Webasto PosiCharge DVS Field Service Manual
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Webasto PosiCharge DVS Field Service Manual

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GSE DVS FIELD SERVICE MANUAL
Webasto Charging Systems, Inc.
09030-78B

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Summary of Contents for Webasto PosiCharge DVS

  • Page 1 GSE DVS FIELD SERVICE MANUAL Webasto Charging Systems, Inc. 09030-78B...
  • Page 2 DVS/GSE Field Service Manual Configuration Management Change Description Date 5297 New release 2/12/04 Revised 03/18/22 Webasto Charging Systems, Inc. 09030-78B...

  • Page 3: Table Of Contents

    CHARGING CABLE AND DATA WIRES...............32 3.3.1 Inspecting Cables, Wires and Connectors ..............32 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 Webasto Charging Systems, Inc. 09030-78B...
  • Page 4 Table 2 Fault Codes and Action Key...................14 Table 3. Charge Termination Codes ..................22 Table 4. Power Supply Cabinet Fie ld Replaceable Parts............36 Table 5. Transformer T3 Expected Voltages..............40 Table 6. Relay System Test Points and Expected Values............45 Webasto Charging Systems, Inc. 09030-78B...

  • Page 5: Symbol Usage

    • The unit must be grounded properly with a grounding conductor of size equal to or larger than that recommended by local electrical codes or the installation section of this manual. • Do not touch the uninsulated portion of the output battery connector or an uninsulated battery terminal. Webasto Charging Systems, Inc. 09030-78B...
  • Page 6 Use only on circuits provided with the minimum wire size specified in the installation section. • Protective bollards should be installed where charging equipment location is subject to damage from vehicle activity. Webasto Charging Systems, Inc. 09030-78B...

  • Page 7: General Information

    GENERAL INFORMATION SCOPE This manual is intended to be used by Webasto trained service personnel to assist in the maintenance, dia gnosis, and troubleshooting of the dual vehicle charging system. At no time should troubleshooting be attempted by any person who has not completed Webasto Service Personnel training as there is risk of personal injury or death.

  • Page 8: List Of Terms And Acronyms

    Advanced Features and BMID Programming Manual 06900-01* PowerStation Block Diagram 08500-01 DVS Block Diagram 08750-20* Assembly, Charger, Dual Port – Drawing Package * Documents followed by an asterisk are included in this manual in Appendix A. Webasto Charging Systems, Inc. 09030-78B...

  • Page 9: List Of Equipment

    Bleed down resistor (300Ω, 10W) with Systems, Inc. alligator clips PLCC extraction tool Chip extraction tool Hex wrench, 1/8” Delphi pin extractor 18AWG jumper cable with alligator clips, 6" long PC compatible laptop with hyperterminal --- Webasto Charging Systems, Inc. 09030-78B...

  • Page 10: System Overview

    The DVS works with small monitoring devices mounted on the batteries called the battery monitor/identifier (BMID). The BMID enables the charger to automatically adjust the charge to match the requirements of all of the batteries in your fleet without needing to worry about matching batteries and chargers. Webasto Charging Systems, Inc. 09030-78B...

  • Page 11: System Troubleshooting Guide

    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. Webasto Charging Systems, Inc. 09030-78B...

  • Page 12: Problem Symptoms And Action Key

    Cable undersized for length and current too warm during charge Connector underrated for current Bad crimp or connection within connector Short in output cables Bad cell within pack Battery doesn’t last full shift Algorithm/capacity mismatch Incorrect equalization schedule Webasto Charging Systems, Inc. 09030-78B...
  • Page 13 Utility circuit breaker trips Rectifier short, MOV failure or improper 3.4.9 during operation or on system assembly of main capacitors power-up System not charging and Fuse F3 blown 3.4.4 clicking noise from Power Supply cabinet Webasto Charging Systems, Inc. 09030-78B...

  • Page 14: Fault Messages

    Utility Failure PowerServer Utility Input Out of Range Internal Failure PowerServer Internal Hardware Failure 3.4.10 Power Imbalance Power Stage power imbalance in 500A mode Invalid Pilot on Port A Battery connected with invalid pilot 3.2.3 circuit Webasto Charging Systems, Inc. 09030-78B...
  • Page 15 BMID temp sensor out of valid range Failure on Port B Vbat Mismatch on Port B BMID and terminal voltages don’t match Battery Overdischarged Battery excessively discharged on Port B Early Charge Charge terminated unexpectedly 2.7.6 Termination on Port B Webasto Charging Systems, Inc. 09030-78B...

