Webasto DVS 400 User manual

09190-W-03-01.docx
Operation and Maintenance Manual
GSE Intelligent Fast Charging Systems
DVS 400
English

DVS Installation Manual
09190-W-03-01.docx Page 2 of 27 Webasto Charging Systems, Inc.
© 2019 Webasto Charging Systems, Inc. All rights reserved.
PosiCharge™ systems is a product line of Webasto Charging Systems, Inc. Webasto and the Webasto logo are trademarks of Webasto
Charging Systems, Inc. Corporate names, trademarks, registered trademarks, service marks, symbols, and logos stated herein are
property of their respective companies. Specifications are subject to change without notice. Images of the power cycling and test systems
are representative; production models may vary. 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. Changes or modifications to this product not completed by an
authorized service provider could void the product warranty.
These commodities, technology or software were exported from the United States in accordance with the Export Administration
Regulations. Diversion contrary to US law prohibited
PosiCharge™ systems, a product line of Webasto Charging Systems, Inc..
1.866.767.4242 | [email protected] | @posicharge | posicharge.com
© 2019 Webasto Charging Systems Inc.

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Table of Contents
Table of Contents............................................................................................................................................3
List of Figures..................................................................................................................................................4
List of Tables...................................................................................................................................................4
1Overview...................................................................................................................................................6
1.1 Getting Started....................................................................................................................................6
1.2 Applicable Documents........................................................................................................................7
2Safety Precautions - Read before using................................................................................................8
2.1 Symbol usage.....................................................................................................................................8
2.2 Safety Instruction................................................................................................................................8
2.3 Technical Support...............................................................................................................................9
3System Description ...............................................................................................................................10
3.1 Options and Accessories..................................................................................................................11
4System Installation ................................................................................................................................11
5Operation................................................................................................................................................12
5.1 System Start Up................................................................................................................................12
5.2 Charging ...........................................................................................................................................13
5.3 Equalization ......................................................................................................................................15
5.4 Full / Over Charging..........................................................................................................................15
5.5 Reduced Charging............................................................................................................................15
5.6 Viewing Charge Data or Fault / Warning Screens............................................................................15
5.7 Data Logs, Charger Configuration and Advanced Programming Features......................................16
5.8 External Status Indicator Configuration (Optional)...........................................................................18
6DVS 400 Periodic Maintenance ............................................................................................................18
6.1 DC Power Output Cable Service......................................................................................................18
6.1.1 SBX/SYX Connector Service ....................................................................................................18
6.2 Troubleshooting................................................................................................................................19
6.2.1 How to Use This Section...........................................................................................................19
6.2.2 ESD Precautions.......................................................................................................................20
6.2.3 Problem Symptoms and Action Key..........................................................................................20
6.2.4 Fault Messages.........................................................................................................................22
6.2.5 Actions.......................................................................................................................................24
6.2.6 Charge Termination Codes .......................................................................................................27

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List of Figures
FIGURE 1.1. DVS 400 FAST CHARGING SYSTEM..................................................................................................6
FIGURE 5.1. START UP SCREENS.......................................................................................................................12
FIGURE 5.2. CONNECTING STATUS SCREENS.....................................................................................................13
FIGURE 5.3. FRONT PANEL LAYOUT...................................................................................................................14
FIGURE 5.4. CHARGE COMPLETE SCREENS.......................................................................................................14
FIGURE 5.5. REPRESENTATIVE CHARGING DATA SCREENS.................................................................................15
FIGURE 5.6. REPRESENTATIVE FAULT OR WARNING SCREENS............................................................................16
FIGURE 5.7. TOP LEVEL MENU FOR ADVANCED FEATURES.................................................................................17
FIGURE 6.1 CORRECT PIN ALIGNMENT...............................................................................................................19
FIGURE 6.2 INCORRECT PIN ALIGNMENT............................................................................................................19
List of Tables
TABLE 5.1. LED LABELS AND MEANINGS ............................................................................................................14
TABLE 6.1 PROBLEM SYMPTOMS AND ACTION KEY.............................................................................................20
TABLE 6.2 FAULT CODES AND ACTION KEY........................................................................................................22
TABLE 6.3 CHARGE TERMINATION CODES..........................................................................................................27

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1 Overview
The Dual Vehicle (DVS) Fast Charging System (Figure 1.1) is an advanced charging system that can quickly and
safely charge industrial batteries.
Figure 1.1. DVS 400 Fast Charging System
Charging intelligence is built into the system to make charging extremely simple: just plug in any IPC compatible
battery and the system starts charging it correctly. There is no need to be concerned about which charger is
designed or programmed for which battery. After completing a charge, the system shuts off automatically.
The DVS’s Rapid Charging Intelligence (RCI) makes it capable of charging much more quickly than a conventional
charger without damage to the battery. Battery voltage and temperature are monitored precisely, allowing charging
to be as rapid as possible without exceeding manufacturers' recommendations. The charge history of the pack is
tracked and equalization is automatically performed on the pack according to a pre-set schedule. This results in
better use of the batteries with minimal effort on the user’s part.
1.1 Getting Started
Before you begin, take the time to familiarize yourself with the Cautions in Section 2. To get your system up and
running quickly perform the following steps:

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1. Ensure the DVS 400 Fast Charging System installation and utility power requirements are followed. (Refer to
DVS 400 Installation Manual).
2. Install the Battery Monitor / Identifier (BMID) onto the battery pack. (Refer to BMID or BatteryRx Installation
Manual)
3. Once BMID is installed, the battery pack may be connected to the charger.
4. If your BMID does not come pre-configured, you will need to initialize the new BMID. (Refer to BMID
Programming and Advanced Features Manual)
5. Once the BMID has been initialized, the battery pack is ready to begin charging.
1.2 Applicable Documents
TITLE
Part Number
DVS 400 Installation Manual
09190-W-76
BMID Installation Manual
11717-W-03
BMID Programming and Advanced Features
BatteryRx Installation Manual
06701-W-03
16672-W-03

