Webasto PosiCharge DVS 330 User manual

Operations and Maintenance Manual
GSE Intelligent Fast Charging System
DVS 330 380VAC/50Hz with Emergency OFF

DVS Fast Charging System Operation and Maintenance Manual
09910-W-03-02 Page 2 of 27 Webasto Charging Systems, Inc.
Webasto Customer Service:
[phone]
[email protected]
© 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.

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Table of Contents
1OVERVIEW........................................................................................................................ 5
1.1 GETTING STARTED .......................................................................................................... 5
1.2 APPLICABLE DOCUMENTS ............................................................................................... 5
2SAFETY PRECAUTIONS - READ BEFORE USING................................................... 6
2.1 SYMBOL USAGE ............................................................................................................... 6
2.2 SAFETY INSTRUCTION...................................................................................................... 6
3SYSTEM DESCRIPTION.................................................................................................. 9
3.1 OPTIONS AND ACCESSORIES ............................................................................................ 9
4SYSTEM INSTALLATION............................................................................................... 9
5OPERATION..................................................................................................................... 10
5.1 SYSTEM START UP......................................................................................................... 10
5.2 CHARGING..................................................................................................................... 11
5.3 EQUALIZATION .............................................................................................................. 13
5.4 FULL /OVER CHARGING................................................................................................ 14
5.5 REDUCED CHARGING..................................................................................................... 14
5.6 VIEWING CHARGE DATA OR FAULT /WARNING SCREENS............................................. 14
5.7 DATA LOGS,CHARGER CONFIGURATION AND ADVANCED PROGRAMMING FEATURES. 15
6DVS/MVS 330 PERIODIC MAINTENANCE............................................................... 17
6.1 DC POWER OUTPUT CABLE INSPECTION AND SERVICE ................................................. 17
6.2 INTAKE AND EXHAUST VENT INSPECTION AND SERVICE............................................... 17
7DVS/MVS 330 TROUBLESHOOTING ......................................................................... 18
7.1 HOW TO USE THIS SECTION........................................................................................... 18
7.2 ACTIONS........................................................................................................................ 23

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List of Figures
FIGURE 5.1. ON/OFF/EPO FRONT PANEL BUTTONS............................................................. 10
FIGURE 5.2. START UP SCREENS .............................................................................................. 11
FIGURE 5.3. CONNECTING STATUS SCREENS .......................................................................... 12
FIGURE 5.4. FRONT PANEL LAYOUT........................................................................................ 12
FIGURE 5.5. CHARGE COMPLETE SCREENS ............................................................................ 13
FIGURE 5.6. REPRESENTATIVE CHARGING DATA SCREENS ................................................... 14
FIGURE 5.7. REPRESENTATIVE FAULT OR WARNING SCREENS.............................................. 15
FIGURE 5.8. TOP LEVEL MENU FOR ADVANCED FEATURES................................................... 16
List of Tables
TABLE 5.1. LED LABELS AND DEFINITIONS............................................................................ 13
TABLE 6.1. PERIODIC MAINTENANCE SCHEDULE.................................................................... 17
TABLE 7.1. PROBLEM SYMPTOMS AND ACTION KEY............................................................... 19
TABLE 7.2. FAULT CODES AND ACTION KEY........................................................................... 21
TABLE 7.3. CHARGE TERMINATION CODES ............................................................................. 27

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1 Overview
The DVS/MVS 330 Fast Charging System is an advanced charging system that quickly and
safely charge industrial batteries.
The charger’s Rapid Charging Intelligence (RCI) makes it capable of charging much more
quickly than a conventional charger without damage to the battery. Battery voltage and
temperature are monitored precisely, allowing charging to be as rapid as possible without
exceeding manufacturers' recommendations. The charge history of the pack is tracked and
equalization is automatically performed on the pack according to a pre-set schedule. This
results in better use of the batteries with minimal effort on the user’s part.
1.1 Getting Started
First, familiarize yourself with the caution symbols in Section 2. To get the system up and
running quickly perform the following steps:
1. Ensure the DVS/MVS 330 Fast Charging System installation and utility power requirements
are followed.
2. Install and program the Battery Monitor / Identifier (BMID) onto the battery pack.
3. Once BMID is installed, the battery pack may be connected to the charger.
4. If the BMID does not come pre-configured, initialize the new BMID.
5. Once the BMID has been initialized, the battery pack is ready to begin charging.
1.2 Applicable Documents
TITLE
DVS/MVS 330 System Installation Manual
BMID Installation Manual

