TSB 03-08-06 - Motorcraft Technical Resource
Contents
1. 90 90 AZL IIM yoed VOL ye 5 5 a 0722 01 A90 1919 109 3 Act 20 90 20 00 Ach 20 20 moj ndino uoun ON ON 2 01 SAUD IIM 95010 100 108009 JOU 108009 JOU 104061009 95010 100 10008000 yoed YOL 12 suiny reyo yoed VOL ye suiny reyp yoed aye WO ye SH yz ye yoed ye swny yoed Arayeq ayer ye 1 9952. YOSHOIAN 910 85 5 Bulys p ouo ueq uo 146113299 ne wo aq Aew Bunya sueq 10 0 ae egies UY 970 01 8 69 869 01 89 A89 01 9 69 04 AOS AOS 04 01 AO TB 6665 A Article 03 8 6 Figure 1 PAGE 10 BATTERY 1 BATTERY 6 TB 7091 A TB 7092 A Figure 2 Article 03 8 6 Figure 3 Article 03 8 6 BATTERY LAYOUT 2 FRONT OF VEHICLE 4 patteRY3 72 LOW CURRENT WIRE HARNESS CONTROLLER TB 7093 A LO gt lt YOLOVLNOD Figure 4 Article 03 8 6 PAGE 11 BATTERY CAPACITY VS OPERATING TEMPERATURE gt 3 lt a a AMBIENT TEMPERATURE C TB 6667 A Figure 5 Article 03 8 6 PAGE 12 RANGE CONCERNS gt Is the range less than 20 miles refer to testing mileage range NO NO Goto TSB 2 25 09 Is the pack voltage less than volts Do al four wheels spin freely on the hoist YES Free wheel movement Does pack voltage rise with FLOW CHART 1 or habits appear to have affected the range Explain to customer how driving habits affect range refer to vehicle range co
3. BATTERY TYPE PROGRAMMING Check that the battery mode either flooded or gel corresponds to the battery type installed in the vehicle If the battery mode is set incorrectly reset it charge the vehicle for 12 hours and retest How to reset the battery type 1 Battery pack voltage must be above 40V 2 Turn the key in the OFF black dot position press and hold down the Select Reset button Turn the key to the D Drive position Release the Select Reset button Turn the Key to the R Reverse position 0 209 Press and release the Select Reset button to alternate between the flooded and sealed battery modes 7 the key to the OFF black dot position The gauge will automatically exit the reprogramming mode after 10 seconds or exit immediately by pressing the Select Reset button Gauge ICON Description Flooded battery Battery with water ICON Maintenance free battery GEL No ICON gauge defaults to this setting ON BOARD CHARGER DESCRIPTION The battery charger receives 120 volt AC power from an external standard grounded 3 prong outlet and converts it to DC power as required to charge the vehicle battery pack After properly connecting the vehicle to the receptacle the charger will initiate a four stage charging process In the first stage the battery pack is tested If the battery pack passes the charger determines the appropriate charging rate depending upon the voltage of the ba
4. Follow the power down procedure WARNING THE BATTERY PACK CONTAINS HIGH VOLTAGE COMPONENTS AND WIRING HIGH VOLTAGE INSULATED SAFETY GLOVES AND FACE SHIELD MUST BE WORN WHEN PERFORMING THE FOLLOWING STEPS FAILURE TO FOLLOW THIS WARNING MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH WARNING THE BATTERY PACK ASSEMBLY CAN DELIVER IN EXCESS OF 72 VOLTS OF DC POWER IMPROPER HANDLING OF THE BATTERY PACK CAN RESULT IN INJURY OR FATALITY ONLY AUTHORIZED PERSONNEL TRAINED TO WORK WITH BATTERY PACK COMPONENTS ARE PERMITTED TO HANDLE THE BATTERIES WARNING MAKE SURE THE VEHICLE IS NOT BEING CHARGED a Connect the capacitor discharge tool To discharge the motor controller b Touch the NEGATIVE probe of the DVOM to the B battery negative labeled Batt 1 NEG c Touch POSITIVE probe of the DVOM to the load side of the 10 amp fuse for the motor controller circuit This will be the spade connector closest to the front of the fuse holder and it is labeled GAUGE MTR CNTR Article No 03 8 6 Cont d d The DVOM will display any voltage present Repeat Steps 6b and 6c if DVOM reads more than 0 volts To discharge the DC DC converter 1 standard or DC DC 2 optional e Touch the NEGATIVE probe of the DVOM to the B battery negative labeled BATT 1 NEG f Touch the POSITIVE probe of the DVOM to the load side of the 10 amp fuse for the DC DC circuit This will be the spade connector closes
