Webasto DVS100 User manual

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

20182-W-03-01
© 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 | [e-mail] | @posicharge | posicharge.com
© 2019 Webasto Charging Systems Inc.

20182-W-03-01

DVS100 Installation, Operation and Maintenance
IMPORTANT INFORMATION –SAVE THESE INSTRUCTIONS
20182-W-03-01 iv
Table of Contents
1Getting Started .....................................................................................................................1
2Safety Precautions –Read before using ..............................................................................2
2.1 Symbol usage...................................................................................................................2
2.2 Technical Support ............................................................................................................4
2.3 ESD Precautions..............................................................................................................4
2.4 Non-StandardTools ..........................................................................................................4
3System Description...............................................................................................................5
4Installation ............................................................................................................................6
4.1 Preparation.......................................................................................................................6
4.2 Wiring...............................................................................................................................7
4.2.1 General Guidelines ..................................................................................................7
4.2.2 Ground Wire.............................................................................................................7
4.2.3 Charging Cables / Cable Management System .......................................................7
4.2.4 Chassis Ground .......................................................................................................7
4.2.5 Grounding ................................................................................................................7
4.3 Physical Installation..........................................................................................................8
4.4 Connecting AC (Utility) Power........................................................................................10
5Operation............................................................................................................................13
5.1 Start Up..........................................................................................................................13
5.2 System Start Up –Emergency Off (EPO) Option...........................................................13
5.3 Language Selection........................................................................................................14
5.4 Charging.........................................................................................................................15
5.5 Equalization....................................................................................................................17
5.6 Viewing Charge Data Screens .......................................................................................18
5.7 Fault and Warning Screens............................................................................................19
5.8 Charge Event Log ..........................................................................................................21
5.9 Data Logs, Configuration, and Advanced Programming Features .................................23
5.10 Programming Menus....................................................................................................24
5.11 Charger Configuration..................................................................................................25
5.11.1 Clear Backup Memory............................................................................................28
5.11.2 External Light Configuration...................................................................................28
5.11.2.1 Selector Mode .................................................................................................28
5.11.2.2 External Lights 1, 2 and 3................................................................................30
5.11.3 EQ Button Action....................................................................................................30
5.11.3.1 Setting the EQ Button Action...........................................................................30
5.11.4 Auto EQ..................................................................................................................31
5.11.5 Fast Charge SOC Limit..........................................................................................31
5.11.5.1 Setting the Fast Charge SOC Limit .................................................................32
5.11.6 Full Charge Feature Configuration.........................................................................32
5.11.6.1 Setting the Full Charge Feature Parameters...................................................32
5.11.7 Reduced Rate Charge Feature Configuration........................................................33
5.11.7.1 Setting the Reduced Rate Charge Configuration.............................................33
5.11.8 Temperature Readout Selection ............................................................................34
5.11.9 Ventilation System .................................................................................................35
5.11.10 Air Circulation Control .........................................................................................36

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5.11.11 Watering System................................................................................................36
5.11.12 Charger ID..........................................................................................................38
5.11.13 Date and Time....................................................................................................38
5.11.14 Charge Time Control..........................................................................................39
5.11.15 Output Format Selection Menu ..........................................................................40
5.11.16 Port Assignment.................................................................................................41
6Maintenance......................................................................................................................42
6.1 General Maintenance....................................................................................................42
7Technical 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

