Webasto DVS100 Installation, Operation And Maintenance Manual
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Webasto DVS100 Installation, Operation And Maintenance Manual

Mhe intelligent fast charging systems
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Installation, Operation and Maintenance Manual
MHE Intelligent Fast Charging Systems
DVS100 440VAC
English
20182-W-03-01
i

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Summary of Contents for Webasto DVS100

  • Page 1 Installation, Operation and Maintenance Manual MHE Intelligent Fast Charging Systems DVS100 440VAC English 20182-W-03-01...
  • Page 2 No portion of these materials may be duplicated, used, or disclosed without prior written permission from 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.
  • Page 3 20182-W-03-01...

  • Page 4: Table Of Contents

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Table of Contents Getting Started ........................1 Safety Precautions – Read before using ................2 2.1 Symbol usage ........................2 2.2 Technical Support ......................4 2.3 ESD Precautions ......................4 2.4 Non-StandardTools ......................
  • Page 5 Technical Specifications ....................46 List of Tables Table 4-1 Utility and Wiring Information ..................11 Table 4-2 Output Characteristics for DVS100 ................11 Table 5- 1 LED Labels and Meanings ..................15 Table 6- 1 Fault Codes ....................... 45 Table 6- 2 Warning Codes ......................45 20182-W-03-01 Webasto Charging Systems, Inc.
  • Page 6 Figure 3- 1 Components of the Charging System ................ 5 Figure 4- 1 DVS100 Installation ....................9 Figure 4- 2 Bolt Pattern for DVS100 Installation ................ 10 Figure 4- 3 AC Input Terminal Block ..................12 Figure 4- 4 Location of Chassis Ground Connector ..............12 Figure 5- 1A ON/OFF/EPO Front Panel Buttons ...............

  • Page 7: Getting Started

    To get your system up and running quickly perform the following steps: 1. Ensure the DVS100 siting requirements are followed. (Sections 4.5) 2. Connect the 3 phase utility power to the DVS100, and apply power to the DVS100. (Sections 4.6) 3.

  • Page 8: Safety Precautions - Read Before Using

    IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 2 Safety Precautions – Read before using The DVS100 is designed with the safety of the user as the highest priority. However, installation must comply with all local codes, and the following safety precautions must be read and observed.
  • Page 9 A Charge can be stopped by disconnecting the output cable connector or by pressing the stop button on the front panel. The DVS100 is designed to automatically stop a charge event to prevent arcing or burning of the charger connections in the event of a hot disconnect.

  • Page 10: Technical Support

    All non-standard tools are listed in 2.4. If parts or tools are needed in addition to those listed in this manual to perform service, this service is outside the scope of this manual and Webasto should be contacted directly for further assistance.

  • Page 11: System Description

    A fault/warning LED serves to alert the user to fault conditions. The DVS100 works with a small monitoring device mounted on the battery called the battery monitor/identifier (BMID). As shown in Figure 3- 1, when a vehicle equipped with a BMID connects to the charger, the charger communicates with the BMID to ensure optimal charging.

  • Page 12: Installation

    Preparation Unpacking and Inspection The DVS100 is provided fully assembled on a shipping pallet. It is surrounded by a protective shipping box. Remove the packaging and any other shipping materials prior to installation. The following equipment is provided with each system: ...

  • Page 13: Wiring

    IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Wiring 4.2.1 General Guidelines  Check utility configuration tag on DVS100 to make sure that rated input voltage matches local utility voltage. See Table 4-1 for details.  See Table 4-1 for Input / Output parameters.

  • Page 14: Physical Installation

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Physical Installation The DVS100 weighs 240 kg. Always use appropriate equipment for handling the unit. Use a forklift of sufficient capacity to lift the unit. CAUTION Do not use hooks to lift the unit.
  • Page 15 D. CONCRETE PAD REQUIRED ONLY FOR WATER FLOOD CONTROL Figure 4- 1 DVS100 Installation NOTE: We strongly recommend cement curbing, concrete filled steel pipe pillars, or similar protection to be placed around the DVS100 to prevent damage to the DVS100 from a moving vehicle. 20182-W-03-01...

  • Page 16: Connecting Ac (Utility) Power

    Use Copper conductors only. CAUTION Utility power lines to DVS100 must be provided from an appropriately rated utility distribution panel. The utility distribution panel must include a "branch" rated circuit breaker (CB). The CB may also be the "line disconnect" device.

