Webasto PosiCharge DVS 300 Operation And Maintenance Manual
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Webasto PosiCharge DVS 300 Operation And Maintenance Manual

Gse intelligent fast charging systems
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Operation and Maintenance Manual
GSE Intelligent Fast Charging Systems
DVS 300
ENGLISH
23411-W-03-01

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Summary of Contents for Webasto PosiCharge DVS 300

  • Page 1 Operation and Maintenance Manual GSE Intelligent Fast Charging Systems DVS 300 ENGLISH 23411-W-03-01...
  • Page 2 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.

  • Page 3: Table Of Contents

    How to Use This Section ..................19 6.2.2 ESD Precautions ....................19 6.2.3 Problem Symptoms and Action Key ..............19 6.2.4 Fault Messages ....................22 6.2.5 Actions ......................... 25 6.2.6 Charge Termination Codes ................. 29 23411-W-03-01 Page 3 of 29 Webasto Charging Systems, Inc.

  • Page 4: List Of Figures

    ABELS AND EANINGS 6.1 - P ............. 20 ABLE ROBLEM SYMPTOMS AND CTION 6.2 - F ................ 22 ABLE AULT ODES AND CTION 6.3 - C ................. 29 ABLE HARGE ERMINATION ODES 23411-W-03-01 Page 4 of 29 Webasto Charging Systems, Inc.

  • Page 5: Getting Started

    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. 23411-W-03-01 Page 5 of 29 Webasto Charging Systems, Inc.

  • Page 6: Applicable Documents

    BEFORE  Only qualified personnel, familiar with the local code, should install and service this charger. BEGIN  Read and understand the manufacturer’s instructions and your employer’s safety practices manual. 23411-W-03-01 Page 6 of 29 Webasto Charging Systems, Inc.
  • Page 7  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. 23411-W-03-01 Page 7 of 29 Webasto Charging Systems, Inc.

  • Page 8: Technical Support

    Call us for technical support any time a procedural question arises. DO NOT perform a procedure you do not understand. The service desk can be contacted during normal working hours (Pacific Standard Time) by contacting Customer Service at: info@posicharge.com 866-POSICHARGE (866-767-4242). 23411-W-03-01 Page 8 of 29 Webasto Charging Systems, Inc.

  • Page 9: System Description

    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”). 23411-W-03-01 Page 9 of 29 Webasto Charging Systems, Inc.

  • Page 10: Options And Accessories

    65%. Fast charging also increases productivity by eliminating down time for battery changing and avoiding low voltage operation that can reduce vehicle performance. 23411-W-03-01 Page 10 of 29 Webasto Charging Systems, Inc.

  • Page 11: System Start Up

    The system will power up for 10 minutes after the system three-phase AC power is first turned on even without a vehicle connected. A menu item in the master power station can activate a temporary override of the energy saving mode shut down (see section 5.8). 23411-W-03-01 Page 11 of 29 Webasto Charging Systems, Inc.

  • Page 12: Charging

    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) 23411-W-03-01 Page 12 of 29 Webasto Charging Systems, Inc.
  • Page 13 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. 23411-W-03-01 Page 13 of 29 Webasto Charging Systems, Inc.

  • Page 14: Equalization

    Always run a full equalization charge prior to a fast charge on any battery CAUTION pack that has had a cell replaced to ensure the pack is balanced. 23411-W-03-01 Page 14 of 29 Webasto Charging Systems, Inc.

  • Page 15: Full / Over Charging

    During a charge, the screen will say "Charging" and the data will be updated periodically. See Figure 5.5. < C h a r g i n g 5 3 % Figure 5.5 - Representative Charging Data Screens 23411-W-03-01 Page 15 of 29 Webasto Charging Systems, Inc.

  • Page 16: Data Logs, Charger Configuration And Advanced Programming Features

    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”. 23411-W-03-01 Page 16 of 29 Webasto Charging Systems, Inc.
  • Page 17 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. 23411-W-03-01 Page 17 of 29 Webasto Charging Systems, Inc.

  • Page 18: External Status Indicator Configuration (Optional)

    Use only connectors and cable that are rated for the full continuous WARNING current rating of the unit. If you have questions regarding a specific cable assembly or need to obtain documents, please contact Customer Service. 23411-W-03-01 Page 18 of 29 Webasto Charging Systems, Inc.

  • Page 19: Troubleshooting

    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 23411-W-03-01 Page 19 of 29 Webasto Charging Systems, Inc.
  • Page 20 Loss of communication line Bad cell within pack Algorithm/capacity mismatch Charger overheating Incorrect BMID configuration Charger works Loose input or output wiring intermittently Loose BMID connections Low local utility voltage Corrosion of internal components 23411-W-03-01 Page 20 of 29 Webasto Charging Systems, Inc.
  • Page 21 Loose Sheet metal Loose Fan blade or mount Noisy Transformer Miswiring of AC input Excess fumes during Algorithm overcharging batteries charging Underwatered batteries History files incorrect Bad or noisy control board Bad BMID 23411-W-03-01 Page 21 of 29 Webasto Charging Systems, Inc.

  • Page 22: Fault Messages

    DCBus VDC Too Low Common DC Bus Voltage Too Low DCBus VDC Too High Common DC Bus Voltage Too High Charger Power Available power is cutback due to Reduced heat 23411-W-03-01 Page 22 of 29 Webasto Charging Systems, Inc.
  • Page 23 Chrg Vdc Port B High Battery voltage too high for charger BMID B Vbat Too Low Battery voltage too low for BMID BMID B Vbat Too High Battery voltage too high for BMID 23411-W-03-01 Page 23 of 29 Webasto Charging Systems, Inc.
  • Page 24 Failure on Port B Vbat Mismatch on Port BMID and terminal voltages don’t match Battery Battery excessively discharged Overdischarged on Port B Early Charge Charge terminated unexpectedly Termination on Port B 23411-W-03-01 Page 24 of 29 Webasto Charging Systems, Inc.

  • Page 25: Actions

    (SOC) mismatch within the pack, which will prevent the pack from charging properly. Before running a fast charge, make sure you run a long 23411-W-03-01 Page 25 of 29 Webasto Charging Systems, Inc.
  • Page 26 Using insulated gloves and tools, check the torque on all bolted interconnects and power cables, and verify that welded interconnects have not loosened. Tighten all screws and fasteners as needed. 23411-W-03-01 Page 26 of 29 Webasto Charging Systems, Inc.
  • Page 27 Exposure to excessive moisture or corrosive environments may cause intermittent faults. Corroded parts should be replaced. Use the Charger Configuration menu to clear the ‘Battery Backed RAM’. (Note: Disconnecting the backup battery to the computer board automatically sets this fault. 23411-W-03-01 Page 27 of 29 Webasto Charging Systems, Inc.
  • Page 28 Reseat the power stage Temp Sense connectors. Check the heat sink thermistors (Resistance should be greater than 60K ohms). Connect a vehicle to any charging port to wake system up from energy-saving shutdown. 23411-W-03-01 Page 28 of 29 Webasto Charging Systems, Inc.

  • Page 29: Charge Termination Codes

    EQ, battery temp limit exceeded EQ BMID COM LOST EQ, BMID communications lost EQ TIME LIMIT EQ, time limit exceeded EQ USER STOP EQ, user stopped (stop button or disconnected) EQ COMPLETED EQ, normally completed 23411-W-03-01 Page 29 of 29 Webasto Charging Systems, Inc.

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