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List of Figures
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.......................................................................13
Figure 5- 1B Language Selection Screens.................................................................................14
Figure 5- 2 Connecting Status Screens .....................................................................................15
Figure 5- 3 Front Panel Layout ..................................................................................................15
Figure 5- 4 Charge Complete Screens.......................................................................................16
Figure 5- 5 Charging Data Screens ...........................................................................................18
Figure 5- 6 Fault or Warning Screens........................................................................................19
Figure 5- 7 Fault/Warning Log Data Screens.............................................................................20
Figure 5- 8 Charge Event Log Data Screens.............................................................................22
Figure 5- 9 Top Menu Items for the Advanced Features............................................................23
Figure 5- 10 Programming Menu Entry......................................................................................24
Figure 5- 11 Charger Configuration Options..............................................................................27
Figure 5- 12 Clear Backup Memory Menu .................................................................................28
Figure 5- 13 External Light Configuration Menu.........................................................................29
Figure 5- 14 EQ Button Action...................................................................................................30
Figure 5- 15 Auto EQ Menu.......................................................................................................31
Figure 5- 16 Fast Charge SOC Limit Screens............................................................................31
Figure 5- 17 Full Charge Setup Screens....................................................................................33
Figure 5- 18 Reduced Charge Rate Setup Screens...................................................................34
Figure 5- 19 Temperature Readout Selection Screens..............................................................34
Figure 5- 20 Ventilation System Setup.......................................................................................35
Figure 5- 21 Air Circulation Control Setup..................................................................................36
Figure 5- 22 Watering System Standard Screens......................................................................37
Figure 5- 23 Charger ID Screens...............................................................................................38
Figure 5- 24 Date and Time setting menus................................................................................39
Figure 5- 25 Charger Time Control Menu ..................................................................................40
Figure 5- 26 Output Format Selection Menu..............................................................................40
Figure 5- 28 Port Assignment Menu ..........................................................................................41
Figure 6- 1 DC Output Cable Installation ...................................................................................42
Figure 6- 2 Diagnostic port pinout..............................................................................................44

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1 Getting Started
Before you begin, take the time to familiarize yourself with the Cautions in Section 2, and read the
installation instructions in Section 4 completely before you install your new DVS100.
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. Install the BMID onto the battery pack. (Sections 3)
4. Once the BMID is installed, the battery pack may be connected to the charger.
5. If your BMID does not come pre-configured, you will need to initialize the new BMID. (Refer to BMID
programming, document #06701-W-03)
6. Once the BMID has been properly programmed, the battery pack is ready to begin charging.

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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.
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.
DANGER
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.
CAUTION
BEFORE
YOU BEGIN
Read all instructions and cautionary markings on the Industrial
PosiCharge™ (DVS100) Assembly.
Make sure you also read the IMPORTANT SAFETY INSTRUCTIONS
below.
Be sure to leave these instructions with the installed unit for future
reference.
Only qualified personnel should install, use or service this charger.
Read and understand these 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.

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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.
Only qualified service personnel may remove the front or back panels on the DVS100. 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.
Disconnect battery charger from input power and battery connections before installing or
servicing. Lockout/tagout input power.
Do not expose to rain or perform installation/service/repair work when in standing water.
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.
The charging cables must be sized for the full rated current of the DVS100, and inspected
frequently for wear, cuts and abrasion. Do not use worn, damaged, undersized, or poorly spliced
cable.
The DVS100 charging connector is subject to normal wear and tear, and may be damaged by
misuse or abuse. Frequently inspect the connector for cracking, pitting of contacts, fraying of
wires or signs of connector fatigue. A damaged charging connector should be replaced
immediately.
Do not install or place unit on, over or near combustible surfaces.
Do not install unit near flammables.
Do not block air intake or exhaust.
Ensure that the Battery Monitor/Identifier (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.
Protective bollards or Armco barriers should be installed where charging equipment location is
subject to damage from vehicle activity.
Do not install unit where it will be exposed to direct sunlight.
To avoid shock hazard, only install cables approved by PosiCharge™for indoor use.
Do not subject the cable or coupler to damage or stress. Do not step on the coupler cable.
Do not hang from the coupler cable.
Do not disassemble the DVS100.

DVS100 Installation, Operation and Maintenance
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2.2 Technical Support
This manual is intended to provide an authorized, fully trained installation technician with the
information and guidance necessary to safely install the DVS100 equipment.
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.
Training may be scheduled by contacting Customer Service at Webasto at:
[email protected]
866-POSICHARGE (866-767-4242)
2.3 ESD Precautions
Electronic circuits are sensitive to damage from electrostatic Discharge. Persons servicing this
equipment should be trained in proper techniques for avoiding ESD damage to electronic circuits.
As a minimum, when handling circuit boards, wear an appropriate ESD wrist strap connected to the
equipment chassis.
2.4 Non-StandardTools
No.
Equipment Description
Suggested Supplier
Part Number
A.
Multimeter
Fluke
Model 79 or
equivalent
B.
Bleed down resistor (100, 10W)
with Probe tips
---
---
C.
Metric socket set, deep well, 8MM to
17MM
---
---
D.
RS-232 Diagnostic Cable
---
---

