Webasto PosiCharge DVS 300 Manual

Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400
31504-03-0101 Webasto Charging Systems, Inc.1
Intelligent Fast-Charging System
Ground Support Equipment (GSE)
Operation & Maintenance Manual
DVS300 / 330 / 330 IP55 / 400
MVS330 / 400

Intelligent Fast-Charging System GSE O&M for DVS300 / 330 / 330 IP55 / 400 and MVS330/400
31504-03-0101 Webasto Charging Systems, Inc.2
© Webasto Charging Systems, Inc., 2023. All rights reserved.
ProCoreTM is a product line of Webasto Charging Systems, Inc. (WCSI). Webasto Charging Systems and the
Webasto Charging Systems logo are trademarks of WCSI. Corporate names, trademarks, registered trademarks,
service marks, symbols, and logos stated herein are the property of the respective companies.
Changes or modications to this product not completed by an authorized service provider could void the
product warranty.
Disclaimer: This manual includes the latest information available at the time of printing. WCSI reserves the
right to make changes to this manual and/or product without further notice. Specications are subject to
change without notice.
No portion of these materials may be duplicated, used, or disclosed without prior written permission from WCSI.

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Owner’s Record
Model:
PosiCharge™
Serial Number (SN):
Purchase date:
Output power:
A NOTE ABOUT CUSTOMER SUPPORT
Please write down the unit serial number in the Owner’s Record below to ensure superior service, and have
it available when contacting Webasto Customer Service. The serial number can be found on the nameplate
rating label on the left side of the unit.
Customer Support: [email protected]
1-866-767-4242
Parts: [email protected]

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CONTENTS
1 – SAFETY PRECAUTIONS – READ BEFORE USING ........................................................... 6
1.2 – Symbol Usage ..................................................................................................................6
1.3 – Safety Instructions.............................................................................................................6
2 – GENERAL INFORMATION .................................................................................................... 9
2.1 – Technical Support.............................................................................................................. 9
2.2 – Applicable Documents.......................................................................................................9
2.3 – Acronyms, Abbreviations and Symbols .......................................................................... 10
3 – OVERVIEW ........................................................................................................................... 11
3.1 – System Description ........................................................................................................ 11
Figure 1 – DVS300 / 330 / 330 IP55 / 400 ...................................................................... 11
Figure 2 – MVS330 / 400 ................................................................................................ 11
3.2 – System Function .............................................................................................................13
Figure 3 – Front Panel Layout ........................................................................................ 13
3.3 – Options and Accessories.................................................................................................14
4 – OPERATION ..........................................................................................................................15
4.1 – Getting Started................................................................................................................15
4.2 – Only for MVS Setups: Conguring the Main Station and Support Stations. ................... 16
Figure 4 – Power Station Control Board Location........................................................... 16
Figure 5 – Detailed View of the DIP Switch in Parallel Conguration ............................. 17
4.3 – System Startup................................................................................................................19
Figure 6 – Startup Windows............................................................................................ 19

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4.4 – Charging..........................................................................................................................20
Figure 7 – Connecting status Windows .......................................................................... 20
Figure 8 – Charge Completed / Stopped Windows......................................................... 21
4.5 – Equalization.....................................................................................................................22
4.6 – Data Logs, Charger Conguration, and Advanced Programming Features.................... 23
Figure 9 – Representative Charging Data Window......................................................... 23
Figure 10 – Representative Fault or Warning Window ................................................... 23
4.7 – External Status Indicator Conguration (Optional).......................................................... 24
Figure 11 – Top Level Menu for Advanced Features....................................................... 24
5 – MAINTENANCE .................................................................................................................... 25
5.1 – DVS Periodic Maintenance Schedule ............................................................................ 25
5.2 – DC Power Output Cable Service..................................................................................... 25
Figure 12 – Correct PIN Alignment ................................................................................. 26
Figure 13 – Incorrect PIN Alignment ............................................................................... 26
5.3 – Air Filter Maintenance for DVS330 IP55 ......................................................................... 28
New Air Filters Meet IP55 Standards .............................................................................. 28
DVS330 IP55 Side Air Vents........................................................................................... 29
DVS330 IP55 Front and Rear Vents ............................................................................... 29
6 – TROUBLESHOOTING .......................................................................................................... 33
6.1 – Problem Symptoms, Probable Causes, and Action Codes............................................. 33
6.2 – Fault and Warning Codes and Messages, Descriptions, and Action Codes ................... 36

