Webasto SVS100 User manual

23435-W-03-01
Installation, Operation and Maintenance Manual
GSE Intelligent Fast Charging Systems
SVS100

SVS100 Installation, Operation and Maintenance Manual
23435-W-03-01 2Webasto Charging Systems, Inc.
© 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
1Getting Started.....................................................................................................................................6
2Safety Precautions –Read before using..............................................................................................7
2.1 Symbol usage.................................................................................................................................. 7
2.2 Technical Support...........................................................................................................................9
2.3 List of Provided Equipment............................................................................................................ 9
2.4 Non-StandardTools......................................................................................................................... 9
2.5 ESD Precautions.............................................................................................................................9
3System Description ...........................................................................................................................10
4Installation.........................................................................................................................................11
4.1 Preparation....................................................................................................................................11
4.2 Equipment Access ........................................................................................................................11
4.3 Conduit Connections .................................................................................................................... 11
4.4 Cable Management System Installation....................................................................................... 12
4.5 Wiring...........................................................................................................................................12
4.5.1 General Guidelines..............................................................................................................12
4.5.2 Ground Wire........................................................................................................................ 12
4.5.3 Charging Cables ..................................................................................................................12
4.5.4 Chassis Ground....................................................................................................................12
4.5.5 Grounding............................................................................................................................12
4.5.6 Hardware .............................................................................................................................12
4.6 Physical Installation...................................................................................................................... 13
4.7 Converting to 600VAC input .......................................................................................................15
4.7.1 Main Power Transformer T1............................................................................................... 15
4.7.2 ControlPower Transformer T2............................................................................................16
4.7.3 Idle Power Supervisory Board (IPSB) ................................................................................ 16
4.8 Connecting AC (Utility) Power....................................................................................................17
4.9 Checklist....................................................................................................................................... 21
5Operation...........................................................................................................................................22
5.1 Start Up.........................................................................................................................................22
5.2 Energy Saving Idle Shutdown...................................................................................................... 22
5.3 Charging .......................................................................................................................................22
5.4 Equalization..................................................................................................................................24
5.5 Viewing Charge Data Screens......................................................................................................25
5.6 Fault and Warning Screens...........................................................................................................26
5.7 Charge Event Log.........................................................................................................................27
5.8 Data Logs, Configuration, and Advanced Programming Features...............................................29
5.9 Programming Menus ....................................................................................................................30
5.10 Charger Configuration ...............................................................................................................31
5.10.1 External Light Configuration .............................................................................................. 34
5.10.1.1 Selector Mode..............................................................................................................34
5.10.1.2 External Lights 1, 2 and 3............................................................................................36
5.10.2 EQ Button Action................................................................................................................ 36
5.10.2.1 Setting the EQ Button Action......................................................................................36
5.10.3 Auto EQ...............................................................................................................................37
5.10.4 Fast Charge SOC Limit.......................................................................................................37
5.10.4.1 Setting the Fast Charge SOC Limit .............................................................................37
5.10.5 Full Charge Feature Configuration......................................................................................38
5.10.5.1 Setting the Full Charge Feature Parameters.................................................................38
5.10.6 Reduced Rate Charge Feature Configuration...................................................................... 39

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5.10.6.1 Setting the Reduced Rate Charge Configuration.........................................................39
5.10.7 Temperature Readout Selection .......................................................................................... 40
5.10.8 Ventilation System ..............................................................................................................40
5.10.9 Air Circulation Control .......................................................................................................41
5.10.10 Watering System..............................................................................................................41
5.10.11 Charger ID........................................................................................................................ 43
5.10.12 Date and Time..................................................................................................................43
5.10.13 Charge Time Control .......................................................................................................44
5.10.14 Output Format Selection Menu........................................................................................ 45
6Maintenance ......................................................................................................................................46
6.1 General Maintenance....................................................................................................................46
7External Interface Specifications (Diagnostic Port)..........................................................................48
8Technical Specifications ...................................................................................................................50
9California Energy Commission (CEC) Appliance Efficiency Compliance...................................... 50
List of Tables
Table 4-1 Utility and Wiring Information.....................................................................................17
Table 4-2 Output Characteristics for GSE SV100......................................................................18
Table 5- 1 LED Labels and Meanings........................................................................................23
Table 6- 1 Fault Codes...............................................................................................................49
Table 6- 2 Warning Codes.........................................................................................................50
List of Figures
Figure 3- 1 Components of the Charging System......................................................................10
Figure 4- 1 Proper GSE SVS-100 Installation............................................................................14
Figure 4- 2 Bolt Pattern for GSE SVS-100 Installation (Dimensions in Inches)..........................15
Figure 4- 3 GSE SVS-100 Location of Transformer Taps Terminal Block .................................15
Figure 4-4 Dual Voltage Systems (480/600VAC) - Location of Auxiliary Transformer Terminal
Block....................................................................................................................................16
Figure 4-5 Dual Voltage Systems (480/600VAC) - Location of IPSB TB1 Terminal Block.........16
Figure 4- 6 Location of AC Input Terminal Block.......................................................................19
Figure 4- 7 Location of Chassis Ground Connector..................................................................20
Figure 5- 1 Connecting Status Screens .....................................................................................22
Figure 5- 2 Front Panel Layout ..................................................................................................23
Figure 5- 3 Charge Complete Screens.......................................................................................23
Figure 5- 4 Charging Data Screens ...........................................................................................25
Figure 5- 5 Fault or Warning Screens........................................................................................26
Figure 5- 6 Fault/Warning Log Data Screens.............................................................................27
Figure 5- 7 Charge Event Log Data Screens.............................................................................28
Figure 5- 8 Top Menu Items for the Advanced Features............................................................29
Figure 5- 9 Programming Menu Entry........................................................................................30
Figure 5- 10 Charger Configuration OptionsClear Backup Memory...........................................33