5. PACK REMOVAL AND REPLACEMENT Remove Batteries 1 vehicle off charge 2 Remove front seat bottom cushions and remove seat frames from H bracket 3 Remove front stanchion cover NOTE IT IS NOT NECESSARY TO REMOVE THE H BRACKET OR THE PARK BRAKE HANDLE 4 Check for continuity from battery pack negative and positive to the frame If there is continuity do not remove battery terminals until the leak is found 5 Power down vehicle as described in the Service Manual 6 Disconnect all battery cables from the threaded terminals 7 Remove all battery hold downs 8 Remove batteries as seen in Figure 3 Replace Batteries NOTE SEE FIGURE 4 FOR PROPER BATTERY LOCATION AND PLACEMENT 1 Install battery 2 amp 5 polarity must be correct 2 Install battery 3 amp 4 polarity must be correct 3 Install battery 1 amp 6 polarity must be correct 4 Attach all battery cables 107 132 Lb in 12 15 Nem fuse amp harness connections 5 Reinstall all battery hold downs 107 132 Lb in 12 15 Nem Article No 03 8 6 Cont d 6 Install front stanchion cover 7 Check battery pack voltage approximately positive 72V should be present 8 Put vehicle on a 12 hour charge with the on board charger NOTE ALL BATTERIES INCLUDING NEW BATTERIES MUST BE WITHIN 2VDC OF EACH OTHER BE CONSIDERED BALANCED IF THEY ARE NOT REFER TO THE BATTERY PACK BALANCING SECTION OF THIS ARTICLE
6. charging circuit charger cord or charging inlet receptacle is malfunctioning If pack voltage is less than 20 volts the batteries must be individually charged with DPI chargers specified within this TSB DPI smart chargers will not activate if the battery is below 3Vdc NOTE The information in Technical Service Bulletins is intended for use by trained professional technicians with the knowledge tools and equipment to do the job properly and safely It informs these technicians of conditions that may occur on some vehicles or provides information that could assist in proper vehicle service The procedures should not be performed by do it yourselfers Do not assume that a condition described affects your or truck Contact a Ford Lincoln or Mercury dealership to determine whether the Bulletin applies to your vehicle Copyright 2003 Ford Motor Company PAGE 1 Article 03 8 6 Cont d Batteries The battery pack consists of 6 individual 12 volt modules Battery modules are defined as the individual 12 volt batteries which when connected in series make up the 72 volt battery pack The Th nk Neighbor uses lead acid deep cycle batteries which are different from typical automotive starting batteries Only Ford Motor Company recommended batteries should be used for replacements Use of any unauthorized battery may negatively affect the battery range life and durability and will not be covered under warranty NOT
7. CK CONTAINS HIGH VOLTAGE COMPONENTS AND WIRING HIGH VOLTAGE INSULATED SAFETY GLOVES AND FACE SHIELD MUST BE WORN WHEN PERFORMING THE FOLLOWING STEPS FAILURE TO FOLLOW THIS WARNING MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH WARNING THE BATTERY PACK ASSEMBLY CAN DELIVER IN EXCESS OF 72 VOLTS OF DC POWER IMPROPER HANDLING OF THE BATTERY PACK CAN RESULT IN INJURY OR FATALITY ONLY AUTHORIZED PERSONNEL TRAINED TO WORK WITH BATTERY PACK COMPONENTS ARE PERMITTED TO HANDLE THE BATTERIES WARNING MAKE SURE THE VEHICLE IS NOT BEING CHARGED a Connect the capacitor discharge tool To discharge the motor controller b Touch the NEGATIVE probe of the DVOM to the B battery negative labeled Batt 1 NEG c Touch POSITIVE probe of the DVOM to the load side of the 10 amp fuse for the motor controller circuit This will be the spade connector closest to the front of the fuse holder and it is labeled GAUGE MTR CNTR d The DVOM will display any voltage present Repeat steps 4b and 4c if DVOM reads more than 0 volts To discharge the DC DC converter 1 standard or DC DC 2 optional e Touch the NEGATIVE probe of the DVOM to the B battery negative labeled BATT 1 NEG f Touch the positive probe of the DVOM to the load side of the 10 amp fuse for the DC DC circuit This will be the spade connector closest to the front of the fuse holder and it is labeled DC DC g The DVOM will display a