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2 Safety Precautions - Read before using
2.1 Symbol usage
Throughout this manual, take special note of the information marked with the following symbols:
DANGER
Contains information about safety practices necessary to prevent personal injury or
death.
WARNING
Contains information about safety practices necessary to prevent fire or equipment
overheating.
CAUTION
Contains information to prevent shock hazard or possible damage to the
equipment during installation and service.
NOTE: Offers helpful information for installation or usage, but does not contain personnel or equipment safety
related information.
2.2 Safety Instruction
CAUTION
BEFORE YOU
BEGIN
•Read all instructions and cautionary markings on the Industrial PosiCharge DVS
400 Assembly.
•Make sure you also read the IMPORTANT SAFETY INSTRUCTIONS below.
•Be sure to leave these instructions in a safe and easily accessible location for
future reference.
•Only qualified personnel, familiar with the local code, should install and service this
charger.
•Read and understand the manufacturer’s instructions and your employer’s safety
practices manual.
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. The input power circuitry
and internal circuits are live whenever input power is on. An incorrectly installed or
improperly grounded charger is a hazard.
•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.
•Do not remove the cover. There are no user serviceable parts inside. Refer all servicing to qualified service
personnel. Opening the system, or attempted repair by other than qualified service personnel, voids the
warranty.
•Disconnect battery charger from input power and battery connections before installing or servicing. Lockout /
Tagout input power according to OSHA 29 CFR 1910.147.
•Do not use when in standing water.
•Before disconnecting the battery, turn off the charger by pressing the stop button on the front panel. The DVS
400 is designed to automatically stop a charge event to minimize arcing or burning of the charger connections in
the event of a hot disconnect.

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•The charging leads must be capable of the full rated current of the DVS 400, and inspected frequently for wear,
cuts and abrasion. Do not use worn, damaged, undersized, or poorly spliced cable.
•The DVS 400 power connector may be damaged by misuse or abuse. Frequently inspect the connector for
cracking, pitting of contacts, fraying of wires or signs of connector fatigue. Should any indication be present,
immediate replacement of the connector will be necessary.
•Do not wear rings, watches, necklaces, tie clips, or conductive jewelry when working with batteries, as a short
circuit through conductive jewelry may cause severe burns.
DANGER
BATTERY GASES AND ELECTROLYTE CAN BE HAZARDOUS: Charging
batteries produces fumes and gases that may be hazardous.
•Charging batteries may leak corrosive electrolyte that can cause skin and eye irritation and damage equipment
and clothing. Avoid contact and follow battery manufacturer’s recommended practices for cleaning the battery
pack.
•Thoroughly wash all items brought into contact with battery electrolyte with a solution of baking soda and water.
•Batteries produce explosive gases. Do not smoke, perform operations that cause sparking, or have an ignition
source near batteries.
•Ventilate the area to prevent the buildup of fumes and gases.
WARNING
IMPROPER INSTALLATION CAN CAUSE FIRE
•Do not install or place unit on, over or near combustible surfaces.
•Do not install unit near flammables.
•Do not block or filter airflow to the unit (allow minimum of 6” clearance around unit).
•Ensure that the BMID is properly installed according to the BMID installation instructions.
•Replace blown fuses only with same type and rating of fuse.
•Do not overload building wiring - be sure power supply system is properly sized, rated and protected to handle
this unit. Use only on circuits provided with the minimum wire size specified in the installation section.
2.3 Technical Support
Call technical support any time a procedural question arises. DO NOT perform a procedure you do not understand.
Customer Service can be contacted during normal working hours (Pacific Standard Time) by calling:
[e-mail]
866-POSICHARGE (866-767-4242)

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3 System Description
The DVS 400 Fast Charging System is a transistor-based fast charging system that provides all of the battery
charging and equalizing required for your application. It provides a constant current-constant voltage-constant
current (IEI) charge profile that precisely controls the charge rate, and optimally charges your batteries by precisely
adjusting the current in response to the batteries’ capacity, temperature and age.
The keypad and display on the front of the DVS 400 provide the user interface to the charger. The alphanumeric
display panel constantly updates the charger and battery status, and allows access into the programming menus
through the keypad. Four status LEDs allow the user to determine from a distance when the charge is in progress,
at 80% complete, fully charged, or in equalization. A fault/warning LED serves to alert the user to fault conditions.
The DVS 400 works with a small monitoring device mounted on the battery 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 mismatching batteries and chargers.
Each BMID is pre-configured with the following information:
1. An identification number, which can help track the charging history of a specific battery.
2. A type code, indicating the manufacturer and type of battery.
3. The number of cells in the battery.
4. The ampere-hour capacity of the battery.
5. The start current limit of the battery pack for optimal charging.
6. The State of Charge (SOC) limit of the battery. This will determine the SOC at which the charging will stop.
7. Internal resistance.
8. Maximum ampere-hours between equalizations.
9. Maximum days between equalizations.
10. Equalization day of the week.
11. Voltage limit for Fast Charging and Equalization.
12. Battery temperature foldback.
13. Initialize BMID.
Typically, the battery dealer or another authorized service technician will install the BMID on the battery and
configure it before delivery to the customer. BMIDs may also be reconfigured on site through the charger front panel
(see the “BMID Programming and Advanced Features Manual”).