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3 System Description
The keypad and display provide the user interface to the charger. The display constantly updates
the charger and battery status, and allows access to the programming menus through the keypad.
Four (4) status LEDs indicate when a 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 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.
Figure 3- 1 Components of the Charging System
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 configured on site
through the charger front panel (see the “BMID Programming Manual”).
Many different sizes and types of industrial battery packs may be charged with the DVS100.
Choose the correct BMID and BMID programming for the nominal voltage and size of your pack.
WARNING
IMPROPER INSTALLATION CAN CAUSE FIRE

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4 Installation
This section outlines the requirements and procedures for installing the DVS100. Read the entire
section before proceeding with installation, and make sure you have read and understood the
warnings in Section 2. Installation should be completed by an experienced electrician and should
conform to all relevant electrical codes.
4.1 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:
One DVS100 system
DVS Installation Manual
CD manual
The following equipment is shipped to truck retrofit location
Two BMID system with related connectors
Two BMID thermistor kit
The “BMID Programming” Manual
NOTE: Additional connector sets and BMID kits may be purchased from your authorized DVS100
Dealer.

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4.2 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.
4.2.2 Ground Wire
Green or green with a yellow stripe and attached to the compression lug provided.
4.2.3 Charging Cables / Cable Management System
To avoid shock hazard, only install cables approved by PosiCharge™for indoor use. Use
H01N2-D (EN 50272-3) or similar type.
DANGER
CABLES CARRY HIGH POWER/CURRENT
Damaged Cables and/or connectors can be a serious safety hazard.
Cables must be secured with an Approved Cable Management System.
Cables are to be kept off the floor.
Failure to use a Cable Management System may invalidate Product
Warranty.
4.2.4 Chassis Ground
See Table 4-1 for wiring size and additional information.
Use copper conductors only.
Minimum ground wire size is listed. Refer to local electrical codes for reference.
4.2.5 Grounding
DVS100 must be connected to an equipment-grounding conductor routed with the circuit
conductors. Connections must comply with all local codes and ordinances (EN 50178 Part
1).
The DVS100 must be grounded in accordance with the Facilities Utility grounding method.
See Table 4-1 for minimum ground wire size.

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4.3 Physical Installation
CAUTION
The DVS100 weighs 240 kg. Always use appropriate equipment for
handling the unit. Use a forklift of sufficient capacity to lift the unit.
Do not use hooks to lift the unit.
Do not tip the unit. It must be kept in vertical position.
The external dimensions of the DVS100 are:
- Base: 51,9 x 62,3 cm (20.44 x 24.50 in)
- Height: 130.7 cm (51.47 in)
Location
Choose your installation location to:
Avoid temperature and humidity extremes.
Minimize moisture and dust.
Provide adequate air circulation to prevent the buildup of fumes.
Install on a cement pad minimum 18cm (7”) above surrounding curbing or walkways for water
flood control, see Figure 4- 1
Maintain a minimum of 46cm (18”) of clearance on the sides of the unit for proper
ventilation.
Maintain 91,5cm (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.

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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.
A . 91.4cm (36 IN) MINIMUM WORKING CLEARANCE ON FRONT AND BACK,
INCLUDING TOP.
B. PAD MUST BE A MINIMUM OF 17.8cm (7 IN) ABOVE SURROUNDING CURB
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
91.4cm
(36 in)
MIN.
91.4cm (36in) MIN.
A
A
A
72.4cm
(28.5 in)
MIN.
86.4cm
(34 in)
MIN.
C
C
17.8cm (7.00 in) MIN
CONCRETE HEIGHT
CONCRETE BOLT ANCHOR
6.4cm (1/4") DIA X 12.7cm (5.0") LG
B
45.7cm
(18 in)
MIN. A
A
45.7cm
(18 in)
MIN.
91.4cm
(36 in)
MIN.
A
B