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1 – SAFETY PRECAUTIONS – READ BEFORE USING
The ground support equipment (GSE) (charger power station[s] and power server: the unit) is designed with
user safety as the highest priority. Operation and maintenance, however, must comply with all local codes; and
the following safety precautions must be read and observed.
1.2 – Symbol Usage
Take special note of the information marked with the following symbols throughout this manual:
DANGER Indicates information about safety practices necessary to prevent personal
injury or death.
WARNING Indicates information about safety practices necessary to prevent re or
equipment overheating.
CAUTION Indicates information about safety practices necessary to prevent shock hazard
or possible damage to the equipment during installation and service.
NOTE Indicates 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
Assembly.
• Make sure that you also read the IMPORTANT SAFETY INSTRUCTIONS
on pages 2 and 3.
• Be sure to leave these instructions with the installed unit for future reference.
• Only qualied personnel should install, use, or service the unit.
• Read and understand these manufacturer’s instructions and your employer’s
safety practices manual.
1.3 – Safety Instructions

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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 a size equal
to or larger than that recommended by local electrical codes or the Intelligent
Fast-Charging System Ground Support Equipment (GSE) Installation Guide.
• Do not touch the uninsulated portion of the output battery connector or an
uninsulated battery terminal.
• Do not remove the cover(s). Only qualied service personnel may remove
the cover(s) on the unit. There are no user serviceable parts inside. Refer
all servicing to qualied service personnel. Opening, or attempting to install
or repair, the system by anyone other than qualied service personnel voids
the warranty.
• Disconnect the battery charger from the input power and battery connections
before servicing the unit. Lock out/tag out input power according to OSHA 29
CFR 1910.147.
• Do not use/service/repair it when it is in standing water.
• Before disconnecting the battery, stop charging by pressing the Stop button on
the front panel of all power stations. Power stations are designed to stop an
electric charge automatically, in the event of a hot disconnection, to minimize
arcing or burning of the charger connections.
• The charging leads must be capable of the full-rated current of the DVS,
and inspected frequently for wear, cuts, and abrasion. Do not use worn,
damaged, undersized, or poorly spliced cables.
• The DVS 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.

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DANGER BATTERY GASES AND ELECTROLYTES CAN BE HAZARDOUS
• Charging batteries produces fumes and gases that may be hazardous.
• Charging batteries may leak corrosive electrolytes that can cause skin
and eye irritation, and damage equipment and clothing. Avoid contact, and
follow the battery manufacturer’s recommended practices for cleaning the
battery pack.
• Thoroughly wash all items brought into contact with the 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 place the unit on, over, or near combustible surfaces.
• Do not place the unit near ammable items.
• Do not block the air intake to, or exhaust from the unit. Allow a minimum of
6″ of clearance around the unit.
• Do not block airow to the unit.
• Replace blown fuses only with the same type and rating of fuse.
• Do not overload the building wiring. Be sure that the utility power service is
• Properly sized, rated, and protected to handle this unit. Use the unit only with
the circuits provided, with the minimum wire size specied in the installation
guide.
CAUTION ELECTROSTATIC DISCHARGE PRECAUTIONS
Electronic circuits are sensitive to damage from electrostatic discharge (ESD).
Persons servicing this equipment should be trained in proper techniques for
avoiding ESD damage to electronic circuits.
Wear an appropriate ESD wrist strap connected to the equipment chassis, as a
minimum, when handling circuit boards.

