Webasto DVS 400 User manual

09190-W-03-01.docx
Operation and Maintenance Manual
GSE Intelligent Fast Charging Systems
DVS 400
English

DVS Installation Manual
09190-W-03-01.docx Page 2 of 27 Webasto Charging Systems, Inc.
© 2019 Webasto Charging Systems, Inc. All rights reserved.
PosiCharge™ systems is a product line of Webasto Charging Systems, Inc. Webasto and the Webasto logo are trademarks of Webasto
Charging Systems, Inc. Corporate names, trademarks, registered trademarks, service marks, symbols, and logos stated herein are
property of their respective companies. Specifications are subject to change without notice. Images of the power cycling and test systems
are representative; production models may vary. No portion of these materials may be duplicated, used, or disclosed without prior written
permission from Webasto Charging Systems, Inc.
Disclaimer: this manual includes the latest information available at the time of printing. Webasto Charging Systems, Inc. Reserves the right
to make changes to this manual and/or product without further notice. Changes or modifications to this product not completed by an
authorized service provider could void the product warranty.
These commodities, technology or software were exported from the United States in accordance with the Export Administration
Regulations. Diversion contrary to US law prohibited
PosiCharge™ systems, a product line of Webasto Charging Systems, Inc..
1.866.767.4242 | [email protected] | @posicharge | posicharge.com
© 2019 Webasto Charging Systems Inc.

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Table of Contents
Table of Contents............................................................................................................................................3
List of Figures..................................................................................................................................................4
List of Tables...................................................................................................................................................4
1Overview...................................................................................................................................................6
1.1 Getting Started....................................................................................................................................6
1.2 Applicable Documents........................................................................................................................7
2Safety Precautions - Read before using................................................................................................8
2.1 Symbol usage.....................................................................................................................................8
2.2 Safety Instruction................................................................................................................................8
2.3 Technical Support...............................................................................................................................9
3System Description ...............................................................................................................................10
3.1 Options and Accessories..................................................................................................................11
4System Installation ................................................................................................................................11
5Operation................................................................................................................................................12
5.1 System Start Up................................................................................................................................12
5.2 Charging ...........................................................................................................................................13
5.3 Equalization ......................................................................................................................................15
5.4 Full / Over Charging..........................................................................................................................15
5.5 Reduced Charging............................................................................................................................15
5.6 Viewing Charge Data or Fault / Warning Screens............................................................................15
5.7 Data Logs, Charger Configuration and Advanced Programming Features......................................16
5.8 External Status Indicator Configuration (Optional)...........................................................................18
6DVS 400 Periodic Maintenance ............................................................................................................18
6.1 DC Power Output Cable Service......................................................................................................18
6.1.1 SBX/SYX Connector Service ....................................................................................................18
6.2 Troubleshooting................................................................................................................................19
6.2.1 How to Use This Section...........................................................................................................19
6.2.2 ESD Precautions.......................................................................................................................20
6.2.3 Problem Symptoms and Action Key..........................................................................................20
6.2.4 Fault Messages.........................................................................................................................22
6.2.5 Actions.......................................................................................................................................24
6.2.6 Charge Termination Codes .......................................................................................................27

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List of Figures
FIGURE 1.1. DVS 400 FAST CHARGING SYSTEM..................................................................................................6
FIGURE 5.1. START UP SCREENS.......................................................................................................................12
FIGURE 5.2. CONNECTING STATUS SCREENS.....................................................................................................13
FIGURE 5.3. FRONT PANEL LAYOUT...................................................................................................................14
FIGURE 5.4. CHARGE COMPLETE SCREENS.......................................................................................................14
FIGURE 5.5. REPRESENTATIVE CHARGING DATA SCREENS.................................................................................15
FIGURE 5.6. REPRESENTATIVE FAULT OR WARNING SCREENS............................................................................16
FIGURE 5.7. TOP LEVEL MENU FOR ADVANCED FEATURES.................................................................................17
FIGURE 6.1 CORRECT PIN ALIGNMENT...............................................................................................................19
FIGURE 6.2 INCORRECT PIN ALIGNMENT............................................................................................................19
List of Tables
TABLE 5.1. LED LABELS AND MEANINGS ............................................................................................................14
TABLE 6.1 PROBLEM SYMPTOMS AND ACTION KEY.............................................................................................20
TABLE 6.2 FAULT CODES AND ACTION KEY........................................................................................................22
TABLE 6.3 CHARGE TERMINATION CODES..........................................................................................................27