8. E WHEN THE VEHICLE IS GOING TO BE STORED FOR 14 DAYS OR MORE THE SERVICE DISCONNECT SWITCH SHOULD BE TURNED OFF PROPER CHARGING OF THE NEIGHBOR IS THE RESPONSIBILITY OF THE CUSTOMER OR THE DEALERSHIP WHILE IN SERVICE THE VEHICLE SHOULD BE PLUGGED IN AT ALL TIMES WHEN IT IS NOT BEING USED OR WHILE IT WAITS FOR SERVICE AND UNTIL RETURNED TO THE CUSTOMER Battery Care The Th nk Neighbor is equipped with a Service Disconnect Switch SDS to help preserve battery life The switch is located under the seats to the rear of the parking brake For vehicles produced after 6 24 02 the switch is located directly under the drivers seat Beginning with a fully charged vehicle the battery pack will remain charged approximately 14 days with the SDS and approximately six months with the SDS OFF The Neighbor is shipped with the switch in the OFF position to preserve battery pack charge vehicle will not be used for more than 14 days fully charge the vehicle 12 hours of charging turn the ignition to the OFF position and turn the service disconnect switch to the OFF position The vehicle can be left unplugged with a fully charged battery and the service disconnect switch turned OFF for up to 6 months It is recommended if possible to charge the vehicle once a month for 12 hours during storage Always store the vehicle with the service disconnect switch OFF at the dealers
9. ELECTRICAL TH NK VEHICLES BATTERY RECOVERY BALANCING AND BATTERY RANGE TIPS Article No 03 8 6 THINK 2002 NEIGHBOR ISSUE Some 2002 Th nk Neighbor vehicles may exhibit no start condition inability to charge or reduced mileage range This may be due to a deeply discharged battery pack failed battery modules or an unbalanced battery pack ACTION Diagnose the health of battery pack and individual battery modules to determine repair action Follow Flow Chart 1 Figure 6 for direction This TSB outlines procedures for evaluating battery health replacing individual battery modules battery recovery and balancing battery modules to maximize pack performance SERVICE INFORMATION Battery recovery and top of charge TOC battery pack balancing is the main subject matter of this article It must be noted that the DPI smart chargers used for recovery and battery pack balancing will not initiate charge unless the battery is above 3Vdc NOTE THE NEW VEHICLE LIMITED WARRANTY DOES NOT COVER DAMAGE CAUSED BY FAILURE TO MAINTAIN THE VEHICLE OR IMPROPERLY MAINTAINING THE VEHICLE IF THE BATTERIES ARE REPLACED UNDER WARRANTY ALL CAUSAL PARTS OF THE ASSOCIATED DAMAGE TO THE BATTERIES MUST BE RETURNED PER WARRANTY RETURN TAG INSTRUCTIONS AND MAY BE ANALYZED FOR FAILURE IN THE ABSENCE OF A CASUAL PART WHICH HAS CAUSED THE BATTERIES TO DISCHARGE BELOW MINIMUM VOLTAGE IT IS PRESUMED THAT THE BATTERIES WE
10. INDIVIDUAL MODULES IN THE BATTERY PACK ALL THE MODULES INCLUDING THE NEW BATTERY MUST BE BALANCED TO TOP OF CHARGE WITH THE SMART DPI CHARGERS Article No 03 8 6 Cont d NOTE DO NOT USE A ROTUNDA OR ANY OTHER BATTERY CHARGER WHICH CHARGES AT GREATER THAN 14 1 VOLTS THIS MAY DAMAGE THE NEIGHBOR BATTERIES Battery Health Testing Using The Micro 490 To Test Th nk Neighbor Battery Modules Do not use cold cranking amps or open circuit voltage tests to determine if a battery module in the pack is defective These tests are not accurate The only accurate method of determining which module is defective is to use the Micro 490 Battery Tester supplied by Rotunda or the charger The battery must be charged before the Micro 490 will accurately test the battery Battery Testing With The Micro 490 There is a draw on the batteries even with the SDS OFF There is a 1 mA draw from the charger the charger is hot at all times and this will negatively affect the Micro 490 The Micro 490 will only provide accurate results when there is no draw on the battery To correctly use the Micro 490 battery tester the pack must be separated into individual battery modules Follow this procedure to test individual batteries 1 Remove the front seat bottom cushion 2 Turn the SDS Service Disconnect Switch OFF 3 Remove the front stanchion cover 4 Follow the power down procedure WARNING THE BATTERY PA
