Webasto SVS80 User manual

20148-W-03-01
Installation, Operation and Maintenance Manual
MHE Intelligent Fast Charging Systems
SVS80 440VAC/60Hz
English

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
IMPORTANT INFORMATION –SAVE THESE INSTRUCTIONS
20148-W-03-01 2 Webasto 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,
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Specifications are subject to change without notice. Images of the power cycling and test systems are representative; production models may vary. No
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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.
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contrary to US law prohibited
PosiCharge™ systems, a product line of Webasto Charging Systems, Inc..
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© 2019 Webasto Charging Systems Inc.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
IMPORTANT INFORMATION –SAVE THESE INSTRUCTIONS
20148-W-03-01 3 Webasto Charging Systems, Inc.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
IMPORTANT INFORMATION –SAVE THESE INSTRUCTIONS
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Table of Contents
1 Getting Started ....................................................................................................................7
2 Safety Precautions –Read before using .............................................................................8
2.1 Symbol usage..................................................................................................................8
2.2 Technical Support .........................................................................................................10
2.3 ESD Precautions...........................................................................................................10
3 System Description............................................................................................................11
4 Installation .........................................................................................................................12
4.1 Preparation....................................................................................................................12
4.2 Wiring............................................................................................................................13
4.2.1 General Guidelines ...............................................................................................13
4.2.2 Ground Wire..........................................................................................................13
4.2.3 Charging Cables / Cable Management System ....................................................13
4.2.4 Chassis Ground ....................................................................................................13
4.2.5 Grounding .............................................................................................................13
4.2.6 Hardware...............................................................................................................13
4.3 Physical Installation.......................................................................................................14
4.4 Connecting AC (Utility) Power.......................................................................................16
5 Operation...........................................................................................................................19
5.1 Start Up.........................................................................................................................19
5.2 Language Selection.......................................................................................................19
5.3 Charging........................................................................................................................20
5.4 Equalization...................................................................................................................22
5.5 Viewing Charge Data Screens ......................................................................................23
5.6 Fault and Warning Screens...........................................................................................24
5.7 Charge Event Log .........................................................................................................25
5.8 Data Logs, Configuration, and Advanced Programming Features ................................27
5.9 Programming Menus.....................................................................................................28
5.10 Charger Configuration.................................................................................................29
5.10.1 Clear Backup Memory........................................................................................31
5.10.2 External Light Configuration...............................................................................31
5.10.2.1 Selector Mode................................................................................................31
5.10.2.2 External Lights 1, 2 and 3...............................................................................33
5.10.3 EQ Button Action................................................................................................33
5.10.3.1 Setting the EQ Button Action..........................................................................33
5.10.4 Auto EQ..............................................................................................................34
5.10.5 Fast Charge SOC Limit......................................................................................34
5.10.5.1 Setting the Fast Charge SOC Limit................................................................35
5.10.6 Full Charge Feature Configuration.....................................................................35
5.10.6.1 Setting the Full Charge Feature Parameters..................................................35
5.10.7 Reduced Rate Charge Feature Configuration....................................................36
5.10.7.1 Setting the Reduced Rate Charge Configuration...........................................36
5.10.8 Temperature Readout Selection ........................................................................37
5.10.9 Ventilation System .............................................................................................37
5.10.10 Air Circulation Control ........................................................................................38
5.10.11 Watering System................................................................................................38
5.10.12 Charger ID..........................................................................................................40
5.10.13 Date and Time....................................................................................................40