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2 – GENERAL INFORMATION
2.1 – Technical Support
Call WCSI technical support any time a procedural question arises. DO NOT perform a procedure you do not
understand. WCSI Customer Service can be contacted during normal working hours (Pacic Standard Time) at the
following e-mail address and phone number. Please have the information ready below to ensure superior service.
[email protected]
866–POSICHARGE (866–767–4242)
For ProCore Chargers For Other PosiCharge Chargers
1. Problem description, including any fault codes
2. Data download from the charger, including
charge logs and fault logs
3. Failed charger SKU number and serial number
4. Failed module SKU number and serial number
5. Customer name, for our reference
6. Ship to company name
7. Ship to company address
8. Ship to contact name
9. Ship to contact phone number
1. Charger model, SKU #, and serial number
2. Problem description, including any fault codes
3. How you diagnosed the problem
4. Customer name, for our reference
5. Ship to company name
6. Ship to company address
7. Ship to contact name
8. Ship to contact phone number
2.2 – Applicable Documents
Title Part Number
BMID I Installation Manual 11717-W-03
BMID III (Battery Rx) Installation Manual 16672-W-03
BMID Programming Manual, Battery RX, SVS/ELT 06701-W-03
Intelligent Fast-Charging System Ground Support Equipment (GSE) Installation Guide
for the DVS300/330/400 and MVS330/400
31504-76

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2.3 – Acronyms, Abbreviations and Symbols
Acronym, Abbreviation or Symbol Meaning
AAmp(s) or Ampere(s)
BMID Battery Monitor and Identier
CC Constant Current (Charging Mode)
CV Constant Voltage (Charging Model
DC Direct Current
DIP Dual In-Line Package
DVS Dual Vehicle System
ESD Electrostatic Discharge
EQ Equalization / Equalize
GSE Ground Support Equipment
IPC Industrial PosiCharge
LED Light Emitting Diode
MVS Multi-Vehicle System
OSHA Occupational Safety and Health Administration
PN Part Number
RCI Rapid Charging Intelligence
SBX® Storage Battery Connector with Auxiliary Contacts
SOC State of Charge
VAC Volts Alternative Current
VDC Volts Direct Current
V Volt(s)
WCSI Webasto Charging Systems, Inc.
°C Degrees Celsius

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3 – OVERVIEW
3.1 – System Description
The Dual Vehicle System (DVS) 300/330/400 (Figure 1) and the Multi-vehicle System (MVS) 330/400 (Figure 2)
are advanced transistor-based, fast-charging systems. These systems can charge industrial batteries quickly and
safely, providing all the battery charging and equalizing required for your application.
Figure 1 – DVS300 / 330 / 330 IP55 / 400 Figure 2 – MVS330 / 400

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Fast Charging
• Dramatically reduces the time it takes to recharge a battery to a high state of charge (SOC).
• Makes opportunity charging possible during available breaks, shift changes, and other idle times; and
keeps a vehicle running all day long without changing batteries.
• Can eliminate the need for a battery changing room, in most two- and three-shift operations, freeing up
oor space and personnel for productive activities and reducing battery inventory by up to 65%.
• Increases productivity by eliminating down time for battery changing and avoiding low-voltage operation
that can reduce vehicle performance.
Rapid Charging Intelligence
• Makes the system capable of charging much more quickly than a conventional charger without damage
to the battery.
• Precisely monitors the battery voltage and temperature, allowing charging to be as rapid as possible
without exceeding the manufacturers’ recommendations.
• Tracks the charge history of the battery pack.
• Automatically performs equalization on the battery pack, according to a preset schedule. This automation
results in better use of the batteries with minimal e󰀨ort on the user’s part.
Rapid Charging Intelligence (RCI) is built into the system to make charging extremely simple. Just connect any
IPC-compatible battery, and the system starts charging it correctly. There is no need to be concerned about
which charger (power station) is designed or programmed for which battery. The system shuts o󰀨 automatically
after completing a charge.

