Webasto DVS100 User manual

DVS100/DVS150 CAN Board
Installation Guide

DVS CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page iof ii
Contents
1. Safety Precautions: Read before Using......................................................................... 1
1.1. Symbol Usage.......................................................................................................................................... 1
2. Document Purpose ......................................................................................................... 2
3. DVS100/DVS150 CAN Board Overview ........................................................................... 2
3.1. Description ............................................................................................................................................... 2
3.2. Function ................................................................................................................................................... 2
3.3. Scope....................................................................................................................................................... 2
3.4. Use Case ................................................................................................................................................. 2
3.5. Equipment................................................................................................................................................ 2
3.6. DVS100/DVS150 Charger Decal, Manufacturer Nameplate, and Caution Label ........................... 3
4. DVS100/DVS150 CAN Board Installation Process .......................................................... 5
4.1. Updating the Charger Software Version ................................................................................................... 6
4.2. Powering off the DVS100/DVS150 Charger.......................................................................................................... 6
4.3. Installing the CAN Board .......................................................................................................................... 7
4.4. Installing the CAN Board for Channel B ................................................................................................. 12
4.5. Powering Back on the DVS100/DVS150 Charger .................................................................................. 16
Figures
Figure 1 DVS100/DVS150 Charger Decal ..................................................................................................... 3
Figure 2 DVS100/DVS150 Charger Decal, Manufacturer Nameplate, and Caution Label Placements ……….4
Figure 3 Caution Label ................................................................................................................................... 5

DVS CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page ii of ii
Figure 4 CAN Board Mounted to the Mounting Bracket and the X1 and P101 Cables
Connected to the X1 and J101 Connectors, Respectively, on the CAN Board .................................. 7
Figure 5 DVS100/DVS150 Channel A Control Board Assembly...................................................................... 8
Figure 6 CAN Board Assembly Mounting for Channel A ................................................................................. 9
Figure 7 DIP Switches ...................................................................................................................................... 9
Figure 8 CAN Board Connected to the 5–Volt-Direct-Current (-VDC) Supply,
at Port P2, on the Channel A of DVS100/DVS150 Control Board, with the Ribbon Cable ............... 10
Figure 9 P101 Cable Connected from the J101 Connector on the DVS100/DVS150 CAN Board
to the J2 Connector on the Channel A of DVS100/DVS150 Control Board...................................... 10
Figure 10 Disconnected BMID Connector and BMID Cable Tied Securely to the Harness with Cable Ties...... 11
For Channel A cables
Figure 11 X1 Cable Connected to Channel A of TB1 for Communication Connections in the DVS100/DVS150
Charger........................................................................................................................................... 11
Figure 12 Cut BMID Wires Screwed into One Wire Nut ................................................................................... 12
Figure 13 DVS100/DVS150 Channel B Control Board Assembly..................................................................... 12
Figure 14 CAN Board Assembly Mounting for Channel B ............................................................................... 13
Figure 15 DIP Switches .................................................................................................................................. 13
Figure 16 CAN Board Connected to the 5–Volt-Direct-Current (-VDC) Supply,
at Port P2, on the Channel B of DVS100/DVS150 Control Board, with the Ribbon Cable ............... 14
Figure 17 P101 Cable Connected from the J101 Connector on the DVS100/DVS150 CAN Board
to the J2 Connector on the Channel B of DVS100/DVS150 Control Board...................................... 14
Figure 18 Disconnected BMID Connector and BMID Cable Tied Securely to the Harness with Cable Ties...... 15
For Channel B
Figure 19 X1 Cable Connected to Channel B of TB1 for Communication Connections in the DVS100/DVS150
Charger........................................................................................................................................... 15
Figure 20 Cut BMID Wires Screwed into One Wire Nut ................................................................................... 16

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 1 of 17
1. Safety Precautions: Read before Using
The following safety precautions must be read and observed.
•The controller area network (CAN) board is designed with the safety of the user as the highest priority.
•The CAN board design is such that the installer can safely install it.
•Installation must comply with all local codes.
•The CAN board supports safe operation of basic charging functions by a user.
1.1. Symbol Usage
Take special note, in this manual, of the information marked with the following symbols.
DANGER
NOTE
Indicates information about safety practices which, if not followed, may result in death or
serious injury
Indicates helpful information for installation or usage but does not contain personnel or
equipment safety-related information

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 2 of 17
2. Document Purpose
This guide is intended to provide a technician with the information and guidance necessary to install the CAN
board safely onto the DVS100/DVS150 control board.
3. CAN Board Overview
3.1. Description
The CAN board is a circuit board that can be added to the DVS100/DVS150 control board.
3.2. Function
The DVS CAN board sends out a CAN message on the charger’s COMM wires. If a vehicle with a BMS
(Battery Management System) connects to the charger, the BMS will respond to this message and the charger
will begin a charge using the IPC CAN protocol. This protocol is used primarily with lithium-Ion batteries.
If a vehicle with a BMID (Battery Monitor Identification Device) connects, the BMID will not respond to the CAN
message. The DVS CAN board will then switch to BMID mode and the charger will charge using the BMID
protocol. This protocol is primarily used with lead-acid batteries.
3.3. Scope
The CAN board can be used only in the DVS100/DVS150 charger.
3.4. Use Case
If a customer connects an DVS100/DVS150 charger to a truck, then the charger automatically detects whether
the truck is using CAN or BMID communication protocols. If the charger detects CAN communication
protocols, then it will charge according to those; if it does not detect them—or if it detects BMID
communication protocols—then it will charge according to BMID communication protocols.
3.5. Equipment
Equipment Description
Quantity
Part Number
Comments
DVS100/DVS150 CAN package
1
5911438