11. RE NOT MAINTAINED CORRECTLY AND ALLOWED TO DISCHARGE BATTERY RECOVERY IS AT THE CUSTOMERS DISCRETION AND IS NOT COVERED UNDER WARRANTY If the battery pack voltage is from 68 3V to 80V the vehicle should enable If it does not enable follow the THINK Neighbor no enable troubleshooting flow chart found in TSB 02 25 9 If the battery pack is greater than 20Vdc and less than 68 3Vdc the charger should charge the batteries Refer to the charging section of this TSB for direction If the pack is under 20V the on board charger will not charge the pack and the battery modules must be individually charged Refer to the battery pack balancing amp recovery section If the vehicle mileage range is drastically reduced from the normal range experienced by the customer the pack must be checked referencing the vehicle range concern section It is possible the batteries have been discharged to a very low level and have become unbalanced if so refer to the battery pack balancing section DIAGNOSTICS Follow Flow Chart 1 Figure 6 to determine proper repair procedures Use Figure 1 to assess the state of charge of the battery pack Verify that the charger and charging receptacle are functioning properly by measuring pack voltage as shown in Figure 2 while the vehicle is on charge With the vehicle on charge pack voltage should rise above the static pack voltage If there is no rise in pack voltage after 15 minutes of charging the charger
12. atus 8 Reassemble the seats and stanchion covers 19 Keep the vehicle plugged into the onboard charger until delivered to the customer DPI smart charger operating instructions The charger uses a sophisticated charging algorithm that continuously tests the charging process from start to finish Once the charger senses a battery connection of greater than 3Vdc it immediately begins its 5 stage charging process as described below in order of which stage the charging process occurs PRE QUALIFICATION TEST STAGE ONE Yellow L E D Flashing This first stage tests the battery and determines the condition of your battery Further charging will be inhibited if the charger determines that the battery s condition is not conducive to receiving a charge The charger applies a regulated voltage and current charging waveform to the battery while analyzing the charge waveform characteristics with respect to time If your battery is in fairly good condition then the duration of this test is about 40 seconds minimum to 3 hours If your battery has been left in a state of discharge for a long period of time days to months then the charger may require 3 hours to determine if the battery will even accept a charge This length of time is required because the plates have become severely sulfated similar to iron rusting and the charger needs time to analyze the battery through the sulfated plates Sulfating on the plates begins to break dow
13. cteristic of these batteries Batteries should not be replaced simply because the customer achieves less range than when the vehicle was new Some judgment should be exercised when evaluating range Factors affecting mileage range on electric vehicles include Type of tire Vehicles equipped with turf tires will have less range than vehicles equipped with street tires due to greater frictional drag from the wider turf tire Age of battery pack Battery capacity decreases as batteries age Weak or failed individual battery A module that is 2V or more from the other battery modules in the pack or is checked bad by the Micro 490 Temperature Battery capacity decreases as temperature drops Driving style Heavy acceleration demands more power from the battery pack than gradual acceleration Terrain Climbing steep grades may deplete the battery pack Pavement vs Off Road Vehicles driven off road will have less range Lack of free wheel movement Check vehicle for any evidence of brake drag by putting the vehicle on a hoist and checking wheels for free rotation Other Electrical Loads Lights Heater Defogger Powerpoint accessories etc note that all Powerpoint accessories should be disconnected when the vehicle is charging Before recommending replacement of the entire pack to a customer simply because pack capacity has decreased due to age discuss the situation with the customer If the customer is in the