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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5.10.14 Charge Time Control..........................................................................................41
5.10.15 Output Format Selection Menu ..........................................................................42
6 Maintenance......................................................................................................................43
6.1 General Maintenance....................................................................................................43
6.2 External Interface Specifications (Diagnostic Port)........................................................45
7 Technical Specifications....................................................................................................47
List of Tables
Table 4-1 Utility and Wiring Information.....................................................................................17
Table 4-2 Output Characteristics for SVS-80.............................................................................17
Table 5- 1 LED Labels and Meanings........................................................................................20
Table 6- 1 Fault Codes...............................................................................................................46
Table 6- 2 Warning Codes.........................................................................................................47
List of Figures
Figure 3- 1 Components of the Charging System......................................................................11
Figure 4- 1 SVS-80 Installation..................................................................................................15
Figure 4- 2 Bolt Pattern for SVS-80 Installation .........................................................................16
Figure 4- 3 AC Input Terminal Block..........................................................................................18
Figure 4- 4 Location of Chassis Ground Connector..................................................................18
Figure 5- 1 Language Selection Screens...................................................................................19
Figure 5- 2 Connecting Status Screens .....................................................................................20
Figure 5- 3 Front Panel Layout ..................................................................................................20
Figure 5- 4 Charge Complete Screens.......................................................................................21
Figure 5- 5 Charging Data Screens ...........................................................................................23
Figure 5- 6 Fault or Warning Screens........................................................................................24
Figure 5- 7 Fault/Warning Log Data Screens.............................................................................25
Figure 5- 8 Charge Event Log Data Screens.............................................................................26
Figure 5- 9 Top Menu Items for the Advanced Features............................................................27
Figure 5- 10 Programming Menu Entry......................................................................................28
Figure 5- 11 Charger Configuration Options..............................................................................30
Figure 5- 12 Clear Backup Memory Menu .................................................................................31
Figure 5- 13 External Light Configuration Menu.........................................................................32
Figure 5- 14 EQ Button Action...................................................................................................33
Figure 5- 15 Auto EQ Menu.......................................................................................................34
Figure 5- 16 Fast Charge SOC Limit Screens............................................................................34
Figure 5- 17 Full Charge Setup Screens....................................................................................35
Figure 5- 18 Reduced Charge Rate Setup Screens...................................................................36
Figure 5- 19 Temperature Readout Selection Screens..............................................................37
Figure 5- 20 Ventilation System Setup.......................................................................................37
Figure 5- 21 Air Circulation Control Setup..................................................................................38
Figure 5- 22 Watering System Standard Screens......................................................................39
Figure 5- 23 Charger ID Screens...............................................................................................40
Figure 5- 24 Date and Time setting menus................................................................................41
Figure 5- 25 Charger Time Control Menu ..................................................................................41

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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Figure 5- 26 Output Format Selection Menu..............................................................................42
Figure 6-1 DC Output connections.............................................................................................43
Figure 6- 3 Diagnostic port pinout..............................................................................................45