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1 Overview
The Dual Vehicle (DVS) Fast Charging System (Figure 1.1) is an advanced charging system that can quickly and
safely charge industrial batteries.
Figure 1.1. DVS 400 Fast Charging System
Charging intelligence is built into the system to make charging extremely simple: just plug in any IPC compatible
battery and the system starts charging it correctly. There is no need to be concerned about which charger is
designed or programmed for which battery. After completing a charge, the system shuts off automatically.
The DVS’s Rapid Charging Intelligence (RCI) makes it capable of charging much more quickly than a conventional
charger without damage to the battery. Battery voltage and temperature are monitored precisely, allowing charging
to be as rapid as possible without exceeding manufacturers' recommendations. The charge history of the pack is
tracked and equalization is automatically performed on the pack according to a pre-set schedule. This results in
better use of the batteries with minimal effort on the user’s part.
1.1 Getting Started
Before you begin, take the time to familiarize yourself with the Cautions in Section 2. To get your system up and
running quickly perform the following steps:

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1. Ensure the DVS 400 Fast Charging System installation and utility power requirements are followed. (Refer to
DVS 400 Installation Manual).
2. Install the Battery Monitor / Identifier (BMID) onto the battery pack. (Refer to BMID or BatteryRx Installation
Manual)
3. Once BMID is installed, the battery pack may be connected to the charger.
4. If your BMID does not come pre-configured, you will need to initialize the new BMID. (Refer to BMID
Programming and Advanced Features Manual)
5. Once the BMID has been initialized, the battery pack is ready to begin charging.
1.2 Applicable Documents
TITLE
Part Number
DVS 400 Installation Manual
09190-W-76
BMID Installation Manual
11717-W-03
BMID Programming and Advanced Features
BatteryRx Installation Manual
06701-W-03
16672-W-03

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2 Safety Precautions - Read before using
2.1 Symbol usage
Throughout this manual, take special note of the information marked with the following symbols:
DANGER
Contains information about safety practices necessary to prevent personal injury or
death.
WARNING
Contains information about safety practices necessary to prevent fire or equipment
overheating.
CAUTION
Contains information to prevent shock hazard or possible damage to the
equipment during installation and service.
NOTE: Offers helpful information for installation or usage, but does not contain personnel or equipment safety
related information.
2.2 Safety Instruction
CAUTION
BEFORE YOU
BEGIN
•Read all instructions and cautionary markings on the Industrial PosiCharge DVS
400 Assembly.
•Make sure you also read the IMPORTANT SAFETY INSTRUCTIONS below.
•Be sure to leave these instructions in a safe and easily accessible location for
future reference.
•Only qualified personnel, familiar with the local code, should install and service this
charger.
•Read and understand the manufacturer’s instructions and your employer’s safety
practices manual.
DANGER
ELECTRIC SHOCK CAN KILL: Touching live electrical parts can cause fatal shocks or
severe burns. The battery terminals are always electrically live, and the output circuit
is live whenever the battery is connected or being charged. The input power circuitry
and internal circuits are live whenever input power is on. An incorrectly installed or
improperly grounded charger is a hazard.
•The unit must be grounded properly with a grounding conductor of size equal to or larger than that
recommended by local electrical codes or the installation section of this manual.
•Do not touch the uninsulated portion of the output battery connector or an uninsulated battery terminal.
•Do not remove the cover. There are no user serviceable parts inside. Refer all servicing to qualified service
personnel. Opening the system, or attempted repair by other than qualified service personnel, voids the
warranty.
•Disconnect battery charger from input power and battery connections before installing or servicing. Lockout /
Tagout input power according to OSHA 29 CFR 1910.147.
•Do not use when in standing water.
•Before disconnecting the battery, turn off the charger by pressing the stop button on the front panel. The DVS
400 is designed to automatically stop a charge event to minimize arcing or burning of the charger connections in
the event of a hot disconnect.