14. days The manufacturer s rated capacity of the flooded battery is 130 amp hours and the gel battery is 97 amp hours The state of charge the amount of energy available from the battery at any particular time of the individual modules within the pack must be similar or balanced for the pack to function correctly NOTE IT IS NORMAL THAT OVER TIME THE BATTERY PACK CAPACITY WILL DECREASE RESULTING IN DECREASED MILEAGE RANGE WARRANTY REPLACEMENT OF A BATTERY PACK DOES NOT COVER A BATTERY PACK THAT HAS BEEN CYCLED THROUGH A NORMAL LIFE EXPECTANCY REFER TO ADDITIONAL INFORMATION PROVIDED WHEN ASSESSING IF BATTERIES SHOULD BE REPLACED UNDER WARRANTY Testing Mileage Range The Th nk Neighbor achieved 31 miles on the Federal Urban Driving Standard test This drive cycle is complex and probably cannot be reproduced in a dealership environment However the following guidelines will help establish a driving course to determine if a customer is experiencing poor range or if the battery pack is performing as expected Choose driving surfaces that are paved and relatively flat Some moderate hills are acceptable as long as they are not more than 1 2 mile and less than 5 grade Try to find a route that has five or less stops and starts i e stoplights Try to spend at least 55 of the drive cycle time at 70 max speed or around 18 mph Drive vehicle from a full charge 12 18 hr charge cycle and until one bar is s
15. eck battery If battery is severely discharged ensure that all battery loads are disconnected until charger has had a chance to recharge battery 3 Something went wrong with the charging process Try re starting the charge process by disconnecting and reconnecting charger from and to A C power 4 battery is first connected with correct polarity and this L E D is on continuously but no further charge action seems to be taking place then the battery has a terminal voltage that is too low less than 3Vdc for the charger to detect that a connection has been made Disconnect any battery loads and allow time for the battery to recover As a result of severe battery discharge the length of battery recovery time will vary from minutes to hours and days dependent on the length of time that the battery was left in a state of discharge It is not uncommon to find that the battery may require replacement because severe discharge is the single largest cause of battery failure PAGE 6 5 Time Out error The charger uses a safety timer to terminate charging if the process required more time to complete As the batteries age the charge process takes longer and batteries will eventually not accept a charge 6 To reset any fault indicator and restart charging process unplug charger from A C Power for a minimum of 30 seconds Then plug charger back in If charger indicates another fault indicator have battery checked BATTERY
16. hip You must charge the battery pack every 30 days per the Warranty Policy and Procedure Manual even if the service disconnect switch is OFF while the vehicle is at the dealership PAGE 2 NOTE WHILE AT THE DEALERSHIP FOR SERVICE IT IS THE DEALERSHIPS RESPONSIBILITY TO MAINTAIN THE BATTERY PACK CHARGE LEVEL IT IS RECOMMENDED TO CHECK AND DOCUMENT FOR LATER VERIFICATION THE BATTERY PACK VOLTAGE WHEN A VEHICLE IS BROUGHT IN FOR SERVICE AND MONTHLY WHILE IN THE DEALERSHIPS POSSESSION Check For Voltage From The Battery Pack To Chassis 1 Check for pack voltage in the chassis by setting the DVOM to read DC volts 2 Touch the NEGATIVE lead of the DVOM to the battery pack NEGATIVE terminal on battery number one 3 Touch the POSITIVE lead of the DVOM to an unpainted section of the chassis 4 Check for voltage If voltage is found the battery pack short to chassis must be repaired before any further steps are taken Check Each Battery For Polarity 1 Use a DVOM to check battery polarity on each individual module 2 Set the DVOM to DC voltage 3 Touch the POSITIVE lead of the DVOM to the POSITIVE terminal of the battery 4 Touch the NEGATIVE lead of the DVOM to the NEGATIVE terminal of the battery 5 Repeat for all batteries If the polarity is reversed and negative voltage reading is found then remove and replace the battery with a Ford recommended replacement battery NOTE WHEN REPLACING