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Figure 5- 11 Clear Backup Memory Menu .................................................................................34
Figure 5- 12 External Light Configuration Menu.........................................................................35
Figure 5- 13 EQ Button Action...................................................................................................36
Figure 5- 14 Auto EQ Menu.......................................................................................................37
Figure 5- 15 Fast Charge SOC Limit Screens............................................................................37
Figure 5- 16 Full Charge Setup Screens....................................................................................38
Figure 5- 17 Reduced Charge Rate Setup Screens...................................................................39
Figure 5- 18 Temperature Readout Selection Screens..............................................................40
Figure 5- 19 Ventilation System Setup.......................................................................................40
Figure 5- 20 Air Circulation Control Setup..................................................................................41
Figure 5- 21 Watering System Standard Screens......................................................................42
Figure 5- 22 Charger ID Screens...............................................................................................43
Figure 5- 23 Date and Time setting menus................................................................................44
Figure 5- 24 Charger Time Control Menu ..................................................................................44
Figure 5- 25 Output Format Selection Menu..............................................................................45
Figure 6- 1 DC Output connections............................................................................................46
Figure 6- 2 Diagnostic port pinout..............................................................................................48

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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 GSE SVS-100.
To get your system up and running quickly perform the following steps:
1. Ensure the GSE SVS-100 siting requirements are followed. (Sections 4.1 & 4.2)
2. Connect the 3 phase utility power to the GSE SVS-100, and apply power to the GSE SVS-
100. (Sections 4.3 & 4.4)
3. Install the BMID onto the fork lift battery pack. (See Paragraph 2.2)
4. Once 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 and Advanced features Manual)
6. Once the BMID has been initialized, the battery pack is ready to begin charging.

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2 Safety Precautions – Read before using
The GSE SVS100 is designed with the safety of the user as the highest priority. However,
installation must comply with all local codes, and the following safety precautions must be read
and observed.
2.1 Symbol usage
Throughout this manual, take special note of the information marked with the following symbols:
DANGER
Contains information about safety practices necessary to prevent personal
injury or death.
WARNING
Contains information about safety practices necessary to prevent fire or
equipment overheating.
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.
CAUTION
BEFORE
YOU BEGIN
Read all instructions and cautionary markings on the Industrial
PosiCharge (GSE SVS-100) 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 cover on the GSE SVS100. 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 according to OSHA 29 CFR 1910.147.
Do not perform installation/service/repair work when in standing water.

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Before disconnecting the battery, turn off the charger by pressing the stop button on the front
panel. The GSE SVS-100 is designed to automatically stop a charge event to prevent arcing
or burning of the charger connections in the event of a hot disconnect.
The charging cables must be sized for the full rated current of the GSE SVS-100, and
inspected frequently for wear, cuts and abrasion. Do not use worn, damaged, undersized, or
poorly spliced cable.
The GSE SVS-100 power 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.
WARNING
OSHA INSTRUCTION STD 1-11.4
OCTOBER 30, 1978
4. Action
“Battery charging” areas where power industrial truck batteries are charged
only—no maintenance is performed, batteries are not removed from the
trucks and no electrolyte is present in the area—are not subject to the
requirement of 29 CFR 1910.178 (g) (2). The charging areas shall be in
compliance with 29 CFR 1910.178 (g) (1), (8), (9), (10), (11) and (12).
Personal protective equipment shall be used when and where required.
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 air intake or exhaust.
Do not block or filter airflow to the unit (allow minimum of 18” clearance around unit).
Ensure that the Battery Monitor/Identifier (BMID) is properly installed according to the BMID
installation instructions.
Replace blown fuses only with same type and rating of fuse.
Do not overload building wiring - be sure power supply system is properly sized, rated and
protected to handle this unit. Use only on circuits provided with the minimum wire size
specified in the installation section.
Protective balusters should be installed where charging equipment location is subject to
damage from vehicle activity.
To avoid shock hazard, only install cables approved by PosiCharge for outdoor 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 GSE SVS100.
Only use metal conduit above ground.
Follow the National Electrical Code (NEC) and local codes. NEC and local codes take
precedence. If any instructions in this manual conflict with NEC or local codes, contact
Webasto Charging Systems, Inc. for further information