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•The charging leads must be capable of the full rated current of the DVS 400, and inspected frequently for wear,
cuts and abrasion. Do not use worn, damaged, undersized, or poorly spliced cable.
•The DVS 400 power connector may be damaged by misuse or abuse. Frequently inspect the connector for
cracking, pitting of contacts, fraying of wires or signs of connector fatigue. Should any indication be present,
immediate replacement of the connector will be necessary.
•Do not wear rings, watches, necklaces, tie clips, or conductive jewelry when working with batteries, as a short
circuit through conductive jewelry may cause severe burns.
DANGER
BATTERY GASES AND ELECTROLYTE CAN BE HAZARDOUS: Charging
batteries produces fumes and gases that may be hazardous.
•Charging batteries may leak corrosive electrolyte that can cause skin and eye irritation and damage equipment
and clothing. Avoid contact and follow battery manufacturer’s recommended practices for cleaning the battery
pack.
•Thoroughly wash all items brought into contact with battery electrolyte with a solution of baking soda and water.
•Batteries produce explosive gases. Do not smoke, perform operations that cause sparking, or have an ignition
source near batteries.
•Ventilate the area to prevent the buildup of fumes and gases.
WARNING
IMPROPER INSTALLATION CAN CAUSE FIRE
•Do not install or place unit on, over or near combustible surfaces.
•Do not install unit near flammables.
•Do not block or filter airflow to the unit (allow minimum of 6” clearance around unit).
•Ensure that the BMID is properly installed according to the BMID installation instructions.
•Replace blown fuses only with same type and rating of fuse.
•Do not overload building wiring - be sure power supply system is properly sized, rated and protected to handle
this unit. Use only on circuits provided with the minimum wire size specified in the installation section.
2.3 Technical Support
Call technical support any time a procedural question arises. DO NOT perform a procedure you do not understand.
Customer Service can be contacted during normal working hours (Pacific Standard Time) by calling:
[e-mail]
866-POSICHARGE (866-767-4242)

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3 System Description
The DVS 400 Fast Charging System is a transistor-based fast charging system that provides all of the battery
charging and equalizing required for your application. It provides a constant current-constant voltage-constant
current (IEI) charge profile that precisely controls the charge rate, and optimally charges your batteries by precisely
adjusting the current in response to the batteries’ capacity, temperature and age.
The keypad and display on the front of the DVS 400 provide the user interface to the charger. The alphanumeric
display panel constantly updates the charger and battery status, and allows access into the programming menus
through the keypad. Four status LEDs allow the user to determine from a distance when the charge is in progress,
at 80% complete, fully charged, or in equalization. A fault/warning LED serves to alert the user to fault conditions.
The DVS 400 works with a small monitoring device mounted on the battery called the battery monitor/identifier
(BMID). The BMID enables the charger to automatically adjust the charge to match the requirements of all of the
batteries in your fleet, without needing to worry about mismatching batteries and chargers.
Each BMID is pre-configured with the following information:
1. An identification number, which can help track the charging history of a specific battery.
2. A type code, indicating the manufacturer and type of battery.
3. The number of cells in the battery.
4. The ampere-hour capacity of the battery.
5. The start current limit of the battery pack for optimal charging.
6. The State of Charge (SOC) limit of the battery. This will determine the SOC at which the charging will stop.
7. Internal resistance.
8. Maximum ampere-hours between equalizations.
9. Maximum days between equalizations.
10. Equalization day of the week.
11. Voltage limit for Fast Charging and Equalization.
12. Battery temperature foldback.
13. Initialize BMID.
Typically, the battery dealer or another authorized service technician will install the BMID on the battery and
configure it before delivery to the customer. BMIDs may also be reconfigured on site through the charger front panel
(see the “BMID Programming and Advanced Features Manual”).