17. howing on the gauge NOTE VEHICLE RANGE DOES VARY FROM VEHICLE TO VEHICLE IT IS CONSIDERED ACCEPTABLE TO ACHIEVE 20 MILES OR GREATER ON FULL DRIVE CYCLE USING THE ABOVE DRIVE CYCLE CONDITIONS OTHER APPLICABLE ARTICLES 02 25 9 WARRANTY STATUS INFORMATION ONLY OASIS CODES 203000 203100 203200 204000 204100 206000 601300 602300 603300 607000 607500 610700 611000 614000 622000 PAGE 9 pijos suno 5184 20 24 AZL 5591 JO 70 96 01 1 08 s 10 alm 10 JOU 20 00 Ack 20 00 90 90 Ack BPA 89143A ayes 0 ye swiny VOL ye reyp SH ayes VOL ye 01 O AY EL
18. n as the charge is passed through the battery but in some cases the sulfation may have become so great that only time will allow for the removal of the sulfate CONSTANT CURRENT CHARGE STAGE TWO Yellow L E D Continuous The charger is charging the battery at full rated output This stage ends once the battery s terminal voltage reaches the factory preset voltage level of approximately 14 3Vdc PAGE 5 Article 03 8 6 Cont d CONSTANT VOLTAGE CHARGE STAGE THREE Yellow L E D Continuous This stage forces the cells of the battery to become equalized in charge and finishes when the battery has approached near 100 state of charge FLOAT CHARGE STAGE FOUR Green L E D Continuous The charger regulates the battery terminal voltage at about 13 25Vdc which maintains the battery at full state of charge A regular periodic check on your charging system if left unattended and powered is still recommended just as you would with any electrical appliance While in Float Mode if the charger senses a load that has activated e g pump motor the charger recycles to the Charging Mode to start charging RECYCLE CHARGE STAGE FIVE Once every 84 days the charge cycle restarts from Stage One FAULT L E D DISPLAY Red L E D Flashing Indicates a CHARGING FAULT as a result of one of the following condition 1 Charger Output Lead connections are reversed 2 Pre Qualification Test failed ch
19. ncerns in this TSB isthe pack twelve months or older Explain to customer pack life as it relates to range expectancy Refer to battery capacity section of this TSB 0 2 0 2 0 0 a q 2 0 2 i gt 0 0 9 1 Is the pack voltage less than 20 volts 16127 SSM 15708 and service manual for charger troubleshooting Is there continuity from battery pack negative or positive fo the Is the polarity of the batteries reversed Follow power shut down procedure and separate all batteries chassis YES Repair voltage leak module refer to battery pack synchronization and recovery section Figure 6 Article 03 8 6 Remove and replace battery Charge all batteries individual with the Smart DPI chargers NOTE Battery module must he above 3V de before the DPI charger Will inititate pack negative or positive to the chassis Repair voltage leak refer to the electrical leakage diagnosis section of the service manual Is the green light illuminated on the Smart charger after a ful charge Remove and replace battery module refer to battery pack synchronization and recovery section Is each individual battery within 2 of each other refer to battery pack synchronization and recovery section of this TSB Check with Micor 490 at 550CCA and replace bad modules Balance batteries by individually chargi
20. ng them with the Smart DPI charges then place vehicle on charge for twelve hours with onboard charger Balance batteries by individual charging them with the Smart DP chargers the place vehicle on charge for twelve hours with onboard charger Does all batteries pass the Micro 490 tester set at 5500 Remove and replace battery module refer to battery pack synchronization and recovery section TB 7094 A PAGE 13
