Excessive Power Dissipation on DC Path

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Too much power dissipation (heat loss) is detected on the DC charging path. This indicates abnormally high resistance in series with the battery, potentially in cables, connectors, or internal components, leading to energy loss and heating.

• Loose, corroded, or damaged connections in the DC charging path (e.g., at battery terminals, charger output, or cable splices).
• Undersized or damaged charging cables that have insufficient current carrying capacity or excessive resistance.
• An internal fault within the charger's DC components or unusually high internal resistance within the battery itself.

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1. 1

   Inspect all DC cable connections for tightness, signs of corrosion, discoloration, or localized overheating.

2. 2

   Verify the gauge and integrity of the DC charging cables, ensuring they are adequately sized for the maximum charging current.

3. 3

   Measure voltage drop across connectors and cable sections during charging to pinpoint areas of abnormally high resistance.