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 3 of 17
3.6. DVS100/DVS150 Charger Decal, Manufacturer Nameplate, and Caution Label
An DVS100/DVS150 charger decal (sticker) (Figure 1) indicating that the DVS100/DVS150 charger is CAN
compatible is adhered to the front-panel door of the charger, on the lower-middle right side, under the
instructions label (Figure 2).
3.6.1. Place the supplied caution label (31407) (Figure 3) on either side of the manufacturer nameplate.
Ensure that the caution label does not impede the airflow. (Figure 2).
Figure 1 DVS100/DVS150 Charger Decal

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 4 of 17
Figure 2 DVS100/DVS150 Charger Decal, Manufacturer Nameplate, and Caution Label Placements
DVS100/150
CHARGER DECAL
Manufacturer
name plate label
Caution label

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 5 of 17
Figure 3 Caution Label
4. DVS100/DVS150 CAN Board Installation Process
A technician should install the CAN board. Installation must comply with the provisions of all local electrical
codes in the country of installation. The following sections walk technicians through a four-step installation
process.
.
Step 1: Updating the Charger Software Version
Step 2: Powering off the DVS100/150 Charger
Step 3: Installing the Board
Step 4: Powering Back on the DVS100/DVS150 Charger

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 6 of 17
Step 1
4.1. Updating the Charger Software Version
4.1.1. Update the charger software to version 3.00.00.48 or later, using IPC Charger Tool software
version 3.004 or later. Contact your local PosiCharge service representative for copies of the
latest software versions.
Step 2
4.2. Powering off the DVS100/DVS150 Charger
4.2.1. Power off the DVS100/DVS150 charger before installation.
DANGER RISK OF SHOCK
The DVS100/DVS150 charger needs to be powered off during installation. Do not
restore power to the charger until the installation is completed. Failure to follow these
instructions could result in shock or electrocution.
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.

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 7 of 17
Step 3
4.3. Installing the CAN Board
The CAN board comes preassembled and double-wrapped in a box. The board is mounted to the bracket with
flange facing upward (Figure 4). The X1 and P101 cables are connected to the X1 and J101 connectors,
respectively, on the board (Figure 4).
NOTE The DVS100/DVS150 CAN board snaps on to the mounting bracket.
Ensure that the P101 cable is connected to the J101 connector, as shown in Figure 4.
Figure 4 CAN Board Mounted to the mounting Bracket and the X1 and P101 Cables
Connected to the X1 and J101 Connectors, Respectively, on the CAN Board
Yellow wire
Pin 1
J101 connector
X1 connector
Yellow wire
Pin 1
X1 cable
P101 cable

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 8 of 17
4.3.1. Loosen the two top- and bottom-right nuts from the DVS100/DVS150 control board assembly (Channel
A) (Figure 5).
Figure 5 DVS100/DVS150 Channel A Control Board Assembly
4.3.2. Place the DVS100/DVS150 CAN board assembly on the Channel A of DVS100/DVS150 control
board assembly, over the loosened nuts, and slide the CAN board toward the control board, as
shown in Figure 5 approximately, and tighten the two nuts.
NOTE The baud rate can be set with the dual in-line package (DIP) switches on the CAN board
(Figures 6 and 7), by using the below DIP switch table.
Baud Rate DIP 1
125 kbps On
250 kbps Off

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 9 of 17
Figure 6 CAN Board Assembly Mounting for Channel A
Figure 7 DIP Switches
Note: DIP switches shall
be accessible.
CAN board assembly

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 10 of 17
4.3.3. Connect the DVS100/DVS150 CAN board ribbon cable connector to port P2 on the Channel A of
DVS100/DVS150 control board(Figure 8).
Figure 8 CAN Board Connected to the 5–Volt-Direct-Current (-VDC) Supply, at
Port P2, on the Channel A of DVS100/DVS150 Control Board, with the
Ribbon Cable
4.3.4. Connect the P101 cable from the J101 connector on the Channel A of DVS100/DVS150 CAN board
to the J2 connector onthe DVS100/DVS150 control board (Figure 9).
Figure 9 P101 Cable Connected from the J101 Connector on the CAN Board to the
J2 Connector on the Channel A of DVS100/DVS150 Control Board