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3.2 – System Function
Charge Prole
The DVS provides a constant current–constant voltage–constant current (I-E-I) charge prole that precisely
controls the charge rate, and optimally charges the batteries by precisely adjusting the current in response to
the capacity, temperature, and age of the batteries.
Battery Monitor and Identier
The DVS works with a battery monitor and identier (BMID), which is a small monitoring device mounted on the
battery. The BMID enables the charger (power station) to adjust the charge automatically to match the requirements
of all of the batteries in the eet, eliminating mismatching batteries and chargers (power stations).
User Interface
The keypad and display on the front of the DVS (Figure 3) provide the user interface to the charger (power
station). The alphanumeric display panel constantly updates the charger (power station) and battery status, and
allows access into the programming menus through the keypad. Four status light-emitting diodes (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.
Figure 3 – Front Panel Layout

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3.3 – Options and Accessories
The following options and accessories are available through your authorized Industrial PosiCharge DVS
Fast-Charging System dealer. Contact WCSI customer service directly for any other replacement parts.
Battery Monitors and Identiers
Many di󰀨erent sizes and types of industrial battery packs may be charged with the DVS Fast-Charging System.
Choose the correct BMID for the nominal voltage of your pack.
24V BMID P/N 08660-W
36V - 48V BMID P/N 08661-W
72V - 80V BMID P/N 08662-W
Contact Customer Service for Dual SBX or Euro cable kits.
Thermistor Options
Choose the correct thermistor type for your battery. Submersible thermistors are designed for installation
through the battery case into the battery electrolyte of ooded battery cells. Exterior thermistors are designed
to be glued onto the exterior of sealed batteries. DO NOT submerge exterior thermistors into electrolyte as
corrosion will result in erroneous readings.
Submersible (ooded battery) thermistor P/N 09525-xxx
Exterior (sealed battery) thermistor P/N 08664

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4 – OPERATION
4.1 – Getting Started
Take the time before you begin to familiarize yourself with section 1.2 Safety Instructions. Perform the following
steps to get your system up and running quickly.
1. Ensure that the Fast-Charging DVS installation and utility power requirements are followed. Refer to the
Intelligent Fast-Charging System Ground Support Equipment Installation Guide PN 31504-76.
2. Install the BMID onto the battery pack. Refer to the BMID I Installation Manual PN 11717-W-03 or BMID
III Battery Rx Installation Manual PN 16672-W-03.
The battery dealer or other authorized service technician, however, typically will install the BMID on the
battery pack and congure it before delivery to the customer.
Each BMID is pre-congured with the following information:
• An identication number, which can help track the charging history of a specic battery.
• A type code, which indicates the manufacturer and type of battery.
• The number of cells in the battery.
• The ampere-hour capacity of the battery.
• The start current limit of the battery pack for optimal charging.
• The battery SOC limit, which determines when the charging will stop.
• The internal resistance.
• The maximum ampere-hours between equalizations.
• The maximum days between equalizations.
• The equalization day of the week.
• The voltage limit for fast charging and equalization.
• The battery temperature foldback.
• The BMID initialization.
3. The battery pack may be connected to the charger (power station) once the BMID is installed.
4. Initialize the BMID if it (is new and) does not come pre-congured.
Refer to the BMID Programming Manual, Battery RX, SVS/ELT [PN 06701-W-03].)
BMIDs also may be recongured on site through the charger (power station) front panel. (Refer to the
BMID Programming Manual, Battery RX, SVS/ELT [PN 06701-W-03].)
5. The battery pack is ready to begin charging once the BMID has been initialized.

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4.2 – Only for MVS Setups: Conguring the Main Station and Support Stations.
The MVS Intelligent Fast-Charging System is very exible. It requires each new installation to be congured for
the total number of power stations in the system.
1. Install the system.
2. Set the maximum port current conguration for each of the power stations. Each power station contains
a control board that is mounted on the inside surface of the door (Figure 4).
3. Remove the three Phillips screws on the right-hand side of the power station door to open the door.
Figure 4 – Power Station Control Board Location
Control Board DIP Switch Bank

