Webasto SVS300 Installation, Operation And Maintenance Manual
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Webasto SVS300 Installation, Operation And Maintenance Manual

Mhe intelligent fast charging systems
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Installation, Operation and Maintenance Manual
MHE Intelligent Fast Charging Systems
SVS300 440VAC
English
12442-W-03--01

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Summary of Contents for Webasto SVS300

  • Page 1 Installation, Operation and Maintenance Manual MHE Intelligent Fast Charging Systems SVS300 440VAC English 12442-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 IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS 0153-W-03-01...

  • Page 4: Table Of Contents

    5.10.10 Air Circulation Control ....................35 5.10.11 Watering System ......................35 5.10.12 Charger ID ........................37 5.10.13 Date and Time ......................37 5.10.14 Charge Time Control ....................38 5.10.15 Output Format Selection Menu ..................39 Maintenance ........................ 40 20153-W-03-01 Webasto Charging Systems, Inc.
  • Page 5 Figure 5- 21 Air Circulation Control Setup .................. 35 Figure 5- 22 Watering System Standard Screens ..............36 Figure 5- 23 Charger ID Screens ....................37 Figure 5- 24 Date and Time setting menus ................38 20153-W-03-01 Webasto Charging Systems, Inc.
  • Page 6 IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Figure 5- 25 Charger Time Control Menu .................. 38 Figure 5- 26 Output Format Selection Menu ................39 Figure 6- 1 DC Output connections .................... 40 Figure 6- 2 Diagnostic port pinout ....................42 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 7: Getting Started

    5. If your BMID does not come pre-configured, you will need to initialize the new BMID. (Refer to BMID programming, document #06701) Once the BMID has been properly programmed, the battery pack is ready to begin charging. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 8: Safety Precautions - Read Before Using

    Only qualified service personnel may remove the front or back panels on the SVS-300. There are no user serviceable parts inside. Refer all servicing to qualified service personnel. Opening the system or attempted installation or repair by other than qualified service personnel voids the warranty. 20153-W-03-01 Webasto Charging Systems, Inc.
  • Page 9  Follow the National Electrical Code (NEC) and local codes. NEC and local codes take precedence. If any instructions in this manual conflict with NEC or local codes, contact Webasto Charging Systems, Inc. for further information. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 10: Technical Support

    Non-StandardTools Equipment Description Suggested Supplier Part Number Multimeter Fluke Model 79 or equivalent Bleed down resistor (100, 10W) with Probe tips Metric socket set, deep well, 8MM to 17MM RS-232 Diagnostic Cable 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 11: System Description

    (see the “BMID Programming Manual”). Many different sizes and types of industrial battery packs may be charged with the SVS-300. Choose the correct BMID and BMID programming for the nominal voltage and size of your pack. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 12: Installation

    The following equipment is shipped to truck retrofit location  One BMID system with related connectors  One BMID thermistor kit The “BMID Programming” Manual  NOTE: Additional connector sets and BMID kits may be purchased from your authorized SVS-300 Dealer. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 13: Wiring

     The SVS-300 must be grounded in accordance with the Facilities Utility grounding method.  See Table 4-1 for minimum ground wire size. 4.2.6 Hardware Manufacturer does not supply all external mounting hardware. User-supplied hardware may be needed to complete the installation. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 14: Physical Installation

    Maintain a minimum of 18” of clearance on the sides of the unit for proper ventilation.  Maintain 36” minimum clearance on Front and Back for servicing as required by local codes.   Do not install unit where it will be exposed to direct sunlight. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 15: Figure 4- 1 Svs-300 Installation

    OR WALKWAYS FOR WATER FLOOD CONTROL. C. PAD SIZE MINIMUM FOR A SINGLE CHARGER 86.4cm (34") X 72.4cm (28.5") CONCRETE 3000 PSI MIN D. CONCRETE PAD REQUIRED ONLY FOR WATER FLOOD CONTROL Figure 4- 1 SVS-300 Installation 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 16: Connecting Ac (Utility) Power

    CAUTION down of the unit. Incorrect power wire installation, or failure to properly ground unit may result in a severe shock hazard. DANGER Use Copper conductors only. CAUTION 20153-W-03-01 Webasto Charging Systems, Inc.