21. ny voltage present Repeat steps 4b and 4c of DVOM reads more than 0 volts 5 Disconnect all battery cables from the threaded terminals 6 Connect the Micro 490 to the lead doughnut of the battery terminal The battery must be charged for the Micro 490 to properly test the battery Do not test connecting the tester clamp to the stainless steel stud or nut NOTE CLAMP ON EITHER THE LEAD DONUT AT THE BASE OF THE THREADED STUD OR THE BATTERY CABLE EYELET DO NOT CLAMP ON THE THREADED STUD OR THE NUT THE STUD AND NUT ARE NOT RELIABLE CONDUCTORS AND TEST RESULTS WILL NOT BE ACCURATE PAGE 3 Article 03 8 6 Cont d 7 bad battery is found record the indictment codes on the repair order as they are required for payment of the warranty claim 8 If replacing an individual battery module is required the pack must be balanced to top of charge Refer to the battery balancing section of the TSB for instructions BATTERY PACK BALANCING AND RECOVERY The DPI smart charger must be used to balance and recover battery packs The DPI smart charger is an advanced full featured charger It has an intelligent microprocessor that performs scientific calculations also called an Algorithm to determine the batteries state of charge It monitors the battery terminal s voltage and charge current change with respect to time where other chargers simply monitor a battery s terminal voltage against an internally p
22. reset voltage level and then always incorrectly displays a CHARGED indication once the battery terminal voltage has reached a certain level which occurs when your battery s state of charge is only at approximately 40 to 75 DPI Contact Information Diversified Power International 414 Century Court Piney Flats TN 37686 USA 423 538 9002 NOTE BATTERY PACK RANGE MAY DECREASE INITIALLY AFTER REPLACING BALANCING OR RECOVERING BATTERIES HOWEVER THE RANGE SHOULD INCREASE AFTER APPROXIMATELY 4 6 FULL BATTERY PACK DISCHARGES AND CHARGES Procedure For Smart DPI Charging All the batteries must be balanced by fully charging each battery to TOC even when replacing individual modules If all batteries are not balanced at TOC the pack will have diminished range and may fail within several months Follow the procedure to balance the battery pack 1 Remove the front seat bottom cushion 2 Turn SDS Service Disconnect Switch OFF PAGE 4 3 Check pack voltage if pack voltage is under 20 volts continue to Step 4 If the voltage is over 20 volts charge the vehicle for 12 hours with the on board charger Refer to the charger troubleshooting section of the Service Manual if the pack voltage does not rise within 15 minutes after the charger is plugged in NOTE IT IS NOT NECESSARY TO REMOVE THE H FRAME OR PARK BRAKE LEVER AND CABLE 4 Remove front seats 5 Remove the front stanchion cover 6
23. second or third year of vehicle warranty when battery coverage is pro rated the customer may choose to accept some reduced range and delay pack replacement until absolutely necessary Article No 03 8 6 Cont d Battery Capacity Mileage range of the neighbor is determined by customer driving cycle and battery capacity and is not directly related to voltage A neighbor battery may test above 12 volts yet still have poor capacity Capacity is analogous to the size of the fuel tank in an internal combustion vehicle Battery capacity is affected by temperature see Figure 5 and changes as batteries age It is also affected by the rate of discharge The faster the batteries are discharged the less battery capacity is available and the faster the batteries will be recharged The more slowly the batteries are discharged the more pack capacity is used and the longer it will take to recharge the batteries Battery capacity increases for about the first 75 to 150 cycles of a flooded battery and the first 25 to 75 cycles of a gel battery After the capacity peak is reached the battery pack stabilizes and then capacity begins to decline Battery maintenance and charging habits directly impact peak capacity and the point in time when peak capacity is reached Proper maintenance and regular charging will increase time to peak as well as peak capacity After battery capacity has stopped increasing which is estimated to take approximately 90