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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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 SVS-80.
To get your system up and running quickly perform the following steps:
1. Ensure the SVS-80 siting requirements are followed. (Sections 4.5)
2. Connect the 3 phase utility power to the SVS-80, and apply power to the SVS-80.
(Sections 4.6)
3. Install the BMID onto the battery pack. (Sections 3)
4. Once the BMID is installed, the battery pack may be connected to the charger.
5. If your BMID does not come pre-configured, you will need to initialize the new BMID.
(Refer to BMID programming, document #06701-W-03)
6. Once the BMID has been properly programmed, the battery pack is ready to begin charging.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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2 Safety Precautions – Read before using
The SVS-80 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.
DANGER
Contains information to prevent shock hazard or possible damage to the
equipment during installation and service.
NOTE: Offers helpful information for installation or usage, but does not contain personnel or
equipment safety related information.
CAUTION
BEFORE
YOU BEGIN
Read all instructions and cautionary markings on the Industrial
PosiCharge™ (SVS-80) Assembly.
Make sure you also read the IMPORTANT SAFETY INSTRUCTIONS
below.
Be sure to leave these instructions with the installed unit for future
reference.
Only qualified personnel should install, use or service this charger.
Read and understand these Manufacturer’s instructions and your
employer’s safety practices manual.
DANGER
ELECTRIC SHOCK CAN KILL: Touching live electrical parts can cause fatal
shocks or severe burns. The battery terminals are always electrically live,
and the output circuit is live whenever the battery is connected or being
charged. The input power circuitry and internal circuits are live whenever
input power is on. An incorrectly installed or improperly grounded charger is a
hazard.
The unit must be grounded properly with a grounding conductor of size equal to or larger
than that recommended by local electrical codes or the installation section of this manual.
Do not touch the uninsulated portion of the output battery connector or an uninsulated battery
terminal.
Only qualified service personnel may remove the front or back panels on the SVS-80. 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.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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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 expose to rain or perform installation/service/repair work when in standing water.
A Charge can be stopped by disconnecting the output cable connector or by pressing the
stop button on the front panel. The SVS-80 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 SVS-80, and inspected
frequently for wear, cuts and abrasion. Do not use worn, damaged, undersized, or poorly
spliced cable.
The SVS-80 charging connector is subject to normal wear and tear, and may be damaged by
misuse or abuse. Frequently inspect the connector for cracking, pitting of contacts, fraying of
wires or signs of connector fatigue. A damaged charging connector should be replaced
immediately.
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.
Do not install or place unit on, over or near combustible surfaces.
Do not install unit near flammables.
Do not block air intake or exhaust.
Ensure that the Battery Monitor/Identifier (BMID) is properly installed according to the BMID
installation instructions.
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 bollards or Armco barriers should be installed where charging equipment location
is subject to damage from vehicle activity.
Do not install unit where it will be exposed to direct sunlight.
To avoid shock hazard, only install cables approved by PosiCharge™for indoor use.
Do not subject the cable or coupler to damage or stress. Do not step on the coupler cable.
Do not hang from the coupler cable.
Do not disassemble the SVS-80.
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.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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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 SVS-80 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 PosiCharge
should be contacted directly for further assistance.
Training may be scheduled by contacting Customer Service at:
Phone : [phone]
E-mail : [email protected]
2.3 ESD Precautions
Electronic circuits are sensitive to damage from electrostatic Discharge. Persons servicing this
equipment should be trained in proper techniques for avoiding ESD damage to electronic
circuits. As a minimum, when handling circuit boards, wear an appropriate ESD wrist strap
connected to the equipment chassis.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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3 System Description
The keypad and display provide the user interface to the charger. The display constantly
updates the charger and battery status, and allows access to the programming menus through
the keypad.
Four (4) status LEDs indicate when a charge is in progress, at 80% complete, fully charged, or
in equalization. A fault/warning LED serves to alert the user to fault conditions.
The SVS-80 works with a small monitoring device mounted on the battery called the battery
monitor/identifier (BMID). As shown in Figure 3- 1, when a vehicle equipped with a BMID
connects to the charger, the charger communicates with the BMID to ensure optimal charging.
Figure 3- 1 Components of the Charging System
Typically, the battery dealer or another authorized service technician will install the BMID on the
battery and configure it before delivery to the customer. BMIDs may also be configured on site
through the charger front panel (see the “BMID Programming Manual”).
Many different sizes and types of industrial battery packs may be charged with the SVS-80.
Choose the correct BMID and BMID programming for the nominal voltage and size of your pack.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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WARNING
IMPROPER INSTALLATION CAN CAUSE FIRE
4 Installation
This section outlines the requirements and procedures for installing the SVS-80. Read the entire
section before proceeding with installation, and make sure you have read and understood the
warnings in Section 2. Installation should be completed by an experienced electrician and
should conform to all relevant electrical codes.
4.1 Preparation
Unpacking and Inspection
The SVS-80 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 SVS-80 system
SVS Installation Manual
CD manual
The following equipment is shipped to truck retrofit location
One BMID system with related connectors
One BMID thermistor kit
The “BMID Programming” Manual
NOTE: Additional connector sets and BMID kits may be purchased from
your authorized SVS-80 Dealer.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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4.2 Wiring
4.2.1 General Guidelines
Check utility configuration tag on SVS-80 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.
4.2.2 Ground Wire
Green or green with a yellow stripe and attached to the compression lug provided.
4.2.3 Charging Cables / Cable Management System
To avoid shock hazard, only install cables approved by PosiCharge™for indoor use.
DANGER
CABLES CARRY HIGH POWER/CURRENT
Damaged Cables and/or connectors can be a serious safety hazard.
Cables must be secured with an Approved Cable Management System.
Cables are to be kept off the floor.
Failure to use a Cable Management System may invalidate Product
Warranty.
4.2.4 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.
4.2.5 Grounding
SVS-80 must be connected to an equipment-grounding conductor routed with the circuit
conductors. Connections must comply with all local codes and ordinances.
The SVS-80 must be grounded in accordance with the Facilities Utility grounding
method.
See Table 4-1 for minimum ground wire size.
4.2.6 Hardware
Manufacturer does not supply all external mounting hardware. User-supplied hardware may be
needed to complete the installation.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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4.3 Physical Installation
CAUTION
The SVS-80 weighs 110 kg. 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 SVS-80 are:
- Base: 49.78 x 43.94 cm (19.6 x 17.3 in)
- Height: 89.92cm (35.4 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 on a cement pad minimum 7” above surrounding curbing or walkways for water flood
control, see Figure 4- 1
Maintain a minimum of 18” of clearance on the sides of the unit for proper ventilation.
Maintain 36” minimum clearance on Front and Back for servicing as required by local codes.
Do not install unit where it will be exposed to direct sunlight.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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Figure 4- 1 SVS-80 Installation
A . 91.4cm (36 IN) MINIMUM WORKING CLEARANCE ON FRONT AND BACK
B. PAD MUST BE A MINIMUM OF 17.8cm (7 IN) ABOVE SURROUNDING CURB
OR WALKWAYS FOR WATER FLOOD CONTROL.
C. PAD SIZE MINIMUM FOR A SINGLE CHARGER 69.9 cm (27.5 in) X 61 cm (24 in)
CONCRETE 3000 PSI MIN
D. CONCRETE PAD REQUIRED ONLY FOR WATER FLOOD CONTROL
91.4cm
(36 in)
MIN.
30.5cm (12in) MIN.
A
A
A
61 cm
(24 in)
MIN.
69.9 cm
(27.5 in)
MIN.
C
C
17.8cm (7.00 in) MIN
CONCRETE HEIGHT
CONCRETE BOLT ANCHOR
6.4cm (1/4") DIA X 12.7cm (5.0") LG
B
45.7cm
(18 in)
MIN. A
A
45.7cm
(18 in)
MIN.
91.4cm
(36 in)
MIN.
D
D
D