  • Page 16: Actions

    This component may be replaced by a qualified service technician. Refer to the section listed in the right column for more information. Contact Webasto Customer Service for availability of spare parts. At utility power disconnect box, measure voltage between phases and confirm that all measurements are within acceptable range of nominal voltage.
  • Page 17 (Note: Use of ventilated battery packs and/or fans may be required in certain applications. Contact Webasto Customer Service). If a cell within a pack is failing, or a failed module has been replaced with a new module, there will be a state of charge (SOC) mismatch within the pack which will prevent the pack from charging properly.
  • Page 18 USE EXTREME CAUTION WHEN TROUBLESHOOTING the DVS WITH ANY PANEL REMOVED. ELECTRIC SHOCK CAN KILL: Touching live electrical parts can cause fatal shocks or severe burns. The input power circuitry and internal circuits are live whenever input power is on. DANGER Webasto Charging Systems, Inc. 09030-78B...
  • Page 19 If a VBAT MISMATCH error occurs, check the PowerStation cabinet display and observe the voltage. If the voltage looks correct for the battery, the problem is most likely in the high current path or the voltage sense path. Check for continuity throughout Webasto Charging Systems, Inc. 09030-78B...
  • Page 20 USE EXTREME CAUTION WHEN TROUBLESHOOTING the DVS WITH ANY PANEL REMOVED. ELECTRIC SHOCK CAN KILL: Touching live electrical parts can cause fatal shocks or severe burns. The input power circuitry and internal circuits are live whenever input power is on. DANGER Webasto Charging Systems, Inc. 09030-78B...
  • Page 21 I/O board or the RS232 to RS 422 Converter. If, after setting the system for master only, the problem goes away continue adding stations/ports until the problem returns. Check the network wiring from station to station at the point where the fault returned and check/replace the station control board. Webasto Charging Systems, Inc. 09030-78B...

  • Page 22: Charge Termination Codes

    EQ, battery temp limit exceeded 24 EQ BMID COM LOST EQ, BMID communications lost 25 EQ TIME LIMIT EQ, time limit exceeded 26 EQ USER STOP EQ, user stopped (stop button or disconnected) 27 EQ COMPLETED EQ, normally completed Webasto Charging Systems, Inc. 09030-78B...

  • Page 23: Maintenance And Repair

    Access to Top Enclosure 1. Remove the two screws on each side of the lid and the three in front. 2. Remove the lid to gain access to the: a. DC Buss Terminals b. Output Cable Terminals Webasto Charging Systems, Inc. 09030-78B...

  • Page 24: Powerstation Periodic Maintenance

    PowerStation cabinet (as viewed from the front). Your laptop must be configured with Webasto's downloader application. You must also have a serial communication cable to connect from your laptop’s serial port to the connector on the DVS.

  • Page 25: Door Assembly (P/N 07308)

    2. Open door 90° and lift door assembly approximately one inch using even upward force along hinge axis. This will free the door from the two hinge pins on the power station. 3. Reverse these steps to install door assembly. Webasto Charging Systems, Inc. 09030-78B...

  • Page 26: Cooling Fans (P/N 06903)

    To replace: 1. Unplug the AC and DC connectors 2. Compress the locking plastic standoffs and pull off one at a time. 3. Snap the new supply on. 4. Reinstall the AC and DC connections. Webasto Charging Systems, Inc. 09030-78B...

  • Page 27: 15V Power Supply (P/N 08340)

    3. Drill out the rivets using a 3/16" drill bit. 4. Install new terminal using 3/16" rivets with the washers, or by using #10 screws, nuts, washers and lockwashers. 5. Replace power cables. Webasto Charging Systems, Inc. 09030-78B...

  • Page 28: Contactor (P/N 06902)

    1. Unplug the faston connections 2. Remove the mounting screws and remove switch. 3. Reverse these steps to install new switch, adding heatsink compound if needed (there should be a thin film). Webasto Charging Systems, Inc. 09030-78B...

  • Page 29: Control Board (P/N 08067)

    1. Disconnect all cables and note original locations. 2. Disconnect ribbon cable from display. 3. Remove nuts from threaded standoffs. 4. Release snap-on standoff retainers by squeezing gently. 5. Remove board. 6. Reverse these steps to install the board. Webasto Charging Systems, Inc. 09030-78B...

  • Page 30: Display Board (P/N 06457)

    1. Remove the 7/16th nut that mounts the 2/0 cable to the buss bar between the contactors. 2. Remove the 2 phillips head screws 3. Slide the Current Sensor over the lug to remove 4. Reverse these steps to install the sensor Webasto Charging Systems, Inc. 09030-78B...

  • Page 31: Bmid

    The BMID does not operate at all and cannot communicate with the DVS. If the wiring is correct and you still cannot communicate with the BMID from the DVS, the BMID must be replaced. Webasto Charging Systems, Inc. 09030-78B...

  • Page 32: Replacing The Bmid

    3. Using the Delphi pin extractor, remove the White (pin A) and White/Orange (pin B) pins from the Pilot / Data connector. 4. Remove the BMID from the battery and send to Webasto for analysis. 5. Place new BMID in location where failed BMID was installed.

  • Page 33: Power Supply Cabinet

    Gently place rear panel in a safe spot. Figure 2 shows the unit with the rear panel removed. Figure 2. Cabling Between Cabinets Webasto Charging Systems, Inc. 09030-78B...