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3.1 Options and Accessories
The following options and accessories are available through your authorized Industrial PosiCharge DVS 400 Fast
Charging System dealer. For any other replacement parts, contact customer service directly:
Battery Monitor and Identifiers (BMID)
Many different sizes and types of industrial battery packs may be charged with the DVS 400 Fast Charging System.
Choose the correct BMID for the nominal voltage of your pack.
24V BMID P/N 08660-W
36V – 48V BMID P/N 08661-W
72V – 80VBMID P/N 08662-W
Contact Customer Service for Dual SBX or Euro cable kits.
Thermistor Options
Choose the correct thermistor type for your battery. Submersible thermistors are designed for installation through
the battery case into the battery electrolyte of flooded battery cells. Exterior thermistors are designed to be glued
onto the exterior of sealed batteries. DO NOT submerge exterior thermistors into electrolyte, as thermistor corrosion
will result in erroneous readings.
Submersible (flooded battery) thermistor P/N 09525-xxx
Exterior (sealed battery) thermistor P/N 08664
Diagnostic Cable P/N 06969
4 System Installation
Refer to the DVS 400 Installation Manual that came with your system.

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5 Operation
Fast charging dramatically reduces the time to recharge a battery to a high state of charge. Fast charging makes it
possible to opportunity charge during available breaks, shift changes and other idle time and keep a vehicle running
all day long without changing batteries. In most two- and three-shift operations, fast charging can eliminate the need
for a battery changing room, freeing up floor space and personnel for productive activities and reducing battery
inventory by up to 65%. Fast charging also increases productivity by eliminating down time for battery changing and
avoiding low voltage operation that can reduce vehicle performance.
5.1 System Start Up
Once the system has been properly installed (mechanically and electrically) it is ready to be powered. When you first
power up your DVS 400 Fast Charging System, it will perform a lamp test. The display will then show the initial
status screen containing the model number and the software version. The DVS 400 will then sequence through the
two more status screens before reaching “Charger Ready Connect Vehicle”. See
Figure 5.1. When initialization is complete, the screens for each charge port will alternate. Note that there is an
arrow in the upper left or right corner of the screen indicating which channel’s data is currently being displayed.
Figure 5.1. Start-up Screens
DVS 40kW 500 Amps
Version xx.xx.xx.xx
Configuring Network
Starting PowerServer
Station Unavailable
Please see system stat
Charger Ready
Connect Vehicle

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5.2 Charging
(Note: The numbers shown as part of the screen display in this section of the manual are for illustration purposes
only. The actual numerical combination of voltage, current, and temperature will vary with the type of battery pack
being charged.)
Step 1: Connect battery to charger
To start charging, simply connect the battery to either charge port of the charger. The charger will establish
communication with the BMID, calculate the current state of charge, identify the correct charging profile, and
start charging. At each step, the charger will display the corresponding Status screen (see Figure 5.2). During
“Preparing for Charge”, the DVS 400 counts down while preparing to charge. Charging preparation includes
measuring the Open Circuit Voltage (OCV) of the battery pack and calculating the State of Charge (SOC) to
determine what the initial current should be to charge the pack properly. Once the charge starts, and the
“Charging” screen is displayed, the current is ramped up from zero to the target initial current while the charger
monitors the pack voltage.
Figure 5.2. Connecting Status Screens
Note that the screen examples shown above have a left-facing arrow at the left of line 1. This indicates that the
display applies to charge port A. A right-facing arrow at the right of line 1 indicates that the display applies to
charge port B. The display screen will periodically update the charging data as the charge progresses. In
addition, the front panel has several status LEDs that indicate the current status of the vehicle under charge and
whether it is scheduled for an equalization charge (see Figure 5.3 and Table 5.1).
<Charger Ready
Connect Vehicle
<Vehicle Connected
Getting Config Info
<Starting Fast Charge
Please Wait XX Sec
<Charging 53%
50.1 V 500A 40C
Vehicle Connected
Communication Established