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2 Safety Precautions - Read before using
2.1 Symbol usage
Throughout this manual, take special note of the information marked with the following
symbols:
DANGER
Contains information about safety practices necessary to prevent
personal injury or death.
WARNING
Contains information about safety practices necessary to prevent
fire or equipment overheating.
CAUTION
Contains information to prevent shock hazard or possible damage
to the equipment during installation and service.
NOTE: Offers helpful information for installation or usage, but does not contain personnel or
equipment safety related information.
2.2 Safety Instruction
CAUTION
BEFORE YOU BEGIN:
Read all instructions and cautionary markings on the Industrial
PosiCharge DVS/MVS 330 System Assembly.
Make sure you also read the IMPORTANT SAFETY
INSTRUCTIONS below.
Be sure to leave these instructions in a safe and easily accessible
location for future reference.
Only qualified personnel, familiar with the local code, should
install and service this charger.
Read and understand the manufacturer’s instructions and your
employer’s safety practices manual.

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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 size equal to or larger
than that recommended by local electrical codes or the installation manual.
Do not touch the uninsulated portion of the output battery connector or an uninsulated
battery terminal.
Do not remove the cover. There are no user serviceable parts inside. Refer all servicing to
qualified service personnel. Opening the system, or attempted repair by other than qualified
service personnel, voids the warranty.
Using the OFF and/or Emergency Power OFF (EPO) button does NOT remove the input
power completely from the system. 120VAC still exists at R1 on the Door Assembly, on
TB2 on the left interior wall, and on TB1 on the interior top wall of the PowerStation even
after the OFF and/or EPO button has been pressed.
Disconnect battery charger from input power and battery connections before installing or
servicing. Lockout/tagout input power according to OSHA 29 CFR 1910.147.
Do not use when in standing water.
The charging leads must be capable of the full rated current of the DVS/MVS 330 system,
and inspected frequently for wear, cuts and abrasion. Do not use worn, damaged,
undersized, or poorly spliced cable.
The DVS/MVS 330 power connectors may be damaged by misuse or abuse. Frequently
inspect the connector for cracking, pitting of contacts, fraying of wires or signs of connector
fatigue. Should any indication be present, immediate replacement of the connector will be
necessary.
Do not wear rings, watches, necklaces, tie clips, or conductive jewelry when working with
batteries, as a short circuit through conductive jewelry may cause severe burns.
DANGER
BATTERY GASES AND ELECTROLYTE CAN BE
HAZARDOUS:
Charging batteries produces fumes and gases that may be hazardous.
Charging batteries may leak corrosive electrolyte that can cause skin and eye irritation and
damage equipment and clothing. Avoid contact and follow battery manufacturer’s
recommended practices for cleaning the battery pack.
Thoroughly wash all items brought into contact with battery electrolyte with a solution of
baking soda and water.

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Batteries produce explosive gases. Do not smoke, perform operations that cause sparking,
or have an ignition source near batteries.
Ventilate the area to prevent the buildup of fumes and gases.
WARNING
IMPROPER INSTALLATION CAN CAUSE FIRE
Do not install or place unit on, over or near combustible surfaces.
Do not install unit near flammables.
Do not block or filter airflow to the unit (allow minimum of 6” clearance around unit).
Ensure that the BMID is properly installed according to the BMID installation instructions.
Replace blown fuses only with same type and rating of fuse.
Do not overload building wiring - be sure the 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 manual.

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3 System Description
The DVS/MVS 330 Fast Charging System is a fast charging system that provides battery
charging and equalizing required for the application. It provides a constant current-constant
voltage-constant current (IEI) charge profile that precisely controls the charge rate, and
optimally charges your batteries by adjusting the current in response to the battery’s specific
condition.
The keypad and display on the front of the DVS 330 provide the user interface to the charger.
The alphanumeric display panel constantly updates the charger and battery status, and allows
access to the programming menus through the keypad. Four status LEDs allow the user to
determine from a distance when the charge is in progress, at 80% complete, fully charged, or in
equalization. A fault/warning LED serves to alert the user to fault conditions.
The DVS/MVS 330 system operates with a small monitoring device mounted on the battery
called the battery monitor/identifier (BMID). The BMID enables the charger to automatically
adjust the charge to match the requirements of any battery type.
3.1 Options and Accessories
The following options and accessories are available through your authorized Industrial
PosiCharge dealer. Contact your local distributor for the latest option & accessory parts list.
Battery Monitor and Identifiers (BMID)
Many different sizes and types of industrial battery packs may be charged with the DVS/MVS
330 Fast Charging System. The basic options are as follows:
BMID
oI & III
Thermistor
oSubmersible for flooded batteries
oExternal for sealed batteries
Diagnostic Cable
A diagnostic cable is used for data downloads and firmware uploads.
4System Installation
Refer to the DVS/MVS 330 System Installation Manual, for detailed information