24. t to the front of the fuse holder and it is labeled DC DC g The DVOM will display any voltage present Repeat Steps 6f and 6g if DVOM reads more than 0 volts 7 Disconnect all battery cables from the threaded terminals 8 Check each battery with a voltmeter for reversed polarity if reversed polarity is found scrap battery immediately NOTE DO NOT CHARGE ANY BATTERIES THAT HAVE REVERSED POLARITY 9 Check each individually battery module voltage if battery voltage varies more than 2V the batteries must be balanced to the TOC with the Smart DPI chargers NOTE BATTERY MODULE VOLTAGE MUST BE A LEAST 3VDC FOR THE SMART DPI CHARGER TO INITIATE CHARGE 10 Connect the DPI smart battery charger to each battery s lead doughnut then plug charger in follow charging instructions from the DPI charger manufacture 11 Allow the charger to run the diagnostics 12 If the light stays red the battery is either at too low of voltage or has reversed polarity 13 If within 2 5 minutes the light turns yellow or flashing yellow this means the charger is charging 14 Charge the battery until the light turns green approximately 8 12 hours 15 When batteries are fully charged disconnect the power to the chargers and then disconnect the terminal clips and remove the chargers 16 Reconnect the battery cables 107 132 Lb in 12 15 Nem and check the pack voltage 17 Power up the vehicle to verify running st
25. ttery pack and charges the battery pack In the second and third stages the voltage is regulated and the charging is completed The battery pack is maintained at full state of charge in the fourth stage If the vehicle is left connected to the charger the charger will automatically reinitiate a new charge cycle every 28 days The rate at which the battery pack charges will vary depending on the type of batteries installed To ensure a fully charged battery pack the vehicle should be charged continuously and uninterrupted for 12 hours The instrument cluster battery type ICON must be set for the type of batteries that are installed in the vehicle to prevent excessive charge time or damage to the batteries The battery charger should only be operated with the supplied GFCI charger cord it will send a signal to the instrument cluster gauge The instrument cluster gauge will then display the charging indicator ICON if the SDS in and will prevent the vehicle from being driven ON BOARD CHARGER OPERATION 1 If battery pack voltage is above 63V at plug in charger will charge at full 10A rate normal operation 2 If battery pack voltage is below 63V at plug in deep discharge condition charger will charge at 2A for 3 hours At completion of Step 2 at charge of 2A for 3 hours the charger will check battery pack voltage and determine next charging sequence a If battery pack voltage is below 50V charger will shut do
26. wn error condition b If battery pack voltage is between 50V and 63V charger will charge at 4A for 2 more hours If battery pack voltage is greater than 63V charger will begin a normal charge cycle at 10A PAGE 7 Article 03 8 6 Cont d At completion of Step 4b at charge of 4A for 2 hours the charger will check battery pack voltage and determine next sequence If voltage is below 63V charger will shut down error condition If voltage is greater than 63V charger will begin a normal charge cycle at 10A NOTE IF THE CHARGER SHUTS DOWN FOR AN ERROR IT IS POSSIBLE TO UNPLUG AND REPLUG THE CHARGER TO RESET THE CHARGE CYCLE WARNING DO NOT CHARGE THE BATTERIES WITH THE WEATHER ENCLOSURE CLOSED OR THE VEHICLE COVER IN PLACE A BUILD UP OF HYDROGEN GAS CAN RESULT WHICH CAN EXPLODE THE CHARGING AREA SHOULD BE WELL VENTILATED VEHICLE RANGE CONCERNS Check each individual battery and make sure they are all within 2V of each other If they are not within 2V check each battery with the Micro 490 by connecting to the lead doughnut if one or more are bad replace with new batteries Balance all batteries by individually charging each of them with the DPI smart charger reference the battery pack balancing section for instruction PAGE 8 Factors Affecting Mileage Range Of The Vehicle The battery pack will decrease in capacity over time resulting in decreased mileage range This is a chara
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