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Table 5.1. LED Labels and Meanings
LED Label
Color
When Steady Lit
When Flashing
Equalizing
green
Battery undergoing equalization
Equalization scheduled
Charge Complete
green
Charge Complete and stopped
N/A
80% Charged
green
The Battery SOC is >= 80%
N/A
Charging
amber
Battery connected and charging
N/A
Fault/Warning
red
Fault (charge stopped)
Warning (check log)
Figure 5.3. Front Panel Layout
Step 2: Stop Charging
Once the battery has been fast-charged to the SOC preset in the BMID, the DVS 400 will stop the charge and
illuminate the “Charge Complete” LED. If an equalization charge is scheduled for this battery pack, the Charge
Complete will not illuminate until the equalization has been completed. The operator may stop charging at any
time without waiting for the charge to complete, by pressing the "STOP" button.
After a charge has been completed or stopped by the user, the screen will indicate the method in which the
charge was stopped and the data values just before the end of charging will be displayed (see Figure 5.4).
Figure 5.4. Charge Complete Screens
Step 3: Disconnect battery cables from charger
NOTE: If the operator disconnects the cables without pressing STOP, the charger will immediately stop charging
and prevent any arcing or damage to either the charger or battery. However it is strongly recommended that
operators press the STOP button first.
<Chg Complete 81%
62.2V 50.0A 55C
<Chg Stopped 62%
60.1V 500A 50C
or

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5.3 Equalization
Proper equalization is necessary for the health of the pack. Too little equalizing may lead to sulfation and decreased
capacity, whereas excessive equalizing may lead to high water loss and more maintenance. We recommend
equalizing at least once a week, but twice a week is optimal for pack life under continuous use.
The equalization schedule is stored in the BMID and run automatically (see the “BMID Programming and Advanced
Features Manual” for information on how to modify the pre-set equalization schedule). To manually schedule an
equalization during a charge, simply press the “Equalize” button at any time during a charge, the equalize light will
start flashing indicating an equalization is scheduled, and the battery pack will be equalized following the fast charge.
To bypass the fast charge and start an equalization charge on a battery pack at any state of charge, press and hold
the “Equalize” button for three (3) seconds, the equalize light will illuminate without flashing, and the charger will start
a full equalization on the pack without a fast charge.
To cancel a requested equalization charge, press the Equalize button and the Equalize LED will turn off.
CAUTION
Always run a full equalization charge prior to a fast charge on any battery pack that
has had a cell replaced to ensure the pack is balanced.
5.4 Full / Over Charging
Full/Over Charging is a feature that allows the user to fully charge a battery to 100% and then Over Charge the
battery for a predetermined period of time. This feature resembles the Equalization procedure in that Over Charging
utilizes the Finish Current setting of Equalization. However, this feature enables the user to set a time window when
Full/Over Charge can take place. It also allows the user to control the length of time that the battery is Over
Charged. If the charger is actively charging during the time window set by the user, and the feature is enabled,
Full/Over Charging will be performed. The time window, as well as the length of Over Charging, is set through the
“Full/Over Charge Setup” submenu of the “Charger Configuration” menu.
5.5 Reduced Charging
Reduced Charging allows the user to set a predetermined rate of current during a user defined time window. The
current, as well as the time window, is set through the “Reduced Charge Rate Setup” Submenu of the “Charger
Configuration” menu. If the charger is actively charging during the time window, and the feature is enabled, the
charging current will be reduced to the user-selected value. The current will remain at this level as long as the
charge is within the specified window.
5.6 Viewing Charge Data or Fault / Warning Screens
While charging, the display screen is periodically updated with the latest charging data including voltage, current,
battery temperature, and battery state of charge. If there is a fault or warning, the fault or warning message will be
displayed instead.
Charging data. This screen displays the voltage, current, state of charge, and temperature of the battery. During a
charge, the screen will say "Charging" and the data will be updated periodically. See Figure 5.5.
Figure 5.5. Representative Charging Data Screens
Fault/Warning Screens
In the event of a fault or a warning, a fault/warning screen will appear automatically (see Figure 5.6). The
fault/warning screen shows an assigned fault number and the name that indicates the type of fault or warning.
Check Table 6.2 and
Table 6.3 in the troubleshooting guide for a complete listing of faults and warnings.
<Charging 53%
50.1V 500A 40C