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5 Operation
Fast charging dramatically reduces the time to recharge a battery to a high state of charge. Fast
charging makes it possible to opportunity charge during available breaks, shift changes and
other idle time and keep a vehicle running all day long without changing batteries.
5.1 System Start Up
After proper installation (mechanically and electrically), the system is ready to be powered.
With the external 380VAC, 50Hz input applied to the system, press the green ON button
located on the front door assembly. See Figure 5.1.
Figure 5.1. 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. Internally, the accessory 120VAC still remains enabled when the system is powered-off
using the OFF or Emergency OFF button. Turn off the AC input to the system and remove all
output connections prior to performing any service to the system. Before restarting the system
after any emergency, be sure the system has been returned to a safe, operable condition before
pressing the ON button to restart the system.
When power is applied to the DVS/MVS 330 Fast Charging System, it will perform a lamp test.
The display will then show the initial status screen containing the model number and the
software version. The Charger will then sequence through two more status screens before
reaching “Charger Ready Connect Vehicle.” See Figure 5.2. When initialization is complete,
the screens for each charge port will alternate. Note that there is an arrow in the upper left or
right corner of the screen indicating which channel’s data is currently being displayed.

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Figure 5.2. Start up Screens
5.2 Charging
(Note: The numbers shown as part of the screen display in this section of the manual are for
illustration purposes only. The actual numerical combination of voltage, current, and
temperature will vary with the type of battery pack being charged.)
Step 1: Starting a Charge
To start charging, connect the battery to either charge port of the charger. The charger will
establish communication with the BMID, calculate the current State Of Charge (SOC), identify
the correct charging profile, and start charging.
The charger will display the corresponding Status screen (see Figure 5.3.)
DVS/MVS 33kW
yyy Amps
Configuring Network
Starting PowerServer
Charger Ready
Connect Vehicle

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Figure 5.3. Connecting Status Screens
Note that the screen examples shown above have a left-facing arrow at the left of line 1. This
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.
Figure 5.4. Front Panel Layout
<Charger Ready
Connect Vehicle
<Vehicle Connected
Getting Config Info
<Starting Fast Charge
Please Wait 30 Sec
<Charging
53%
50.1 V 500A
Vehicle Connected
Comm Established
Count Down

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Table 5.1. LED Labels and Definitions
LED Label
Color
When Steady Lit
When Flashing
Equalizing
Green
Battery undergoing equalization
Equalization
scheduled
Charge Complete
Green
Charge Complete and stopped
N/A
80% Charged
Green
The Battery SOC is >= 80%
N/A
Charging
Amber
Battery connected and charging
N/A
Fault/Warning
Red
Fault (Charge stopped)
Warning (Check log)
Step 2: Stopping a charge
The charger will stop automatically when the charger reaches a full charge, detects a
disconnection of the charge connector, or will stop when a fault occurs. It can be manually
stopped as well if the operator presses the “Stop” button.
NOTE: It is not necessary to press the red OFF button to terminate a charge. The OFF button
is only used to remove power to the system.
After a charge has been completed or stopped by the user, the screen will indicate the method
by which the charge was stopped. The display will also contain the data values obtained at the
end of charging (see Figure 5.5).
Figure 5.5. Charge Complete Screens
NOTE: If the operator disconnects the cables without pressing STOP, the charger will
immediately stop charging and prevent any arcing or damage to either the charger or battery.
Step 3: Disconnect battery cables from charger
5.3 Equalization
Proper equalization is necessary for the health of the pack. Too little equalizing may lead to
sulfation and decreased capacity, whereas excessive equalizing may lead to high water loss and
more maintenance. Webasto recommends equalizing at least once a week.
The equalization schedule is stored in the BMID and is automatically initiated according to its
preprogrammed schedule. To manually schedule an equalization during a charge, simply press
the “Equalize” button at any time during a charge, the equalize light will start flashing
indicating an equalization is scheduled, and the battery pack will be equalized following the fast
charge.
<Chg Complete
81%
62.2V 50.0A
<Chg Stopped
62%
60.1V 500A
or