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 11 of 17
4.3.5. Disconnect the BMID connector J13(P13) from the Channel A of DVS100/DVS150
control board, and tie it, along with the attached BMID cable, securely to the harness
with provided cable ties (Figure 10).
Figure 10 Disconnected BMID Connector J13(P13) and BMID Cable Tied Securely to the Harness with Cable
Ties For Channel A cables
4.3.6. Remove the four BMID wires
that go to the DVS100/DVS150
control board (Pilot Rtn, Pilot,
Data andDIR) from terminal
block TB1 of Channel A, which
is located at the bottom left of
the DVS100/DVS150 charger.
4.3.7. Connect the X1 cable from the X1
connector on the CAN board to
TB1 of Channel A in the
DVS100/DVS150 charger (Figure
11), as listed below.
4.3.7.1. Yellow wire to the Pilot terminal
4.3.7.2. Red wire to the Pilot terminal Figure 11 X1 Cable Connected to Channel A of TB1 for
Communication Connections in DVS100/DVS150 Charger
4.3.7.3. White wire to the Data terminal
4.3.7.4. Black wire to the Dir terminal
NOTE Twisting wires (Figure 11) is recommended for longer distances. Keeping them close
together, however, is more important than twisting them.

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 12 of 17
4.3.8. Route the X1 cable along the
existing cables, with a provided
cable tie.
4.3.9. Screw the BMID wires into one
wire nut (Figure 12), bend them
back, and secure them to the
harness with a provided cable tie.
Figure 12 Cut BMID Wires Screwed into One Wire Nut
4.4. Installing the CAN Board for Channel B
4.4.1. Loosen the two top- and bottom-right nuts from the DVS100/DVS150 control board assembly (Channel
B) (Figure 13).
Figure 13 DVS100/DVS150 Channel B Control Board Assembly
4.4.2. Place the DVS100/DVS150 CAN board assembly on the Channel B of DVS100/DVS150 control
board assembly, over the loosened nuts, and slide the CAN board toward the control board, as
shown in Figure 13, approximately, and tighten the two nuts.

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 13 of 17
NOTE The baud rate can be set with the dual in-line package (DIP) switches on the CAN board
(Figures 14 and 15), by using the below DIP switch table.
Baud Rate DIP 1
125 kbps On
250 kbps Off
Figure 14 CAN Board Assembly Mounting for Channel B
Figure 15 DIP Switches
Note: DIP switches shall
be accessible.
CAN board assembly

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 14 of 17
4.4.3. Connect the DVS100/DVS150 CAN board ribbon cable connector to port P2 on the Channel B of
DVS100/DVS150 control board(Figure 16).
Figure 16 CAN Board Connected to the 5–Volt-Direct-Current (-VDC) Supply, at
Port P2, on the Channel B of DVS100/DVS150 Control Board, with the
Ribbon Cable
4.4.4. Connect the P101 cable from the J101 connector on the Channel B of DVS100/DVS150 CAN board
to the J2 connector onthe DVS100/DVS150 control board (Figure 17).
Figure 17 P101 Cable Connected from the J101 Connector on the CAN Board to
the J2 Connector on the Channel B of DVS100/DVS150 Control Board

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 15 of 17
4.4.5. Disconnect the BMID connector J13(P13) from the Channel B of DVS100/DVS150
control board, and tie it, along with the attached BMID cable, securely to the harness
with provided cable ties (Figure 18).
Figure 18 Disconnected BMID Connector J13(P13) and BMID Cable Tied Securely to the Harness with Cable
Ties For Channel B
4.4.6. Remove the four BMID wires
that go to the DVS100/DVS150
control board (Pilot Rtn, Pilot,
Data andDIR) from terminal
block TB1 (in Channel B), which
is located at the bottom right of
the DVS100/DVS150 charger.
4.4.7. Connect the X1 cable from the X1
connector on the CAN board to
TB1 (of Channel B) in the
DVS100/DVS150 charger (Figure
19), as listed below.
4.4.7.1. Yellow wire to the Pilot terminal
4.3.7.2. Red wire to the Pilot terminal Figure 19 X1 Cable Connected to Channel B of TB1 for
Communication Connections in DVS100/DVS150 Charger
4.4.7.3. White wire to the Data terminal
4.4.7.4. Black wire to the Dir terminal
NOTE Twisting wires (Figure 19) is recommended for longer distances. Keeping them
close together, however, is more important than twisting them.

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 16 of 17
4.4.8. Route the X1 cable along the
existing cables, with a provided
cable tie.
4.4.9. Screw the BMID wires into one
wire nut (Figure 20), bend them
back, and secure them to the
harness with a provided cable tie.
Figure 20 Cut BMID Wires Screwed into One Wire Nut
Step 4
4.5. Powering Back on the DVS100/DVS150 Charger
4.5.1. Power back on the DVS100/DVS150charger after installation.

DVS-CAN Board
Installation Guide
5911436 A01
Webasto Charging Systems, Inc.
Page 17 of 17
Webasto Charging Systems, Inc.
1333 S. Mayflower Ave., Ste 100
Monrovia, CA 91016, USA
Corporate headquarters:
Friedrichshafener Str. 9
82205 Gilching
Germany
Identification No. • 5911436 A01 • 11/21 • © Webasto Charging Systems, Inc.,