Webasto DVS100 User manual

20182-W-76-01.docx
Installation Manual
GSE Intelligent Fast Charging Systems
DVS100 / DVS150
English

20182-W-76-01.docx
© 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

20182-W-76-01.docx
© 2019 Webasto Charging Systems Inc.

DVS100 / DVS150 Installation Manual
IMPORTANT INFORMATION –SAVE THESE INSTRUCTIONS
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Table of Contents
1 Getting Started ............................................................................................................5
2 Safety Precautions –Read before using .....................................................................5
2.1 Symbol usage..........................................................................................................5
2.2 Technical Support ...................................................................................................6
2.3 ESD Precautions.....................................................................................................6
3 System Description......................................................................................................7
4 Installation ...................................................................................................................8
4.1 Preparation..............................................................................................................8
4.2 Wiring......................................................................................................................8
4.2.1 General Guidelines ........................................................................................ 8
4.2.2 Ground Wire................................................................................................... 8
4.2.3 Charging Cables / Cable Management System ............................................. 8
4.2.4 Grounding ...................................................................................................... 8
4.3 Physical Installation.................................................................................................9
4.4 Connecting AC (Utility) Power...............................................................................12
4.5 DC Output Cable Installation.................................................................................15
4.6 Checklist................................................................................................................16
List of Tables
Table 4-1 Utility and Wiring Information..............................................................................12
Table 4-2 Output Characteristics for DVS...........................................................................13
List of Figures
Figure 3- 1 Components of the Charging System.................................................................7
Figure 4- 1 AC Input Terminal Block...................................................................................14
Figure 4- 2 Location of Chassis Ground Connector...........................................................14
Figure 4-3 DC Output Cable Installation .............................................................................15

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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 DVS.
To get your system up and running quickly perform the following steps:
1. Ensure the DVS siting requirements are followed. (Sections 4.5)
2. Connect the 3 phase utility power to the DVS, and apply power to the DVS. (Sections 4.6)
3. Install the BMID on 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 Manual,
document #06701)
6. Once the BMID has been properly programmed, the battery pack is ready to begin charging.
2 Safety Precautions – Read before using
The DVS is designed with the safety of the user as the highest priority. 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™ (DVS)
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.
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 DVS. 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 DVS is designed to automatically stop a charge event to prevent arcing or burning of the charger connections in the
event of a hot disconnect.

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The charging cables must be sized for the full rated current of the DVS, and inspected frequently for wear, cuts and
abrasion. Do not use worn, damaged, undersized, or poorly spliced cable.
The DVS 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.
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 DVS.
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 DVS equipment. For assistance contact PosiCharge™Customer Support at:
Tel.: [phone]
Email: [email protected]
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.

DVS100 / DVS150 Installation Manual
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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 DVS 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 DVS. 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 DVS. 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.
4.1Preparation
Unpacking and Inspection
The DVS 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 DVS system
DVS Installation Manual
CD Manual
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 DVS Dealer.
4.2Wiring
4.2.1 General Guidelines
Check utility configuration tag on DVS to make sure that rated input voltage matches local utility voltage. See Table 4-
1for 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 Grounding
DVS must be connected to an equipment-grounding conductor routed with the circuit conductors. Connections must
comply with all local codes and ordinances.
The DVS must be grounded in accordance with the Facilities Utility grounding method.
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.

DVS100 / DVS150 Installation Manual
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4.3 Physical Installation
DVS100
DVS150
DVS Weight
240kg (529lbs)
280gk (617lbs)
CAUTION
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 DVS-100 and DVS-150 are:
- Base: 51,9 x 62,3cm (20.44 x 24.5 in)
- Height: 130,7cm (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
and Figure 4-2.
Maintain a minimum of 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.

DVS100 / DVS150 Installation Manual
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Figure 4-1 DVS-100 and DVS-150 Installation
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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NOTE: We strongly recommend cement curbing, concrete filled steel pipe pillars, or similar protection to be placed around the
DVS to prevent damage to the DVS from a moving vehicle.
The square mounting holes are 6.5mm X 6.5 mm.
Figure 4-2 Bolt Pattern for DVS100 and DVS150 Installation
35,6 mm
429,3 mm
53,4 mm
585 mm