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To bypass the fast charge and start an equalization charge on a battery pack at any state of
charge, press and hold the “Equalize” button for three (3) seconds, the equalize light will
illuminate without flashing, and the charger will start a full equalization on the pack without a
fast charge. To cancel a requested equalization charge, press the Equalize button and the
Equalize LED will turn off.
CAUTION
Always run a full equalization charge prior to a fast charge on any
battery pack that has had a cell replaced to ensure the pack is
balanced.
5.4 Full / Over Charging
Full/Over Charging is a feature that allows the user to schedule a period of fast charge to 100%,
followed by a brief EQ-like period outside of the normal EQ window. This feature ensures the
battery is maintained for peak performance. The Over Charge feature resembles the
Equalization procedure in that Over Charging utilizes the Finish Current setting of Equalization.
If the vehicle is connected to the charger during the time window set by the user, and the feature
is enabled, Full/Over Charging will be performed automatically. The time window, as well as
the length of Over Charging, is set through the “Full/Over Charge Setup” submenu of the
“Charger Configuration” menu.
5.5 Reduced Charging
Reduced Charging allows the user to reduce power consumption during peak-rate periods. The
feature limits the output current to a predetermine rate during a user defined time window. The
current, as well as the time window, is set through the “Reduced Charge Rate Setup” Submenu
of the “Charger Configuration” menu. If the charger is actively charging during the time
window, and the feature is enabled, the charging current will be reduced to the user-selected
value. The current will remain at this level as long as the charge is within the specified window.
5.6 Viewing Charge Data or Fault / Warning Screens
While charging, the display screen is periodically updated with the latest charging data
including voltage, current, battery temperature, and battery state of charge. If there is a fault or
warning, the fault or warning message will be displayed instead.
Charging data
This screen displays the voltage, current, state of charge, and temperature of the battery. During
a charge, the screen will say "Charging" and the data will be updated periodically. See Figure
5.6.
Figure 5.6. Representative Charging Data Screens
<Charging
53%
50.1V 500A
40C

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Fault/Warning Screens
In the event of a fault or a warning, a fault/warning screen will appear automatically (see Figure
5.7). The fault/warning screen shows an assigned fault number and the name that indicates the
type of fault or warning. Check Table 7.2 and Table 7.3 in Section 7 for a complete listing of
faults and warnings.
Figure 5.7. Representative Fault or Warning Screens
5.7 Data Logs, Charger Configuration and Advanced Programming Features
The DVS/MVS 330 Fast Charging System’s user interface allows a trained user to configure
many of the charge parameters and review recorded data stored in the system’s internal data
logger. All configuration programming is performed through the UI menus that are accessible
directly through the display and the keypad. Pressing the “Select” key will enter the top-level
menu of the advanced features menu (see Figure 5.8).
Details on how to access the advanced features and configuration menus are in the “BMID
Manual.”
<Fault 109
PS1 Trans Fault
Fault 176 >
Port B Battery over discharged
or

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Figure 5.8. Top Level Menu for Advanced Features
1. Charge Event Log - Allows scrolling through the data from the last 200 charge events.
2. Fault/Warning Log - Allows scrolling through the last 100 fault or warning events.
3. Charger configuration - A programming mode for setting the date and time, modifying
charge parameters, setting the equalization schedule, and controlling charge times. Requires
an access code to enter this mode.
4. BMID Data Review - Lists all of the BMID parameters for the unit(s) presently connected
or charging, plus all of the stored charge history and equalization data.
5. BMID Configuration - A programming mode for modifying the BMID parameters of the
unit(s) presently connected. Requires an access code to enter this mode.
6. Display Application Version Information –Allows user to view software version and
hardware configuration information.
ANY STATUS OR
CHARGING SCREEN
Charge Event Log
Fault/Warning Log
Charger
Configuration
SELECT
SELECT
BMID Data
Review
BMID
Configuration
SELECT
SELECT
SELECT
ENTER
Review charge data from
the last 200 charge events
Change charger
config
.
Requires Access code
Change BMID
config
.
Requires Access code
Review data from the last
100 fault or warning events
Review data for batteries
currently connected
SELECT
1
3
4
2
ENTER
ENTER
ENTER
5
ENTER
6
Display Application
Version Information
ENTER
Review Application
Configuration and S/W Version