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The square mounting holes are 6.5mm X 6.5 mm.
Figure 4- 2 Bolt Pattern for DVS100 Installation
4.4 Connecting AC (Utility) Power
CAUTION
Prior to connecting the unit to the utility ensure that:
The available grounding connection meets all state and local
codes.
The main circuit breaker or other “line disconnect” device is
within sight of the unit and is easily accessible to allow complete
power down of the unit.
DANGER
Incorrect power wire installation, or failure to properly ground unit
may result in a severe shock hazard.
CAUTION
Use Copper conductors only.
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.
Utility power must be 50/60Hz, 3 phase, 3 wire plus ground. There must be one wire for each
phase plus one earth ground. See Table 4-1 for information on input current, utility requirement,
and cable sizes. All phase wires must be rated for the full input AC current as listed.
585 mm
53,4 mm
429,3 mm
35,6 mm

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Table 4-1 Utility and Wiring Information
Configuration
2 x 10kW
Input voltages
440 VAC ± 10%
Input AC Current at rated load (Amps)
30 A @ 440V
Input Frequency (Hz)
50 / 60
Number of input Phases (Excluding Ground)
3
Maximum Circuit Breaker Rating (Amps)
30 A, D-characteristic
Minimum Disconnect Switch Voltage Rating (VAC)
600
Minimum Inrush Current Capacity (Amps)
250A, 2 cycle start-up load
THD Max
35%
Minimum Input Conductor Size (mm2)
10mm2
Minimum Grounding Conductor Size (mm2)
10mm2
Minimum Ground Wire Terminal Torque (in-lb)
4-5 Nm
Table 4-2 Output Characteristics for DVS100
Configuration
Port A
Port B
Max Output Power
10 kW
10 kW
Max Output DC Range
16-120 V
16-120 V
Max Output DC Current
200 A
200 A
Minimum Output Wire Size (DC BUS +)
1x 70 mm²
1x 70 mm²
Minimum Output Wire Size (DC BUS -)
1x 70 mm²
1x 70 mm²
Output Cable Connector
320A Euro
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.
NOTE: The grounding wire should have insulation that is green or green with yellow stripe.
4. Ensure good electrical connection by tightening all the screws properly.
5. Close the front door prior to switching on the utility power.

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Figure 4- 3 AC Input Terminal Block
Figure 4- 4 Location of Chassis Ground Connector
CHASSIS
GROUND
CONNECTOR
AC INPUT
TERMINAL
BLOCK
TRANSFORMER
TAPS TERMINAL
BLOCK

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5 Operation
5.1 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. After five seconds, the screen will shift to the charge screens.
5.2 System Start Up –Emergency Off (EPO) Option
With the external AC Input applied to the system, display panel switches on the ON position, press
the green ON button located on the front door assembly. See Figure 5- 1A.
Figure 5- 1A ON/OFF/EPO Front Panel Buttons
Pressing the red OFF button terminates all output power. Pressing the green ON button restarts
the system.
In an Emergency, pressing the large, red Emergency OFF button will also remove all output power
and input power to the Control 230VAC and 24VAC accessory. Before restarting the system after
any emergency, be sure the system has been returned to a safe, operable condition before Pulling
EPO and pressing the ON button to restart the system.
A
B
EMERGENCY
POWER OFF
ON
OFF

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5.3 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. After password has been accepted the “Charger Ready Connect Vehicle”
screen will start flashing. Press the UP arrow and Hold to scroll through the language options,
release when desired language is displayed; Press ENTER to accept the desired language.
Figure 5- 2B Language Selection Screens
Enter key code now, Hold key code until screen starts flashing
DVS100 200 Amps
Version 03.00.00.32
Charger Ready US
Connect Vehicle
Charger Ready EU
Connect Vehicle
Chargeur Prêt
Relier le Véhicule
Ladegerät bereit
Fahrzg anschließen
ENTER
ENTER
Cargador Listo
Conecte el Vehículo
ENTER
Press and Hold UP arrow to select language
preference and ENTER to accept the selection
made.