Webasto DVS300 Operation & Maintenance Manual
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Webasto DVS300 Operation & Maintenance Manual

Webasto DVS300 Operation & Maintenance Manual

Intelligent fast-charging system
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Intelligent Fast-Charging System
GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400
Intelligent Fast-Charging System
Ground Support Equipment (GSE)
Operation & Maintenance Manual
DVS300 / 330 / 330 IP55 / 400
MVS330 / 400
31504-03-0101
1
Webasto Charging Systems, Inc.

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Summary of Contents for Webasto DVS300

  • Page 1 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Intelligent Fast-Charging System Ground Support Equipment (GSE) Operation & Maintenance Manual DVS300 / 330 / 330 IP55 / 400 MVS330 / 400 31504-03-0101 Webasto Charging Systems, Inc.
  • Page 2 © Webasto Charging Systems, Inc., 2023. All rights reserved. ProCore is a product line of Webasto Charging Systems, Inc. (WCSI). Webasto Charging Systems and the Webasto Charging Systems 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 Please write down the unit serial number in the Owner’s Record below to ensure superior service, and have it available when contacting Webasto Customer Service. The serial number can be found on the nameplate rating label on the left side of the unit.

  • Page 4: Table Of Contents

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 CONTENTS 1 – SAFETY PRECAUTIONS – READ BEFORE USING ............6 1.2 – Symbol Usage ........................6 1.3 – Safety Instructions......................6 2 – GENERAL INFORMATION ....................9 2.1 –...
  • Page 5 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4.4 – Charging.......................... 20 Figure 7 – Connecting status Windows ................20 Figure 8 – Charge Completed / Stopped Windows ............21 4.5 – Equalization........................22 4.6 –...

  • Page 6: Safety Precautions - Read Before Using

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 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.
  • Page 7 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 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 8 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 DANGER BATTERY GASES AND ELECTROLYTES CAN BE HAZARDOUS • Charging batteries produces fumes and gases that may be hazardous. • Charging batteries may leak corrosive electrolytes that can cause skin and eye irritation, and damage equipment and clothing.

  • Page 9: General Information

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 2 – GENERAL INFORMATION 2.1 – Technical Support Call WCSI technical support any time a procedural question arises. DO NOT perform a procedure you do not understand.

  • Page 10: Acronyms, Abbreviations And Symbols

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 2.3 – Acronyms, Abbreviations and Symbols Acronym, Abbreviation or Symbol Meaning Amp(s) or Ampere(s) BMID Battery Monitor and Identifier Constant Current (Charging Mode) Constant Voltage (Charging Model...

  • Page 11: Overview

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 3 – OVERVIEW 3.1 – System Description The Dual Vehicle System (DVS) 300/330/400 (Figure 1) and the Multi-vehicle System (MVS) 330/400 (Figure 2) are advanced transistor-based, fast-charging systems. These systems can charge industrial batteries quickly and safely, providing all the battery charging and equalizing required for your application.
  • Page 12 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Fast Charging • Dramatically reduces the time it takes to recharge a battery to a high state of charge (SOC). • Makes opportunity charging possible during available breaks, shift changes, and other idle times; and keeps a vehicle running all day long without changing batteries.

  • Page 13: System Function

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 3.2 – System Function Charge Profile The DVS provides a constant current–constant voltage–constant current (I-E-I) charge profile that precisely controls the charge rate, and optimally charges the batteries by precisely adjusting the current in response to the capacity, temperature, and age of the batteries.

  • Page 14: Options And Accessories

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 3.3 – Options and Accessories The following options and accessories are available through your authorized Industrial PosiCharge DVS Fast-Charging System dealer. Contact WCSI customer service directly for any other replacement parts.

  • Page 15: Operation

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4 – OPERATION 4.1 – Getting Started Take the time before you begin to familiarize yourself with section 1.2 Safety Instructions. Perform the following steps to get your system up and running quickly.

  • Page 16: Only For Mvs Setups: Configuring The Main Station And Support Stations

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4.2 – Only for MVS Setups: Configuring the Main Station and Support Stations. The MVS Intelligent Fast-Charging System is very flexible. It requires each new installation to be configured for the total number of power stations in the system.
  • Page 17 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4. Set the control board SW1-4 DIP switch in the DIP switch bank (Figures 4 and 5) to the ON position to enable the parallel-mode operation.
  • Page 18 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 6. Set the main/support configuration as follows: Power ON the system and wait for it to complete initialization tests. The display shows the startup windows (Figure 6).

  • Page 19: System Startup

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4.3 – System Startup The DVS is ready to be powered on once it has been properly installed (mechanically and electrically). The system performs a lamp test when first powered on. The display then shows the initial status window containing the model number and software version.