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2.2 Technical Support
This manual is intended to provide an authorized, fully trained installation technician with the
information and guidance necessary to safely install the GSE SVS100 equipment.
All non-standard tools are listed in 2.4. If parts or tools are needed in addition to those listed in
this manual to perform service, this service is outside the scope of this manual and Webasto
should be contacted directly for further assistance.
Training may be scheduled by contacting Customer Service at Webasto at:
[phone]
E-mail: [email protected]
2.3 List of Provided Equipment
Equipment Description
Quantity
Part
Number
Comments
GSE SVS100
1
11000
Kit, Installation, Burton Connector,SVS
1
11290
Cable Management Pole Assy
1
07233
Optional
Cable Management Pole and Pogo
Stick
1
09258
Optional
2.4 Non-StandardTools
No.
Equipment Description
Suggested Supplier
Part Number
A.
Multimeter
Fluke
Model 79 or
equivalent
B.
Bleed down resistor (300, 10W)
with alligator clips
Webasto Charging
Systems, Inc.
C.
Hex wrench set, SAE, 1/8” to 3/8”
---
---
D.
GSE SVS 100 Diagnostic Cable
Webasto Charging
Systems, Inc.
06969
2.5 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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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 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 GSE SVS-100 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 reconfigured on site
through the charger front panel (see the “BMID Programming and Advanced Features Manual”).
Many different sizes and types of industrial battery packs may be charged with the GSE SVS-
100. Choose the correct BMID for the nominal voltage of your pack.

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4 Installation
This section outlines the requirements and procedures for installing the GSE SVS-100. 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.
For geographic locations where summer ambient temperatures consistently exceed 110
degrees Fahrenheit, it is recommended that this product be installed in an area shaded from
direct sunlight. This will minimize any power derating that may occur during operation at
extremely high temperatures.
4.1 Preparation
Unpacking and Inspection
The GSE SVS-100 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 GSE SVS-100 system
This manual
The following equipment is shipped to truck retrofit location
One BMID system with related connectors
One BMID thermistor kit
The “BMID Programming and Advanced Features” Manual
NOTE: Additional connector sets and BMID kits may be purchased from your authorized GSE
SVS-100
Dealer.
4.2 Equipment Access
Be sure to use the proper size driver bits when removing or installing screws to avoid stripping
the heads. A driver with a clutch setting just sufficient to drive the screws should be used to
install them, this will avoid stripping the threads or breaking the threaded inserts. Screws
should be started slowly after aligning the holes to avoid cross threading.
4.3 Conduit Connections
Conduit size for the input connection is 1-1/4".
Conduit size for the output connection is 2".
2" and 1-1/4" threaded hubs are provided.
See document #11290 for acceptable conduit entry locations

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4.4 Cable Management System Installation
Follow instructions per document # 07233.
Note that concrete anchors are provided with installation kit.
4.5 Wiring
4.5.1 General Guidelines
Check utility configuration tag on GSE SVS100 to make sure that rated input voltage
matches local utility voltage. See Table 4-1 for details.
See Table 4-1 for Input/Output parameters.
4.5.2 Ground Wire
Green or green with a yellow stripe and attached to the compression lug provided.
4.5.3 Charging Cables
To avoid shock hazard, only install cables approved by PosiCharge for outdoor use.
4.5.4 Chassis Ground
See Table 4-1 for wiring size (AWG) and additional information.
Use THHN or similar type, 600V, 90° C, suitable for conduit use.
Use copper conductors only.
Minimum ground wire size is listed. Refer to local electrical codes for reference.
4.5.5 Grounding
GSE SVS100 must be connected to an equipment-grounding conductor routed with the
circuit conductors. Connections must comply with all local codes and ordinances.
The GSE SVS100 must be grounded in accordance with the Facilities Utility grounding
method.
See Table 4-1 for minimum ground wire size.
4.5.6 Hardware
Manufacturer does not supply all external mounting hardware. User-supplied hardware may be
needed to complete the installation.

