Webasto DVS300 Installation Manual
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Webasto DVS300 Installation Manual

Webasto DVS300 Installation Manual

Intelligent fast-charging system
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Intelligent Fast-Charging System
Ground Support Equipment (GSE)
Installation Guide for the
DVS300/330/400
and
MVS330/400

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Summary of Contents for Webasto DVS300

  • Page 1 Intelligent Fast-Charging System Ground Support Equipment (GSE) Installation Guide for the DVS300/330/400 MVS330/400...
  • Page 2 GSE Installation Guide for the DVS300/330/400 and MVS330/400 © 2023 Webasto Charging Systems, Inc. All rights reserved PosiCharge™ systems is a product line of Webasto Charging Systems, Inc. (WCSI). Webasto and the Webasto logo are trademarks of WCSI. Corporate names, trademarks, registered trademarks, service marks, symbols, and logos stated herein are the property of the respective companies.
  • Page 3 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Revision History Date Revision Author(s) Reviewer(s) Change(s) 06-16-2021 Ameena Jamaal Charles Degroff and Michael Nathan 10/10/22 Ron Nordyke Ken Choi and Herman Montano 31504-76-0101 Page iii of vi Webasto Charging Systems, Inc.

  • Page 4: Table Of Contents

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Contents Safety Precautions–Read before Using ..................7 1.1. Symbol Usage ........................7 1.2. Safety Instructions ......................... 7 2. General Information ........................10 2.1. Scope ..........................10 2.2. Provided Equipment ......................10 2.3.
  • Page 5 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Figures Figure 1 DVS300/330/400 ..........................14 Figure 2 MVS330/400............................14 Figure 3 DVS300/330/400 Dimensions and Installation ..................15 Figure 4 Weight, Dimensions, and Center of Gravity ..................16 Figure 5 Dimensions and Installation of a Power Station on a Stand ............... 17 Figure 6 DVS300/330/400 Power (Conduit Entry) Locations ................
  • Page 6 GSE Installation Guide for the DVS300/330/400 and MVS330/400 Tables Table 1 System Configurations .......................... 12 Table 2 DVS300 Input and Output Power Characteristics ................. 23 Table 3 DVS330 Input and Output Power Characteristics .................. 24 Table 4 DVS400 Input and Output Power Characteristics ................. 25 Table 5 MVS/330/400 Auxiliary AC Output Characteristics ................

  • Page 7: Safety Precautions-Read Before Using

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 1. Safety Precautions–Read before Using The ground support equipment (GSE) (charger power station[s] and power server: the unit) is designed with user safety as the highest priority. Installation, however, must comply with all local codes; and the following safety precautions must be read and observed.
  • Page 8 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 DANGER ELECTRIC SHOCK CAN KILL • Touching live electrical parts can cause fatal shocks or severe burns. • The battery terminals are always electrically live, and the output circuit is live whenever the battery is connected or being charged.
  • Page 9 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 WARNING IMPROPER INSTALLATION CAN CAUSE FIRE • Do not install or place the unit on, over, or near combustible surfaces. • Do not install the unit near flammable items.

  • Page 10: General Information

    WCSI PN Title 31504-03 Intelligent Fast-Charging System Ground Support Equipment (GSE) Operation and Maintenance Manual for the DVS300/330/400 and MVS330/400 31504-76-0101 Page 10 of 40 Webasto Charging Systems, Inc.

  • Page 11: Acronyms, Abbreviations, And Symbols

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 2.5. Acronyms, Abbreviations, and Symbols Acronym, Abbreviation, or Symbol Meaning Amp(s) or Ampere(s) ANSI American National Standards Institute American Wire Gauge California Energy Commission Direct Current Dual Vehicle System...

  • Page 12: Overview

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 3. Overview 3.1. System Configurations The charger power station and power server (i.e., dual vehicle system [DVS]) can be configured as a complete stand-alone, two-port 30-, 33-, or 40-kW fast-charging system (charger power station) by connecting utility power (a power server) and securing the unit to the floor.
  • Page 13 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Number of Power (Charger) Number Unit Unit Constituents Options Power of Ports Stations Option 1 DVS System 40-kW MVS400 parallel • One power station with two ports (DVS top)

  • Page 14: Specifications

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Charger Charger power Ports power stations Ports station Ports Power server Power server Figure 1 DVS300/330/400 Figure 2 MVS330/400 3.2. Specifications 3.2.1. Physical Characteristics of GSE Component Height Width Depth Weight DVS 300/330/400 60″...