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4. Set the control board SW1-4 DIP switch in the DIP switch bank (Figures 4 and 5) to the ON position to
enable the parallel-mode operation.
• Figure 5 shows a detailed view of the [SW1-4] DIP switch in the parallel conguration. When parallel
operation is enabled and only one vehicle is connected to the power station then both power sections
in the charger are combined to deliver maximum power.
• The installation software utility program then sets the maximum port current conguration. If the
SW1-4 switch is set to the OFF position, then this conguration is limited based on the model design.
5. Apply the power.
• The power station installed and wired nearest to the power server must be congured as the main station
of the system and all other power stations as support stations. This conguration is accomplished through
the use of the front-panel conguration menus (Figure 3).
• The factory default setting for all power stations is the support setting.
Figure 5 – Detailed View of the DIP Switch in Parallel Conguration

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6. Set the main/support conguration as follows:
A) Power ON the system and wait for it to complete initialization tests. The display shows the
startup windows (Figure 6).
B) Enter the key code down-arrow+Enter on the front panel (Figure 3) to display the Charger
Conguration Menu.
C) Use the SELECT button to scroll to the Network Cong. Setup menu, and press the ENTER
button. The next sub-menu allows the user to select the type of power server to be used with
the system.
D) Select from the following options: COMM VARIABLE POWER, FIXED POWER 80 KW, FIXED
POWER 60 KW, FIXED POWER 40 KW, and FIXED POWER 33 KW.
Earlier versions of the power server use the COMM VARIABLE POWER mode. The NGPS
power server uses the FIXED POWER modes.
E) Enter the number of ports to be congured in the system, once the desired power server mode
is congured. The number of ports in a system is twice the number of power stations, since
each power station in the system has two ports (A and B). The main power station is included
in the total port count. A system with 5 power stations (1 main and 4 support), therefore, would
be congured for 10 ports.
F) Reboot the entire system by cycling the system power once the main station has been properly
congured (see section 4.2 System Startup). This step is necessary to complete the system
conguration.
Refer to the Intelligent Fast-Charging System Ground Support Equipment Installation Guide
PN 31504-76 for complete descriptions of the main/support station conguration

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4.3 – System Startup
The DVS is ready to be powered on once it has been properly installed (mechanically and electrically). The
system performs a lamp test when rst powered on. The display then shows the initial status window containing
the model number and software version. The system then sequences through two more status windows before
reaching the Charger Ready Connect Vehicle window (Figure 6). The windows for each charge port alternate
when initialization is complete.
NOTE An arrow in the upper-left or -right corner of the window indicates which chan-
nel data currently are being displayed.
DVS 40kW 500 Amps
Version xx.xx.xx.xx
Station unavailable
Please see system stat
Conguring network
Starting power server
Charger ready
Connect vehicle
Figure 6 – Startup Windows

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4.4 – Charging
NOTE
The numbers shown as part of the window display in this section of the manual
are only for illustration purposes. The actual numerical combination of voltage,
current and temperature will vary with the type of battery pack being charged.
1. Connect the battery to the charger (power station).
Simply connect the battery to either charge port of the charger (power station) to start charging. The
charger (power station) establishes communication with the BMID, calculates the current SOC, identies
the correct charging prole, and starts charging. The charger (power station), at each step, displays the
corresponding status window (Figure 7).
<Charger ready
Connect vehicle
<Vehicle connected
Getting cong info
<Starting fast charge
Please wait xx sec
<Charging 53%
50.1V 500A 40 °C
Figure 7 – Connecting status Windows
The DVS during the Preparing to Charge step counts down while preparing to charge. Charging preparation
includes measuring the open circuit voltage (OCV) of the battery pack and calculating the SOC to determine
what the initial current should be to charge the pack properly. The current is ramped up from zero to the
target initial current once the charge starts and the Charging window is displayed, while the charger (power
station) monitors the pack voltage.
NOTE The window examples (in Figure 7) have a left-facing arrow at the left of line 1.
This arrow indicates that the display applies to charge port A. A right-facing
arrow at the right of line 1 indicates that the display applies to charge port B.
The display window periodically will update the charging data as the charge
progresses. The front panel (Figure 3), in addition, has several status LEDs
that indicate the current status of the vehicle under charge and whether it is
scheduled for an equalization (Table 1).
Vehicle connected
Communication established