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

    Configuration Single Output Cable Max Output Power (kW) Max Output DC Range (Volts) 16-130 Max Output DC Current (Amps) 95mm Minimum Output Wire Size (DC BUS +, 95mm Minimum Output Wire Size (DC BUS -, 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 18: Figure 4- 3 Ac Input Terminal Block

    3. Ensure good electrical connection by tightening all the screws properly. 4. Close the front door prior to switching on the utility power. Figure 4- 3 AC Input Terminal Block CHASSIS GROUND CONNECTOR Figure 4- 4 Location of Chassis Ground Connector 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 19: Operation

    Press and Hold UP arrow to select language Chargeur Prêt preference and ENTER to accept the selection Relier le Véhicule made. ENTER Ladegerät bereit Fahrzg anschließen ENTER Cargador Listo Conecte el Vehículo Figure 5- 1 Language Selection Screens 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 20: Charging

    The display screen will periodically update the charging data as the charge progresses. In addition, the front panel has several status LEDs which indicate the current status of the battery under charge, and whether it is scheduled for an equalization charge. Figure 5- 3 Front Panel Layout 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 21: Table 5- 1 Led Labels And Meanings

    5 1 . 8 V Figure 5- 4 Charge Complete Screens Step 3: Disconnect battery cables from charger NOTE: If the operator disconnects the cables without pressing STOP, the charger will immediately stop charging and prevent any arcing. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 22: Equalization

    UP and DOWN arrow keys (see Figure 5- 5). The display will return to the Charging screen if there is no button activity for 15 seconds. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 23: Figure 5- 5 Charging Data Screens

    SVS-200 Installation, Operation and Maintenance IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS Figure 5- 5 Charging Data Screens 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 24: Fault And Warning Screens

    3. Clearance Date - Shows the date and time that the fault was cleared. Pre-fault State - Shows the state of the charger when the fault or warning occurred. Either “Charging battery XXXXXXXX” or “Idle”. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 25: Charge Event Log

    3. Charge date screen - Shows the date and time recorded at the beginning and end of the selected charge event. 4. kWhrs Returned – Shows the cumulative kWhrs returned to the battery during the selected charge event. 20153-W-03-01 Webasto Charging Systems, Inc.
  • Page 26 10. Battery Type - Shows the BMID reported battery type of the battery charged during the selected charge event. 11. Battery Data - Lists the BMID reported ID, number of cells, Ah capacity, and nominal voltage of the battery for the battery charged during the selected charge event. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 27: Figure 5- 8 Charge Event Log Data Screens

    Charge type Fast charge Charge time 00:03 3 Ah Returned Charge Start Code: Chg term reason Stopped by user Type Exide flooded Batt0000000K 24Cel 1000Ah Capacity 48V Figure 5- 8 Charge Event Log Data Screens 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 28: Data Logs, Configuration, And Advanced Programming Features

    (see Figure 5- 9). Details on how to access the advanced features and configuration menus are documented in this manual Figure 5- 9 Top Menu Items for the Advanced Features 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 29: Programming Menus

    If a programming menu is entered while a vehicle is charging, the charger will prompt for termination of the charge before allowing programming to continue. The process for entering either programming mode is shown in Figure 5- 10. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 30: Charger Configuration

    Connected and Stop Charging, Connected and Charging, Connected and Equalizing, Port available and Fault or Warning. This feature is only applicable in systems where external lights have been installed and connected to the charger. 20153-W-03-01 Webasto Charging Systems, Inc.
  • Page 31 English US Menu screens. If IDS mode is required, set IDS Mode on the English US Menu screen and then go back to the preferred EU language to finish setting the rest of the Charger’s Configuration. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 32: Figure 5- 11 Charger Configuration Options

    Watering System Fast Charge SOC Configuration Limit SELECT SELECT Full Charge Air Circulation Setup Control SELECT SELECT Reduce Charge Rate Ventilation System Setup Configuration SELECT SELECT Temperature Readout Selection SELECT Figure 5- 11 Charger Configuration Options 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 33: Clear Backup Memory

     Press <enter> to display the Selector Mode setting. (Default is set to Disable)  Press <enter> to change Selector Mode setting.  Use the <up> and <down> buttons to choose the selector mode setting followed by pressing <enter>.  Press <clear> to exit 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 34: Figure 5- 13 External Light Configuration Menu

    Light 3 On When: Conn & Stop Charging Figure 5- 13 External Light Configuration Menu Note: The Selector Mode is mutually exclusive of the External Light function. If Selector Mode is enabled, External Light settings shall be ignored. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 35: Eq Button Action