  • Page 34: Figure 3. Power Supply Cabinet Main Control Panel

    DVS/GSE Field Service Manual CAUTION COVER THE DVS TO KEEP OUT WATER AND PROLONGED DIRECT SUNLIGHT Figure 3. Power Supply Cabinet Main Control Panel Webasto Charging Systems, Inc. 09030-78B...

  • Page 35: Power Supply Cabinet Routine Maintenance

    Check fan operation per section 3.4.8. Check relays K2 and K3 per section 3.4.11. Check MOV1, MOV2 and MOV3 per action RR), page 21. Webasto Charging Systems, Inc. 09030-78B...

  • Page 36: Measuring Line-To-Line Voltage

    If voltages are out of range, turn off power at utility power disconnect box, lock/tag utility disconnect, and measure voltage between phases. If utility voltages do not conform to specifications in WCSI Doc. #08750-10, contact facility electrician. Webasto Charging Systems, Inc. 09030-78B...

  • Page 37: Removal, Test And Replacement Of Fuses

    DVS/GSE Field Service Manual Figure 5. Line-to-Line Test Points 3.4.4 Removal, Test and Replacement of Fuses Figure 6. Fuses F1, F2 and F3 Webasto Charging Systems, Inc. 09030-78B...

  • Page 38: Troubleshooting Main Contactor, K1

    EQUIPMENT WITH ANY PANEL REMOVED. ELECTRIC SHOCK CAN KILL: Touching live electrical parts can cause fatal shocks or severe burns. The input power circuitry and internal circuit s are live whenever input DANGER power is on. Webasto Charging Systems, Inc. 09030-78B...

  • Page 39: Diagnosing Root Cause For Red Fault Light Illumination

    Check continuity of fuses F1 and F3. If either fuse is blown, check internal wiring throughout Power Supply Cabinet, correct any wiring problems, and replace blown fuse. If problem persists, turn utility power on. Using extreme caution, check voltages per the following table: Webasto Charging Systems, Inc. 09030-78B...

  • Page 40: Troubleshooting Thermal Issues

    If one or both fans do not turn on, check all wiring connecting fans to transformer. If wiring and connections appear to be correct, replace the non-functioning fan(s) as follows: • Remove the two screws connecting the fan backing plate to the rear panel. See Figure 9 for detail. Webasto Charging Systems, Inc. 09030-78B...

  • Page 41: Figure 9. Exhaust Fan Detail

    480VAC +/-48VAC. If voltage is outside this range, measure line-to-line utility voltage per 3.4.3. If voltage is within range measure voltage across X1-X3 of transformer T2, which should be 120VAC +/-12VAC. If voltage is outside of this range, replace transformer T2 and re-test. Webasto Charging Systems, Inc. 09030-78B...

  • Page 42: Testing Main Rectifier

    Lock and tag disconnect. Examine rectifier D1 for visible signs of damage. Be sure to look carefully between rectifier fins. Locate AC input cables between main transformer and rectifier D1 per Figure 7, below. There are six of these cables going to D1. Figure 11. Rectifier Connections to Transformer Webasto Charging Systems, Inc. 09030-78B...

  • Page 43: 3.4.10 Troubleshooting Pre -Charge Circuitry

    Next, turn system power on at utility disconnect and re-test per, “System On” values. Unless otherwise noted, “System On” values refer to values present when the system is on and fully functional with the 150VDC bus enabled and the green indicator light on. Webasto Charging Systems, Inc. 09030-78B...

  • Page 44: Figure 13. Relays K2 And K3

    USE EXTREME CAUTION WHEN TROUBLESHOOTING the DVS WITH ANY PANEL REMOVED. ELECTRIC SHOCK CAN KILL: Touching live electrical parts can cause fatal shocks or severe burns. The input power circuitry and internal circuits are live whenever input power is on. DANGER Webasto Charging Systems, Inc. 09030-78B...

  • Page 45: Table 6. Relay System Test Points And Expected Values

    11(9) 12(1) Closed Open If test fails, and K3, A1-A2 shows proper voltage, replace relay assembly 11(9) 14(5) Open Closed If test fails, and K3, A1-A2 shows proper voltage, replace relay assembly Webasto Charging Systems, Inc. 09030-78B...

  • Page 46: 3.4.12 Testing Rectifiers D2 And D3

    Using Diode Test mode on your DMM, measure voltage across the following points on rectifier: DC+ to AC Inputs DC- to AC Inputs If any voltage measurement is less than 0.1VDC, replace rectifier and re-test. Webasto Charging Systems, Inc. 09030-78B...
  • Page 47 DVS/GSE Field Service Manual APPENDIX A The following reference documents are included in this section: WCSI Part No. Document Description Assembly, Top PowerStation, Sheets 12&13 (Block Diagram) 06900-20 Assembly, Charger, Dual Port, DVS 08750-20 Webasto Charging Systems, Inc. 09030-78B...

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