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4.6 Physical Installation
CAUTION
The GSE SVS-100 weighs 390 lbs. 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 GSE SVS-100 are:
- Base: 21.8 x 19.3 in
- Height: 39.4 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 in a cement pad minimum 7” above surrounding curbing or walkways for water flood
control, see Figure 4- 1
Bolt pattern for a GSE SVS100, see Figure 4- 2.
Maintain a minimum of 18” of clearance on the sides of the unit for proper ventilation.
Maintain 36” minimum clearance on Front and Back including top for servicing as required by
local codes.
Do not install unit where it will be exposed to direct sunlight, see paragraph 4.

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Figure 4- 1 Proper GSE SVS-100 Installation
7.00 MIN
CONCRETE HEIGHT
CONCRETE BOLT ANCHOR
1/4 DIA X 5.0" LG
36 IN
MIN.
18 IN
MIN.
18 IN
MIN.
36 IN
MIN.
36 IN MIN.
A . 36 IN MINIMUM WORKING CLEARANCE ON FRONT AND BACK,
INCLUDING TOP.
B. PAD MUST BE A MINIMUM OF 7 IN. ABOVE SURROUNDING CURB
OR WALKWAYS FOR WATER FLOOD CONTROL.
C. PAD SIZE MINIMUM FOR A SINGLE CHARGER 30" X 27"
CONCRETE 3000 PSI MIN
27 IN
MIN.
30 IN
MIN.
A
A
A
A
A
B
C
C

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Figure 4- 2 Bolt Pattern for GSE SVS-100 Installation (Dimensions in Inches)
4.7 Converting to 600VAC input
The GSE SVS100 charger is shipped configured for 480VAC utility input. If you have 600VAC
utility voltage, then the charger needs to be reconfigured to use the 600VAC inputs in three
places:
4.7.1 Main Power Transformer T1
Move black wires (A,B,C) to 600VAC positions shown below:
Figure 4- 3 GSE SVS-100 Location of Transformer Taps Terminal Block

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4.7.2 ControlPower Transformer T2
Figure 4-4 Dual Voltage Systems (480/600VAC) - Location of Auxiliary Transformer Terminal
Block
Note: If the Charger has an ADK transformer blue input wire stays on the 480V.
4.7.3 Idle Power Supervisory Board (IPSB)
Move black wire to 600V input (TB1-5)
Figure 4-5 Dual Voltage Systems (480/600VAC) - Location of IPSB TB1 Terminal Block

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4.8 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 and
the National Electrical Code (NEC).
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 GSE SVS-100 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. There must be one wire for each
phase plus one earth ground. See Table 4-1 for information on input current, utility requirement,
and cable sizes. All phase wires must be rated for the full input AC current as listed.
Table 4-1 Utility and Wiring Information
Configuration
10kW
Input voltages
480
600
Input AC Current at rated load (Amps)
15
12
Input Frequency (Hz)
60
60
Number of input Phases (Excluding Ground)
3
3
Maximum Circuit Breaker Rating (Amps)
20
15
Minimum Disconnect Switch Rating (VAC)
600
600
Minimum Inrush Current Capacity (Amps)
150A, 2 cycle
start-up load
150A, 2 cycle
start-up load
Minimum Input Conductor Size (AWG)
14
14
Minimum Grounding Conductor Size (AWG)
14
14
Minimum Input Wire Terminal Torque (in-lb)
7
7
Minimum Ground Wire Terminal Torque (in-lb)
35-44
35-44
Output Cable Type
Not Applicable
Reference National Electrical Code. ANSI/NFPA 70.1999

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Table 4-2 Output Characteristics for GSE SV100
Configuration
Max Output Power (kW)
10
Max Output DC Range (Volts)
16-120
Max Output DC Current (Amps)
250
Minimum Output Wire Size (DC BUS +, AWG)
2/0
Minimum Output Wire Size (DC BUS -, AWG)
2/0
Installation
1. Remove the screws and open the front door of the GSE SVS-100.
2. Locate the AC Input Terminal Block and the Chassis Grounding Connector.
Refer to Figure 4- 6 and Figure 4- 7.
3. Bring utility wires from the Utility Distribution Panel through conduit, and route them to the AC
Input Terminal Block and the Chassis Grounding Connector.
NOTE: The grounding wire should have insulation that is green or green with yellow stripe.
4. Ensure good electrical connection by tightening the all the screws properly.
5. Close the front door prior to switching on the utility power.

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Figure 4- 6 Location of AC Input Terminal Block

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Figure 4- 7 Location of Chassis Ground Connector