  • Page 20: Charging

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4.4 – Charging The numbers shown as part of the window display in this section of the manual NOTE are only for illustration purposes. The actual numerical combination of voltage, current and temperature will vary with the type of battery pack being charged.
  • Page 21 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 LED Label Color When Steadily Lit When Flashing Equalize Green The battery is undergoing equalization. The equalization is scheduled. Charge Completed Green The charge is completed and stopped.

  • Page 22: Equalization

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 4.5 – Equalization Proper equalization is necessary for the health of the battery pack. Too little equalizing may lead to sulfation and decreased capacity, whereas excessive equalizing may lead to high-water loss and more maintenance. WCSI recommends equalizing at least once per week;...

  • Page 23: Data Logs, Charger Configuration, And Advanced Programming Features

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Viewing Charging Data and Fault and Warning Windows The display window is periodically updated during charging with the latest charging data; which includes the SOC, voltage, charging current, and temperature of the battery (Figure 9).

  • Page 24: External Status Indicator Configuration (Optional)

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 ANY STATUS OR CHARGING WINDOW ENTER Review charging data: Charging Log The last 200 charges ENTER Review data from the 100 Fault / Warning Log...

  • Page 25: Maintenance

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 5 – MAINTENANCE 5.1 – DVS Periodic Maintenance Schedule Item Service Internal DC Power Output Cables Inspect and Replace As Needed SBX Connectors Inspect, Rework or Replace...
  • Page 26 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Procedure for Properly Seating an Incorrectly Seated Pin. 1. Remove the two retaining roll pins from the SBX housing. 2. Pull the red and black auxiliary housings from the SBX housing.
  • Page 27 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Available Connector Kits • PN 06435, Yellow • PN 06436, Blue • PN 07280, Green Components of Each Kit • (One) SBX 350A 600V Connector •...

  • Page 28: Air Filter Maintenance For Dvs330 Ip55

    These filters meet the IP55 Standard for preventing dust and water intrusion into the charger. The filters are designed to last several years, depending on the environment, and Webasto recommends that the filters be cleaned every three to six months (3-6 months) depending on the operating conditions.

  • Page 29: Dvs330 Ip55 Side Air Vents

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 DVS330 IP55 Side Air Vents Intake Air Flow Filter P/N 5911958 Black side of the filter on the inside toward the charger Air Flow Exhaust Filter...
  • Page 30 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Cleaning the Air Filters The IP55 filters can be cleaned using one of four methods: • Using a shop vacuum to remove any dust, water and debris •...
  • Page 31 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Procedure for Removing, Cleaning and Re-installing the Filters Back Filter A. Remove the screws securing the cover to the back side of the charger.
  • Page 32 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Front Filters NOTE: The procedure for removing and re-installing the front filter is identical to the back filter, but the front filter cover does not include a spacer bracket.

  • Page 33: Troubleshooting

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 6 – TROUBLESHOOTING Sections 6.1 and 6.2 diagnose trouble with the DVS and provide codes of actions to be taken. Section 6.3 describes the details of each action code listed in sections 6.1 and 6.2.
  • Page 34 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Action Problem Symptom Probable Cause(s) Code The input or output wiring is loose. The charger (power station) The BMID connections are loose. F, G intermittently works.
  • Page 35 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Action Problem Symptom Probable Cause(s) Code The algorithm is overcharging the batteries. There are excess fumes during charging. The batteries are under-watered. The control board is bad or noisy.

  • Page 36: Fault And Warning Codes And Messages, Descriptions, And Action Codes

    Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 6.2 – Fault and Warning Codes and Messages, Descriptions, and Action Codes This section lists fault and warning codes and messages that may be displayed on the DVS front panel, corresponding descriptions of them, and corresponding action codes.
  • Page 37 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Fault or Action Warning Fault or Warning Message Description Code Code Power stage #2 (port B) has a current PS2 General Failure sensor fault.
  • Page 38 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Fault or Action Warning Fault or Warning Message Description Code Code BMID BAT Over-Temp The battery temperature is too high. The BMID link was lost after the BMID Comm Fail Port A charge started.
  • Page 39 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Fault or Action Warning Fault or Warning Message Description Code Code The BMID link was lost after the BMID Comm Fail Port B charge started.
  • Page 40 Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400 Webasto Charging Systems, Inc. 1960 Walker Avenue Monrovia, CA 91016 Corporate headquarters: Friedrichshafener Str. 9 82205 Gilching Germany 31504-03-0101 Webasto Charging Systems, Inc.

This manual is also suitable for:

Dvs330Dvs330 ip55Dvs400Mvs330Mvs400

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