  • Page 17: Table 4-1 Utility And Wiring Information

    320A Euro Installation / Line Voltage Changeover Instructions 1. Remove the screws and open the front door of the DVS100. 2. Locate the AC Input Terminal Block. Refer to Figure 4- 3. 3. Bring utility wires from the Utility Distribution Panel through conduit, and route them to the AC Input Terminal Block and the Chassis Grounding Connector.
  • Page 18 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS AC INPUT TERMINAL BLOCK TRANSFORMER TAPS TERMINAL BLOCK Figure 4- 3 AC Input Terminal Block CHASSIS GROUND CONNECTOR Figure 4- 4 Location of Chassis Ground Connector 20182-W-03-01 Webasto Charging Systems, Inc.

  • Page 19: Operation

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5 Operation Start Up ™ When you first power up your Industrial PosiCharge , it will perform a lighting sequence test. The display will then show the initial Status Screen containing the model number, the software version and the output current capability.

  • Page 20: Language Selection

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Language Selection At the “Charger Ready Connect Vehicle” Screen, a standard password shall be required to gain entry to the Language Selection option. In the “Charger Ready Connect Vehicle” screen, use the standard password to access the language options.

  • Page 21: Charging

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charging Step 1: Connect battery to charger To start charging, simply connect the battery to the charger. Once the charge starts, and the “Charging” screen is displayed, the current is ramped up from zero to the target start current.

  • Page 22: Equalization

    Once the battery has been fast-charged to the SOC preset in the BMID or Charger, the DVS100 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 23 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Equalization Always run a full equalization charge prior to a fast charge on any battery pack that has had a cell replaced to ensure the pack is balanced. CAUTION Proper equalization is necessary for the health of the pack.

  • Page 24: Viewing Charge Data Screens

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Viewing Charge Data Screens While charging, the display screen is periodically updated with the latest charging data including voltage, current, and battery state of charge. During and after charging, the following additional data display screens may be viewed by scrolling between them using the UP and DOWN arrow keys (see Figure 5- 6).

  • Page 25: Fault And Warning Screens

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charging data. This screen displays the voltage, current, state-of-charge, and temperature of the battery. During a charge, the screen will say "Charging" and the data will be updated periodically.
  • Page 26 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Fault/Warning Log To top level screens CLEAR ENTER CLEAR Fault Event 1 12:29 02/06/07 ENTER Fault Event 2 Warning Code: 119 CLEAR 12:20 02/06/07 BMID TempSensr Fail Fault Event 3...

  • Page 27: Charge Event Log

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charge Event Log The charge event log data screens (see Figure 5- 9) allow the user to review the data from the last 250 fast charge or equalization events performed by the charger. These data are stored in the charger and are preserved even if power is removed from the charger.
  • Page 28 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charge Event Log To top level screens CLEAR ENTER Bat0000000K Event 1 Beg 10:32 02/06/07 ENTER Bat 91270 Event 2 Beg 46.0V 150A 56% CLEAR Beg 9:32 02/06/07 End 46.1V 150A 57%...

  • Page 29: Data Logs, Configuration, And Advanced Programming Features

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Data Logs, Configuration, and Advanced Programming Features ™ The Industrial PosiCharge user interface allows a trained user to configure many of the charge parameters and review recorded data. All configurations are done through menus accessibledirectly through the front panel display and keypad.
  • Page 30 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Figure 5- 10 Top Menu Items for the Advanced Features 20182-W-03-01 Webasto Charging Systems, Inc.

  • Page 31: Programming Menus

    Authorized Service Technician. The programming menus are protected from unauthorized use with an access code. NOTE: Programming should only be performed by experienced fleet managers. Contact your Authorized DVS dealer for the code, or call Webasto customer service at info@posicharge.com 866-POSICHARGE (866-767-4242 The programming menus can change the characteristics of a charge.

  • Page 32: Charger Configuration

    1. To enter the programming modes from the main menu, press ENTER when the desired programming mode is SELECTED. 2. You will be prompted enter the access code. Contact your Authorized PosiCharge™ dealer for the code, or call Webasto customer service at info@posicharge.com 866-POSICHARGE (866-767-4242 4.
  • Page 33 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 9. Ventilation System allows the user to configure the operation of a ventilation system. This feature is only applicable in systems where a ventilation system has been installed and connected to the charger.

  • Page 34: Clear Backup Memory

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charger Configuration CLEAR ENTER CLEAR To top level screens Enter key code now to continue Key code accepted No charge in progress ENTER OK to Stop Charger? OK to Stop Charger?

  • Page 35: Selector Mode

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.1 Clear Backup Memory The clear battery backed RAM Data screens (See Figure 5- 13) allow the user to clear the battery- backed charger memory. This memory contains the charge event log, the fault event log, and the charger configuration parameters.
  • Page 36 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charger Configuration CLEAR External Light Configuration ENTER Selector Mode: Selector Mode: ENTER CLEAR CLEAR Disable Enable SELECT When Selector Mode is enabled, all remaining submenus under both External Light Port Control menus are unavailable &...