  • Page 15: Figure 3 Dvs300/330/400 Dimensions And Installation

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 3.2.3. DVS300/330/400 Figure 3 illustrates the physical characteristics of, and clearance requirements for, the DVS300/330/400. Figure 3 DVS300/330/400 Dimensions and Installation 31504-76-0101 Page 15 of 40 Webasto Charging Systems, Inc.

  • Page 16: Figure 4 Weight, Dimensions, And Center Of Gravity

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 3.2.4. Power Station Figure 4 illustrates the physical characteristics of the power station. Figure 4 Weight, Dimensions, and Center of Gravity 31504-76-0101 Page 16 of 40 Webasto Charging Systems, Inc.

  • Page 17: Figure 5 Dimensions And Installation Of A Power Station On A Stand

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 3.2.5. Power Station on a Stand Figure 5 illustrates the physical characteristics and clearance requirements of the power station on a stand. Figure 5 Dimensions and Installation of a Power Station on a Stand...

  • Page 18: Installation Instructions

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4. Installation Instructions Only authorized installers or authorized repair persons perform installation, maintenance, and repair work on the unit. NOTE EQUIPMENT ACCESS Be sure to use the proper size driver bits when removing or installing screws to avoid stripping the heads.

  • Page 19: Power Station

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.2. Power Station 4.2.1. The conduit size is 2½″ for all DC output connections, for which 2½-inch threaded hubs are provided. (See Figure 7 [B] for conduit entry locations.)

  • Page 20: Power Station Mounting To A Wall

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.3. Power Station Mounting to a Wall 4.3.1. Each power station has the wall mounting back plate installed on the back side. Figure 8 shows how to mount the plate to a wall.

  • Page 21: Power Station Mounting To A Pedestal Stand

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.4. Power Station Mounting to a Pedestal Stand 4.4.1. Each power station has the wall mounting back plate installed on the back side. Figure 9 illustrates the power station pole mounting back plate assembly.

  • Page 22: Figure 10 Cable Management Pole Assembly Installation

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.4.2. Follow the instructions per Figure 10 to install the cable management pole assembly. NOTE The installation kit provides the anchor bolts. Figure 10 Cable Management Pole Assembly Installation...

  • Page 23: Wiring

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.5. Wiring 4.5.1. General Guidelines 4.5.1.1. See Table 2, Table 3, Table 4, Table 5, and Table 6 for input/output parameters. 4.5.1.2. See Figure 11 for the DVS input/output wiring. See Figure 12 for the field wiring. See Figure 13 for the suggested power station wire routing.

  • Page 24: Table 3 Dvs330 Input And Output Power Characteristics

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Table 3 DVS330 Input and Output Power Characteristics Parameter DVS330 MVS330 Input Voltage 380/400 VAC Input Frequency 50/60 Hz Number of Input Phases (Excluding Ground) Three Minimum Circuit Breaker Inrush Rating...

  • Page 25: Table 4 Dvs400 Input And Output Power Characteristics

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Table 4 DVS400 Input and Output Power Characteristics Parameter Value Value Input Voltage 480 VAC 600 VAC Input Frequency 60 Hz 60 Hz Number of Input Phases (Excluding Ground)

  • Page 26: Table 5 Mvs/330/400 Auxiliary Ac Output Characteristics

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Table 5 MVS/330/400 Auxiliary AC Output Characteristics Output voltage 120 VAC Output current 4.2A Minimum conductor size 14 AWG Terminal screw size Minimum wiring terminal torque Reference National Electrical Code. ANSI/NFPA 70.1999...

  • Page 27: Figure 11 Mvs330/400 Wiring Diagram, Detailed View Of The Wiring Compartment

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 See Tables 3–7 for wiring size and type. Figure 11 MVS330/400 Wiring Diagram, Detailed View of the Wiring Compartment 31504-76-0101 Page 27 of 40 Webasto Charging Systems, Inc.

