integrity of the thermistor, reinstall or replace as
needed. If the batteries are overheating, allow the batteries to cool down before charging again. (Note: Use
of ventilated battery packs and/or fans may be required in certain applications. Contact Customer Service)
I)
If a cell within a pack is failing, or a failed module has been replaced with a new module, there will be a state
of charge (SOC) mismatch within the pack, which will prevent the pack from charging properly. Before
running a fast charge, make sure you run a long equalization on the pack to bring it back into balance.
Failure to run equalization on a serviced battery pack prior to fast charging may result in damage to the new
module. If the problem persists or grows worse, replace the battery pack.
J)
Choosing the charge algorithm is very important for the life and utility of the battery pack. An algorithm that
is not matched to the battery being charged will result in undercharge, overcharge or excessive heating of
the battery during charge. Use the Charge Configuration menu to make sure the charge configuration is
appropriate for your battery and application. Use the BMID Configuration menu to check 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.
K)
A battery that is connected at a state of charge (SOC) which is too low to be fast charged safely will be
charged at a low rate until it has recovered sufficiently to accept fast charging. In this case, the user must
press and hold the EQ button to force charging to begin.
L)
If the battery voltage reported by the BMID goes below the minimum allowable volts per cell or exceeds the
maximum allowable volts per cell during a charge event the fault is set. The minimum/maximum allowable
volts/cell are based upon the battery type selected in the BMID Configuration. Check the battery charge