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6 DVS/MVS 330 Periodic Maintenance
The DVS/MVS 330 Charging System requires minimal periodic upkeep to maintain user safety
and system operation.
Table 6.1. Periodic Maintenance Schedule
ITEM
SERVICE
INTERVAL
DC Power Output Cables
Inspect
Daily
Replace
As Needed
DC Power Output Connectors
Inspect
Daily
Rework or Replace
As Needed
Intake and Exhaust Vents
Remove any blockage
Monthly
6.1 DC Power Output Cable Inspection and Service
The DC Output Cables and Connectors are subjected to a high rate of activity and must be
inspected daily for cuts, abrasions and breakage. The DC Connector contacts must also be
inspected for corrosion or pitting. Immediately replace cables and/or connectors that exhibit
any damage.
Refer to the DVS/MVS 330 System Installation Manual for output cable installation
instructions.
WARNING
Use only connectors and cable that are rated for the full continuous
current rating of the unit.
If you have questions regarding a specific cable assembly or need to obtain documents, please
contact Webasto Customer Service.
6.2 Intake and Exhaust Vent Inspection and Service
The intake vents at the rear of the unit and the exhaust vents at the lower front of the system
should be inspected for any reduced airflow or blockage on a monthly basis as a minimum.
Any airflow obstruction should be removed immediately to ensure proper system cooling. In
areas with a level of high dust or debris, inspections and service should be performed at a more
frequent rate.

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7 DVS/MVS 330 Troubleshooting
7.1 How to Use This Section
The following tables should be used in diagnosing trouble with DVS/MVS 330 Fast Charging
System. Use Table 7.1 to relate symptoms to probable causes. Find the symptom that best
describes the problem in the first column and go through the probable causes in the second
column. Use the table’s third column to identify the appropriate action for that probable cause.
See section 7.2 below for a detailed description of each action.
Fault codes that may be displayed on the front panel of the DVS 330 or PowerStation are listed
in Table 7.2. Find the fault code displayed in the first column and review the fault description
in the second column. Use the table’s third column to identify the appropriate action for that
fault. See section 7.2 below for a detailed description of each action.
Charge Termination Codes are listed in
Table 7.3. This table can be used to interpret charge termination codes / messages listed in the
Charge Event logs.
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.

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Table 7.1. Problem Symptoms and Action Key
Symptom
Probable Cause(s)
Action
No Display or LED’s on
Power Station
No AC to charger
Miswiring of AC input
Input Fuse Blown on 120VAC source
D,CC
D,CC
C
One or more LED’s do not
illuminate during lamp test
Burned out LED
II
Display illegible
Display connector not properly seated
Corrosion on internal components
Failed Control Board
II
EE
A
Control panel not responding
to input
Damaged membrane switch
Failed Control Board
II
A
Charger does not start charge
when battery connected
Output connector not completely connected
Pilot line disconnected
Loose or incorrect signal wiring
Corrosion on the signal pins
Battery over discharged
BMID is bad or reading out of range
Failed Control Board
OO
F
F, OO
EE
K
G
A
Charger stops charge before
complete
Battery overheated
Loss of communication with BMID
Bad cell within pack
Charger overheating
Incorrect Charger configuration
H, P
F, OO
I
AA
J
Charger works intermittently
Loose input or output wiring
Loose BMID connections
Low local utility voltage
Corrosion of internal components
F, OO
F, G
DD
EE
Battery takes too long to
charge
Incorrect BMID configuration
Shorted or worn BMID wiring
Loose power cable or battery interconnect
SOC mismatch within pack
Battery too hot when charge started
Battery brought in at extremely low SOC
Bad BMID
J
F
Q
I
H, P
K
G
Pack failing to equalize
Incorrect BMID configuration
J
Output cables or connector
too warm during charge
Bad crimp or connection within connector
Cable wrong gauge
Connector underrated for current
Short in output cables
Bad cell within pack
N
N
N
F, OO
I

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Symptom
Probable Cause(s)
Action
Battery doesn’t last full shift
Premature disconnection of charge cable
Batteries are under watered
Incorrect equalization schedule
Incorrect Charger and/or BMID configuration
Bad cell within pack
Bad BMID
F, OO
P
O
J
I
G
Battery water usage too high
Incorrect equalization schedule
Incorrect BMID configuration
Battery temperature too high
O
J
H, P
Battery temperature too high
Loose battery interconnects
Incorrectly installed temp sensor
Incorrect BMID configuration
Batteries under watered
Cell SOC mismatch
Q
F, G
J
P
I
Charge connector arcs when
disconnected
Failed Control Board
A
Noisy unit
Loose Sheet metal
Loose Fan blade or mount
Noisy Transformer/Inductor
R
R
A
Excessive fumes during
charging
Incorrect Charger and/or BMID configuration
Under watered batteries
J
P
Historical log incorrect
Incorrect BMID configuration
Failed BMID
J
G