  • Page 28: Figure 12 Power Station Field Wiring Diagram

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 See Tables 6 and 7 for installation data. Figure 12 Power Station Field Wiring Diagram 31504-76-0101 Page 28 of 40 Webasto Charging Systems, Inc.

  • Page 29: Figure 13 Power Station Wire Routing Diagram

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 SUGGESTED WIRE ROUTING FOR POWER WIRING WIRE ROUTING AND CABLE CLAMPS FOR COMMUNICATION CABLES Figure 13 Power Station Wire Routing Diagram 31504-76-0101 Page 29 of 40 Webasto Charging Systems, Inc.

  • Page 30: Grounding

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.5.2. Ground Wire 4.5.2.1. The ground wire is green or green with a yellow stripe and attached to the provided compression lug. 4.5.3. Output Wire 4.5.3.1. See Table 2, Table 3, Table 4, Table 5, Table 6, and Table 7 for the wiring size (American wire gauge [AWG]) and additional information.

  • Page 31: Figure 14 Mvs330/400 Wiring Diagram

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.7.3. Wires, including shield terminations, shall be lugged using an insulated ring lug with a No. 6 hole. 4.7.4. Control Cables 4.7.4.1. Control cables run only from the server to the DVS power station (main station).

  • Page 32: Euro Hub Connector Installation

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.8. Euro Hub Connector Installation 4.8.1. Parts Included Figure 15 numbers the eight included parts as follows. 1. Threaded cap 2. Stainless steel washer 3. Rubber grommet 4. Hub connector body 5.

  • Page 33: Figure 16 Electrical Connections For The Euro Hub Connector Installation

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.8.2.7. Connect the large power lugs to the terminal posts (Figure 16). Figure 16 Electrical Connections for the Euro Hub Connector Installation 4.8.2.8. Connect the small communication lugs to the terminal strips (Figure 16). Wires, as well as the plug and the Euro hub connector receptacle, are numbered to match the labeling on the power station.
  • Page 34 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.8.2.14. For the DVS330 (09910-351) with IP55 Apply Sealant filters only: To help prevent water and moisture intrusion into the charger, apply clear silicone sealant (Webasto P/N 04068-M or Dowsil 732 RTV Clear) where the cables enter into the grommet.

  • Page 35: Burton® Hub Connector Installation

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.9. Burton® Hub Connector Installation 4.9.1. Parts Included Figure 19 numbers the six included parts as follows. 1. Threaded cap 2. Washer (included inside the hub connector assembly) 3. Split rubber grommet 4.

  • Page 36: Figure 20 Electrical Connections For The Burton® Hub Connector Installation

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.9.2.8. Connect the large power lugs to the terminal posts. (Figure 20). 4.9.2.9. Connect the small communication lugs to the terminal strips (Figure 20). Wires, as well as the plug and the Burton®...

  • Page 37: Figure 21 Rubber Grommet Installation On The Cables

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.9.2.11. The grommet should be placed on the cables as close to the feedthrough as possible, with the tapered side facing the hub connector body (4) (Figure 21). 4.9.2.12. Push the split rubber grommet (3) into the hub connector body (4), making sure that the two halves line up and that there are no large gaps (Figure 22).

  • Page 38: Cec Efficiency Compliance

    Commission (CEC) Appliance Efficiency standards for large battery chargers. 4.11. Initial Startup Please see the Intelligent Fast-Charging System, Ground Support Equipment (GSE) Operation and Maintenance Manual for the DVS300, DVS330, DVS400, MVS330, and MVS400 (WCSI PN 31504-03), for initial startup instructions.

  • Page 39: Installation And Operational Checkout

    Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 4.12. Installation and Operational Checkout Installation and Operational Checkout Main DVS Auxiliary Auxiliary Auxiliary Serial # Serial # Serial # Serial # _ _ _ _ _ _ _ _ _ _...
  • Page 40 Intelligent Fast-Charging System GSE Installation Guide for the DVS300/330/400 and MVS330/400 Webasto Charging Systems, Inc. 1333 South Mayflower Avenue, Suite 210 Monrovia, CA 91016 1–866–767–4242 | info@posicharge.com | @posicharge | posicharge.com Corporate headquarters: Friedrichshafener Str. 9 82205 Gilching Germany 31504-76-0101 Page 40 of 40 Webasto Charging Systems, Inc.

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