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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 DVS 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 60Hz, 3 phase, 3 wire plus 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.
Table 4-1 Utility and Wiring Information
DVS100
2 x10kW
DVS150
2 x 15kW
Input voltages
400-415V ± 10%
440 ± 10%
400-415V ± 10%
440 ± 10%
Input AC Current at rated load (Amps)
32A at 400V
30A at 440V
50A at 400V
40A at 440V
Input Frequency (Hz)
50 / 60 Hz
50 / 60 Hz
Number of input Phases (Excluding
Ground)
3
3
Maximum Circuit Breaker Rating -
Select per local electrical code
D-characteristic
D-characteristic
D-characteristic
D-characteristic
Minimum Disconnect Switch Voltage
Rating (VAC)
600V
600V
Minimum Inrush Current Capacity
(Amps)
250A
300A
THD Max
35%
35%
Minimum Input Conductor Size
10 mm2
16 mm2
Minimum Ground Wire Terminal Torque
4-5 Nm
4-5 Nm
Output Cable Connector
320A Euro
320A Euro

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Table 4-2 Output Characteristics for DVS
Configuration
DVS100
DVS150
Max Output Power (kW)
2 X 10 kW
2 X 15 kW
Max Output DC Range (Volts)
16-120V
16-130V
Max Output DC Current (Amps)
200A
300A
Minimum Output Wire Size (DC BUS +)
2 X 70mm²
2 X 95mm²
Minimum Output Wire Size (DC BUS -)
2 X 70mm²
2 X 95mm²
Installation / Line Voltage Instructions (400-415VAC)
1. Remove the screws and open the front door of the DVS.
2. Locate the AC Input Terminal Block and the Chassis Ground Connector. Refer to Figures 4-5 thru 4-10.
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. Refer to Figures 4-5 thru 4-10.
NOTE: The grounding wire should have insulation that is green or green with yellow stripe.
4. Close the front door prior to switching on the utility power.
WARNING
ENSURE GOOD ELECTRICAL CONNECTION BY TIGHTENING ALL THE SCREWS PROPERLY

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Figure 4- 1 AC Input Terminal Block
Figure 4- 2 Location of Chassis Ground Connector
CHASSIS
GROUND
CONNECTOR
AC INPUT
TERMINAL
BLOCK
TRANSFORMER
TAPS TERMINAL
BLOCK

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4.5 DC Output Cable Installation
Figure 4-3 DC Output Cable Installation
To install output cable(s):
1. Install output cable(s) ensuring mounting screws and lock washers are properly installed and tightened. Recommended
torque: 8.47 Nm (75 in-lbs)
2. 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 9cm (3.5 inch) are required for output cables

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4.6 Checklist
SYSTEM CHECKED BY
–NAME / SIGNATURE
/
DATE:
CUSTOMER /
LOCATION
/
DATE:
DVS - INSTALLATION AND OPERATIONAL CHECKOUT
DVS
DVS
DVS
DVS
Serial #
Serial #
Serial #
Serial #
_ _ _ _
_ _ _ _
_ _ _ _
_ _ _ _
V_ _ _
_ _
V_ _ _
_ _
V_ _ _
_ _
V_ _ _
_ _
VERIFY AND RECORD SW VERSION
CHECK UNIT IS SECURELY MOUNTED
CHECK AC CIRCUIT BREAKER RATING
DVS100 RATING IS 32 AAC @ 400-415VAC
DVS150 RATING IS 63 AAC @ 400-415VAC
DVS100 RATING IS 30 AAC @ 440VAC
DVS150 RATING IS 57 AAC @ 440VAC
UTILITY CONNECTIONS PROPERLY INSTALLED WITH ALL
FASTENERS TIGHTENED:
CHECK AC TERMINAL BLOCK
CHECK CHASSIS GND CONNECTOR
CHECK INPUT AND OUTPUT WIRES OF AC
CONTACTOR ARE SECURE
ALL DC BUS CONNECTIONS PROPERLY INSTALLED WITH ALL
FASTENERS TIGHTENED:
CHECK DC OUTPUT NEGATIVE
CHECK DC OUTPUT POSITIVE
CHECK DC FUSE
CHECK SHUNT RESISTOR
CHECK OUTPUT CABLE STRAIN RELIEFS ARE SECURED.
BMID COMMUNICATION WIRING IS SECURE AND PROPERLY
CONNECTED
CHECK DC POWER SUPPLY CONNECTION
CHECK CONTROLLER BOARD CONNECTORS ARE SECURELY
AND PROPERLY INSTALLED.
CHECK BASSI CONTROLLER BOARD CONNECTORS ARE
SECURELY AND PROPERLY INSTALLED.
FRONT PANEL LED’s WORK PROPERLY
DISPLAY IS FULLY OPERATIONAL
ALL FRONT PANEL CONTROL BUTTONS ARE FUNCTIONAL
LATEST APPLICATION CODE HAS BEEN LOADED
ALL SCREWS AND WASHERS PROPERLY INSTALLED ON
DOOR AND BACK PANEL
VERIFY DVS CHARGES PROPERLY WHEN CONNECTED TO
VEHICLE
ALL HIGH CURRENT CABLES IN CHARGING PATH ARE
SECURELY FASTENED