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Figure 5.6. Representative Fault or Warning Screens
5.7 Data Logs, Charger Configuration and Advanced Programming Features
The DVS 400 Fast Charging System’s user interface allows a trained user to configure many of the charge
parameters and review recorded data stored in the system’s internal data logger. All configuration programming is
performed through menus that are accessible directly through the display and the keypad. By pressing the “Select”
key, you will enter the top-level menu of the advanced features menu (see Figure 5.7).
Details on how to access the advanced features and configuration menus are in the “BMID Programming and
Advanced Features Manual”.
<Chg Complete 81%
62.2V 50.0A 55C
<Chg Stopped 62%
60.1V 500A 50C
or

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Figure 5.7. Top Level Menu for Advanced Features
1. Charge Event Log - Allows you to scroll through the data from the last 200 charge events.
2. Fault/Warning Log - Allows you to scroll through the last 100 fault or warning events.
3. Charger configuration - A programming mode for setting the date and time, modifying charge algorithms, setting
the equalization schedule, and controlling charge times. Requires an access code to enter this mode.
4. BMID Data Review - Lists all of the BMID parameters for the unit(s) presently connected or charging, plus all of
the stored charge history and equalization data.
5. BMID Configuration - A programming mode for modifying the BMID parameters of the unit(s) presently
connected. Requires an access code to enter this mode.
6. Display Application Version Information – Allows user to view software version and hardware configuration
information.
ANY STATUS OR
CHARGING SCREEN
Charge Event Log
Fault/Warning Log
Charger
Configuration
SELECT
SELECT
BMID Data
Review
BMID
Configuration
SELECT
SELECT
SELECT
ENTER
Review charge data
f
the last 200 charge
t
Change charger
config
.
Requires Access
d
Change BMID
config
.
Requires Access code
Review data from the
lt
100 fault or warning events
Review data for batteries
currently connected
S
E
L
E
C
T
1
3
4
2
ENTER
ENTER
ENTER
5
ENTER
6
Display Application
Version Information
ENTER
Review Application
Configuration and S/W

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5.8 External Status Indicator Configuration (Optional)
If the DVS 400 is configured to drive external status lights, assignment of light outputs will be possible for visual
presentation of the current state of the charger. A set of three lights per port may be controlled to alert the user to
the current state of the charger. This is useful when the user is in a position where the front panel of the DVS 400 is
not visible. The lights will show what the charger is currently doing. The assignment of the lights is configured
through the “Extern Light Port X” submenu of the “Charger Configuration” menu.
6 DVS 400 Periodic Maintenance
Maintenance Schedule
ITEM SERVICE INTERVAL
DC Power Output Cables Inspect and Replace As Needed
SBX/SYX Connectors Inspect, Rework or
Replace As Needed
6.1 DC Power Output Cable Service
Refer to the DVS 400 field service manual, 09190-W-76, for output cable installation instructions. Use only
PosiCharge replacement cable part number 07391 to ensure safe and reliable service.
WARNING
Use only connectors and cable that are rated for the full continuous current
rating of the unit.
If you have questions regarding a specific cable assembly or need to obtain documents, please contact Customer
Service.
6.1.1 SBX/SYX Connector Service
The auxiliary contact pins in SBX and SYX connectors sometimes make intermittent contact when the vehicle is
plugged in to the PosiCharge Charger. This results in a BMID Communication fault or no recognition by the charger
that a vehicle is plugged in.
Check the red and black auxiliary pins in each connector. One or more of the communication pins in the red and
black auxiliary connectors may not be seated properly or there may be damage to the auxiliary connector housing. A
correctly seated pin is all the way forward inside the housing. An incorrectly seated pin is visibly pushed back inside
the housing and the tip of the housing tongue can be seen. Damaged connector housings must be replaced.
Contact PosiCharge for recommended replacement parts.
Procedure:
1) Remove the two retaining roll pins from the SBX or SYX housing
2) Pull the red and black auxiliary housings from the SBX or SYX housing
3) Remove the incorrectly seated pin from the auxiliary housing
NOTE
If an SBX or SYX connector is mounted to a vehicle, it must be removed from its
mount before the roll pins that retain the auxiliary contacts may be removed.

