Webasto DVS 400 Operation And Maintenance Manual
Gse intelligent fast charging systems
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Summary of Contents for Webasto DVS 400
- Page 1 Operation and Maintenance Manual GSE Intelligent Fast Charging Systems DVS 400 English 09190-W-03-01.docx...
- Page 2 © 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.
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Page 3: Table Of Contents
DVS 400 Fast Charging System Operation and Maintenance Manual Table of Contents Table of Contents ............................3 List of Figures ..............................4 List of Tables ..............................4 Overview ..............................6 Getting Started ............................ 6 Applicable Documents ........................7 Safety Precautions - Read before using ....................8 Symbol usage ............................. -
Page 4: List Of Figures
DVS 400 Fast Charging System Operation and Maintenance Manual List of Figures 1.1. DVS 400 F ....................6 IGURE HARGING YSTEM 5.1. S ........................12 IGURE TART UP CREENS 5.2. C ..................... 13 IGURE ONNECTING TATUS CREENS 5.3. F ........................14... - Page 5 DVS 400 Fast Charging System Operation and Maintenance Manual This Page Left Intentionally Blank 09190-W-03-01 Page 5 of 27 Webasto Charging Systems, Inc.
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Page 6: Overview
DVS 400 Fast Charging System Operation and Maintenance Manual 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. -
Page 7: Applicable Documents
DVS 400 Fast Charging System Operation and Maintenance Manual 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. -
Page 8: Safety Precautions - Read Before Using
DVS 400 Fast Charging System Operation and Maintenance Manual Safety Precautions - Read before using Symbol usage Throughout this manual, take special note of the information marked with the following symbols: Contains information about safety practices necessary to prevent personal injury or DANGER death. -
Page 9: Technical Support
DVS 400 Fast Charging System Operation and Maintenance Manual • 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. -
Page 10: System Description
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. -
Page 11: Options And Accessories
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. -
Page 12: Operation
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. -
Page 13: < C H A R G I N G
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. -
Page 14: 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. -
Page 15: Equalization
DVS 400 Fast Charging System Operation and Maintenance Manual 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. -
Page 16: Data Logs, Charger Configuration And Advanced Programming Features
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. -
Page 17: Figure 5.7. Top Level Menu For Figure 6.1 Correct Pina
DVS 400 Fast Charging System Operation and Maintenance Manual ANY STATUS OR CHARGING SCREEN SELECT Review charge data ENTER Charge Event Log f the last 200 charge SELECT Fault/Warning Log ENTER Review data from the 100 fault or warning events... -
Page 18: External Status Indicator Configuration (Optional)
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. -
Page 19: Troubleshooting
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. -
Page 20: Esd Precautions
DVS 400 Fast Charging System Operation and Maintenance Manual 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. - Page 21 DVS 400 Fast Charging System Operation and Maintenance Manual Symptom Probable cause(s) Action Battery doesn’t last full shift Algorithm/capacity mismatch Incorrect equalization schedule Batteries are under watered Bad cell within pack Bad BMID Premature disconnection of charge cable Battery water usage too high...
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Page 22: Fault Messages
DVS 400 Fast Charging System Operation and Maintenance Manual 6.2.5 Fault Messages Table 6.2 Fault Codes and Action Key Code Fault Messages Description Action OS System Failure Power on self test/OS failure Logic Supply Failure Logic power supply failure ADC Failure... - Page 23 DVS 400 Fast Charging System Operation and Maintenance Manual Code Fault Messages Description Action PS2 Undercurrent Powerstage #2(port B) current too low PS2 Trans Failure Powerstage #2(port B) transistor failure PS2 General Failure Powerstage #2(port B) current sensor fault PS2 Overtemp Failure...
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Page 24: Actions
BMID interfaces on the original charge port. 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. - Page 25 400 current sensors, verify that the DVS 400 contactors are closing and check for loose connections. If the DVS 400 contactors are not closing check/replace relays K1 to K4 on the control board or the drivers U10 and U71. Replace the control board if required.
- Page 26 Correct any problems found with the standoffs and cycle power to the DVS 400. If this does not correct the problem, replace the door assembly. Burned out LED’s usually indicate a damaged membrane. Replace the door assembly.
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Page 27: Charge Termination Codes
DVS 400 Fast Charging System Operation and Maintenance Manual 6.2.7 Charge Termination Codes The following table should be used to interpret charge termination codes. Table 6.3 Charge Termination Codes Code Message Description INVALID BATTERY VOLTAGE Fast Charge, Amp-hours exceeded SOC OVER START LIMIT...