  • Page 37: External Lights 1, 2 And 3

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.2.2 External Lights 1, 2 and 3  Press <enter> to display the Light 1 setting. Figure 5- 14)  Press <enter> again to select from the 5 Charger states of operation.

  • Page 38: Auto Eq

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.4 Auto EQ Charger Configuration CLEAR ENTER Auto EQ: Auto EQ: Press ENTER to accept the selection made. Press CLEAR to retain the original value. Figure 5- 16 Auto EQ Menu 5.11.5 Fast Charge SOC Limit...

  • Page 39: Setting The Fast Charge Soc Limit

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.5.1 Setting the Fast Charge SOC Limit From the “Fast Charge SOC Limit” screen press <enter> to display the active Fast Charge SOC Limit setting. Press <enter> again and the adjustable parameter will flash. Use the <up> and <down>...

  • Page 40: Reduced Rate Charge Feature Configuration

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charger Configuration CLEAR Full Charge Setup ENTER Full Charge Enable: ENTER Full Charge Enable: CLEAR CLEAR SELECT SELECT Full Chrg Start time ENTER Press ENTER and use the UP and...

  • Page 41: Temperature Readout Selection

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charger Configuration CLEAR Reduced Charge Rate Setup ENTER ENTER Reduced Rate Enable: Reduced Rate Enable: CLEAR CLEAR SELECT SELECT Reduced Chr Start time ENTER Press ENTER and use the UP and...

  • Page 42: Ventilation System

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.9 Ventilation System NOTE: This section is only applicable if a ventilation system has been installed and connected to the charger. The Ventilation System menus allow the user to set the ventilation system control parameters.

  • Page 43: Air Circulation Control

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.10 Air Circulation Control NOTE: This section is only applicable if an Air Pump System has been installed and connected to the charger. The Air Circulation Control menus allow the user to set the Air Circulation control parameters.
  • Page 44 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Watering System Charger Configuration CLEAR Configuration ENTER CLEAR New Water System Config Water System Config Water System Config SELECT SELECT Water System Type: New Water Sys Type: ENTER/CLEAR Custom Mode...

  • Page 45: Charger Id

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.12 Charger ID Allows the user to enter the 5-character numeric charger ID. From the “Charger ID” screen Press <enter> and the Charger ID will flash. Use the <up> and <down>...

  • Page 46: Charge Time Control

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Set Date and Time Charger Configuration CLEAR ENTER Hours ENTER CLEAR Press ENTER and ENTER use the UP and Minutes ENTER DOWN arrow buttons to set the parameter to the ENTER appropriate value.

  • Page 47: Output Format Selection Menu

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Charger Configuration CLEAR Charge Time Control Press ENTER and use the UP and ENTER DOWN arrow buttons to set the CLEAR parameter to the appropriate value. ENTER Auto Charge Restart...

  • Page 48: Port Assignment

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 5.11.16 Port Assignment Charger Configuration CLEAR ENTER Port Assignment: Port Assignment: Charge Port=A Press ENTER to accept the selection made. Press CLEAR to retain the original value. Figure 5- 28 Port Assignment Menu 20182-W-03-01 Webasto Charging Systems, Inc.

  • Page 49: Maintenance

    All other servicing is to be performed by Authorized service personnel only. Replacing DC Output Power Cables Replacement cables may be purchased directly from your Authorized DVS100 dealer. Use only connectors and cable that are rated for the full continuous...
  • Page 50 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS To install output cable(s): Install output cable(s) ensuring mounting screws and lock washers are properly installed and tightened. Recommended torque: 8.47 Nm (75 in-lbs) Proper Cable management system is required to relieve stress concentration from output...
  • Page 51 DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS External Interface Specifications (Diagnostic Port) Located on the charger front panel is a 9-pin RS232 connector that will allow devices such as laptops to monitor the charger activity, data stream and charge history. As soon as the application software is up and running communications can begin.

  • Page 52: Table 6- 1 Fault Codes

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Table 6- 1 Fault Codes Code Fault Messages Meaning OS System Failure Power on self test/OS failure Pilot Int. Failure Pilot interrupts stopped occurring ADC Failure A to D Converter failure...

  • Page 53: Technical Specifications

    DVS100 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 7 Technical Specifications Model INPUT DUAL PORT OUTPUT number Number Freq Voltage Current AMPS Voltage Rating Curren Phases AMPS DVS100 50/60 16-120 10,0 12 to 40V: 200A+ 72V: 138A...

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