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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NOTE: We strongly recommend cement curbing, concrete filled steel pipe pillars, or similar
protection to be placed around the SVS-80 to prevent damage to the SVS-80 from a moving
vehicle.
The square mounting holes are 6.5mm X 6.5 mm.
Figure 4- 2 Bolt Pattern for SVS-80 Installation
4.4 Connecting AC (Utility) Power
CAUTION
Prior to connecting the unit to the utility ensure that:
The available grounding connection meets all state and local codes
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.
464,8 mm
53,4 mm
342,9 mm
40,6 mm

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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Utility power lines to SVS-80 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 50/60Hz, 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
8kW
Input voltages
440 VAC ± 10%
Input AC Current at rated load (Amps)
15 @ 440V
Input Frequency (Hz)
50 / 60
Number of input Phases (Excluding Ground)
3
Maximum Circuit Breaker Rating (Amps)
20
Minimum Disconnect Switch Voltage Rating
(VAC)
600
Minimum Inrush Current Capacity (Amps)
200A, 2 cycle start-up load
THD Max
52%
Minimum Input Conductor Size (mm2)
6mm2
Minimum Grounding Conductor Size (mm2)
6mm2
Minimum Input Wire Terminal Torque (in-lb)
2.26 Nm
Minimum Ground Wire Terminal Torque (in-lb)
4-5 Nm
Reference National Electrical Code. ANSI/NFPA 70.1999
Table 4-2 Output Characteristics for SVS-80
Max Output Power
8 kW
Max Output DC Range
8-70 V
Max Output DC Current
200 A
Minimum Output Wire Size (DC BUS +)
1x 70 mm²
Minimum Output Wire Size (DC BUS -)
1x 70 mm²

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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Installation / Line Voltage Changeover Instructions
1. Remove the screws and open the front door of the SVS-80.
2. Locate the AC Input Terminal Block. Refer to Figure 4- 3.
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 all the screws properly.
5. Close the front door prior to switching on the utility power.
Figure 4- 3 AC Input Terminal Block
Figure 4- 4 Location of Chassis Ground Connector

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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5 Operation
5.1 Start Up
When you first power up your Industrial PosiCharge™, it will perform a lighting sequence test.
The display will then show the initial Status Screen containing the model number, the software
version and the output current capability. After five seconds, the screen will shift to the charge
screens.
5.2 Language Selection
At the “Charger Ready Connect Vehicle” Screen, a standard password shall be required to gain
entry to the Language Selection option.
In the “Charger Ready Connect Vehicle” screen, use the standard password to access the
language options. After password has been accepted the “Charger Ready Connect Vehicle”
screen will start flashing. Press the UP arrow and Hold to scroll through the language options,
release when desired language is displayed; Press ENTER to accept the desired language.
Figure 5- 1 Language Selection Screens
Enter key code now, Hold key code until screen starts flashing
SVS80 200 Amps
Version 03.00.00.06
Charger Ready US
Connect Vehicle
Charger Ready EU
Connect Vehicle
Chargeur Prêt
Relier le Véhicule
Ladegerät bereit
Fahrzg anschließen
ENTER
ENTER
Cargador Listo
Conecte el Vehículo
ENTER
Press and Hold UP arrow to select language
preference and ENTER to accept the selection
made.

SVS-80 440VAC/60Hz Installation, Operation and Maintenance
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5.3 Charging
Step 1: Connect battery to charger
To start charging, simply connect the battery to the charger. Once the charge starts, and the
“Charging” screen is displayed, the current is ramped up from zero to the target start current.
Figure 5- 2 Connecting Status Screens
The display screen will periodically update the charging data as the charge progresses. In
addition, the front panel has several status LEDs which indicate the current status of the
battery under charge, and whether it is scheduled for an equalization charge.
Figure 5- 3 Front Panel Layout
Table 5- 1 LED Labels and Meanings
SVS80 200 Amps
Version 03.00.00.06
Charger Ready
Connect Vehicle
Vehicle connected
Getting config info
Preparing to charge
Please wait...
Preparing to charge
Please wait 30 sec
Charging 73%
45.5V 150A 23C
Vehicle Connected
Communication established