Webasto PosiCharge DVS - Table of Contents

DVS/GSE GSE DVS Field Service Manual
09030-78B 3 of 49
Webasto Charging Systems, Inc.
TABLE OF CONTENTS
1 SAFETY PRECAUTIONS - READ BEFORE USING..............................................5
1.1 SYMBOL USAGE .....................................................................................................5
2 GENERAL INFORMATION ...................................................................................7
2.1 SCOPE......................................................................................................................7
2.2 HOW TO USE THIS DOCUMENT............................................................................7
2.3 LIST OF TERMS AND ACRONYMS.........................................................................8
2.4 APPLICABLE DOCUMENTS....................................................................................8
2.5 LIST OF EQUIPMENT..............................................................................................9
2.6 SYSTEM OVERVIEW.............................................................................................10
2.7 SYSTEM TROUBLESHOOTING GUIDE................................................................11
2.7.1 How to Use This Section........................................................................................11
2.7.2 ESD Precautions ....................................................................................................11
2.7.3 Problem Symptoms and Action Key........................................................................12
2.7.4 Fault Messages......................................................................................................14
2.7.5 Actions .................................................................................................................16
2.7.6 Charge Termination Codes.....................................................................................22
3 MAINTENANCE AND REPAIR............................................................................23
3.1 POWERSTATION CABINET..................................................................................23
3.1.1 Equipment Access.................................................................................................23
3.1.1.1 Access to Front Enclosure ......................................................................................23
3.1.1.2 Access to Top Enclosure ........................................................................................23
3.1.2 PowerStation Periodic Maintenance........................................................................24
3.1.3 Field Application Software Upgrades......................................................................24
3.1.3.1 Application Software Upgrades..............................................................................24
3.1.4 Field Replaceable Parts (PowerStation Cabinet).......................................................24
3.1.4.1 Door Assembly (P/N 07308)...................................................................................25
3.1.4.2 Cooling Fans (P/N 06903) ......................................................................................26
3.1.4.3 12V Power Supply (P/N 06860)..............................................................................26
3.1.4.4 5V/15V Power Supply (P/N 08340) ........................................................................27
3.1.4.5 Power Stage Assembly (P/N 06906)........................................................................27
3.1.4.6 Power Terminal (P/N 05383) ..................................................................................27
3.1.4.7 Contactor (P/N 06902) ...........................................................................................28
3.1.4.8 Inductor Thermal Switches (P/N 05162)..................................................................28
3.1.4.9 Control Board (P/N 08067).....................................................................................29
3.1.4.10 Display Board (P/N 06457) ..................................................................................30
3.1.4.11 Current Sensors (P/N 05109) ................................................................................30
3.2 BMID......................................................................................................................31
3.2.1 Locating the BMID................................................................................................31
3.2.2 Basic Operation .....................................................................................................31
3.2.3 Troubleshooting Guide...........................................................................................31
3.2.4 Replacing the BMID..............................................................................................32
3.3 CHARGING CABLE AND DATA WIRES...............................................................32
3.3.1 Inspecting Cables, Wires and Connectors................................................................32
3.4 POWER SUPPLY CABINET...................................................................................33
3.4.1 Equipment Access.................................................................................................33
3.4.2 Power Supply Cabinet Routine Maintenance ...........................................................35
3.4.3 Measuring Line-to-Line Voltage .............................................................................36
3.4.4 Removal, Test and Replacement of Fuses................................................................37