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4) Rework the pin so that the tongue of the pin is in-line with the pin body or at a slight downward angle (Figure 3
shows the CORRECT alignment. Figure 4 shows the INCORRECT alignment).
Figure 6.1 Correct Pin Alignment
Figure 6.2 Incorrect Pin Alignment
5) Insert the pin into the red or black auxiliary housing (Note: An audible click can be heard when the pin fully
engages. Pull on the wire to make certain that the pin is properly seated).
6) Reassemble the connector assemblies and test.
The following connector kits are available:
1) P/N 06435 - Yellow
2) P/N 06436 – Blue
3) P/N 07280 – Green
Each kit includes:
(1) SYX 350A 600V Connector, (2) 4/0 Lugs, (2) Roll Pins, (2) Aux. Contact Pins, (1) Red Aux. Connector, (1) Blk
Aux. Connector
Additional kits or individual parts may be available. Contact Customer Service for more information.
6.2 Troubleshooting
6.2.1 How to Use This Section
The following tables should be used in diagnosing trouble with your DVS 400 Fast Charging System. Use Table
6.1 to relate symptoms to probable causes. Find the symptom that best describes the problem in the first
column and go through the probable causes in the second column. Then use the third column to identify the
appropriate action for that probable cause. See section 6.2.5 for a detailed description of each action. Table 6.2
lists fault codes that may be displayed on the front panel of the DVS 400. Find the fault code displayed on the
DVS 400 and use Table 6.2 to find a description of the fault code and an action code.
Table 6.3 lists the Charge Termination Codes. This table can be used to interpret charge termination codes /
messages listed in the Charge Event logs.
Body
Tongue
Body
Tongue

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6.2.2 ESD Precautions
Electronic circuits are sensitive to damage from electrostatic Discharge. Persons servicing this equipment should be
trained in proper techniques for avoiding ESD damage to electronic circuits. As a minimum, when handling circuit
boards, wear an appropriate ESD wrist strap connected to the equipment chassis.
6.2.3 Problem Symptoms and Action Key
Table 6.1 Problem symptoms and Action Key
Symptom Probable cause(s) Action
No Display or LED’s
No AC to charger
Miswiring of AC input
120VAC Input Fuse Blown
D
D
C
One or more LED’s do not illuminate
during lamp test
Burnt out LED
II
Display Illegible
Noisy Environment
Bad Control Board
Corrosion on internal components
Display connector not properly seated
E
B
EE
II
Control panel not responding to input
Bad control board
Noisy Environment
Damaged membrane switch
B
E
II
Charger does not start charge when
battery connected
Output connector not completely connected
BMID is bad or reading out of range
Pilot line disconnected
Bad Control board
Loose or incorrect signal wiring
Corrosion on the signal pins
Battery over discharged
F
G
F
B
F
EE
K
Charger stops charge before complete
Battery overheat
Loss of communication line
Bad cell within pack
Algorithm/capacity mismatch
Charger overheating
Incorrect BMID configuration
H,P
F
I
J
AA
J
Charger works intermittently
Loose input or output wiring
Loose BMID connections
Low local utility voltage
Corrosion of internal components
F
F,G
DD
EE
Battery takes too long to charge
Algorithm/capacity mismatch
Bad BMID
Shorted or worn BMID wire
Loose power cable or battery interconnect
SOC mismatch within pack
Battery too hot when charge started
Battery brought in at extremely low SOC
J
G
F
Q
I
H,P
K
Pack failing to equalize
BMID misprogrammed
J
Output cables or Connector too warm
during charge
Cable undersized for length and current
Connector underrated for current
Bad crimp or connection within connector
Short in output cables
Bad cell within pack
N
N
N
F
I