    ALWAYS ACTIVE - This is the default setting and causes the EQ button to be active at all times. WORKS ON EQ DAY ONLY - This setting causes the EQ button to function only on the day of the week programmed in the BMID for equalization. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 36: Auto Eq

    Use the UP and DOWN arrow buttons to set the parameter to the appropriate value. Press ENTER again to accept the selection made. Press CLEAR to retain the original value Figure 5- 16 Fast Charge SOC Limit Screens 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 37: Full Charge Feature Configuration

    Period” screen and use the <enter>, <up>, and <down> buttons as before to edit. Remember to press <enter> to save your edits. Once you have pressed <enter> to save your edit, the display will stop flashing. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 38: Reduced Rate Charge Feature Configuration

    10:00 am, the current will drop from 320 to 250amps. The charging will continue with this rate limit until the window is closed at 12:00pm when the current limit returns to 320 amps. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 39: Temperature Readout Selection

    From the “Temperature Readout Selection” screen, press <enter> to display the current format. Press <enter> again to enable editing. Use the <up> and <down> arrows to select the desired format for the temperature display and press <enter> to save your configuration. Press <clear> to exit. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 40: Ventilation System

    Ventilation System Configuration ENTER CLEAR Ventilation System CLEAR ENTER Ventilation System Verify Ventilation ENTER ON When Charging Connection CLEAR Ventilation System Verify Ventilation ENTER ON When EQing Connection CLEAR Figure 5- 20 Ventilation System Setup 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 41: Air Circulation Control

    ”Water System Test” screen. From this screen press <enter> to run the water test. There will be a 30 second count down and then watering will begin. Press the <stop> button to end the test. Press the <clear> button to exit. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 42: Figure 5- 22 Watering System Standard Screens

    Water System Test ENTER New Water Sys Type: Philadelphia Low Prs Watering....CLEAR Please wait 30 sec. after 30s countdown Watering....Press STOP to end STOP Valve On Time out Figure 5- 22 Watering System Standard Screens 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 43: Charger Id

    3. Month - Displays and edits the charger internal clock month (valid values 1-12) 4. Day - Displays and edits the charger internal clock day (valid values 1-31). 5. Year - Displays and edits the charger internal clock year (valid values 2000-2099) 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 44: Charge Time Control

    Auto Charge Restart – Displays and edits the number of hours before an automatic charge restart event. This event will take place if a vehicle is left connected to the charger for the time entered after its charge event has completed. 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 45: Output Format Selection Menu

    Output Format display and press <enter> to save your configuration. Press <clear> to exit. Charger Configuration CLEAR Output Format Selection ENTER CLEAR Output Format is: CLEAR Standard Mode Output Format is: IDS Mode Figure 5- 26 Output Format Selection Menu 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 46: Maintenance

    Use only connectors and cable that are rated for the full continuous WARNING current rating of the unit unless the output current of the unit has been adjusted to a lower value. Minimum Bend Radii 3.5 in Figure 6- 1 DC Output connections 20153-W-03-01 Webasto Charging Systems, Inc.
  • Page 47 Proper Cable management system is required to relieve stress concentration from output connector mounting hardware areas Note: 1) Do not remove connector key(s) from Connector 2) Minimum bend radii (3.5 inch) are required for output cables 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 48: External Interface Specifications (Diagnostic Port)

    Signal Signal port pin Description Source Destination Serial data transmit from Charger Diagnostic charger tool Serial data receive to Diagnostic Charger charger tool Serial data ground reference Common Common Figure 6- 2 Diagnostic port pinout 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 49: Table 6- 1 Fault Codes

    Control Bd Supply Control board logic supply failure Current Too Low Powerstage not producing desired current ADC Ref Invalid A to D Converter inputs invalid HW Overvolt Overvoltage detected in hardware HW Overcurrent Overcurrent detected in hardware 20153-W-03-01 Webasto Charging Systems, Inc.

  • Page 50: Technical Specifications

    No Air Pressure has been detected. 7 Technical Specifications Model INPUT OUTPUT number Number Freq Voltage Current AMPS Voltage Rating Curren Phases AMPS SVS-300 50/60 16-130 30.0 12 to 48 cells Flooded or Sealed battery Up to 2500 Ah 20153-W-03-01 Webasto Charging Systems, Inc.

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