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DVS 400 Fast Charging System Operation and Maintenance Manual 

 

09190-W-03-01 

Page 21 of 27 

Webasto Charging Systems, Inc. 

Symptom

 

Probable cause(s)

 

Action

 

Battery doesn’t last full shift 

Algorithm/capacity mismatch 
Incorrect equalization schedule 
Batteries are under watered 
Bad cell within pack 
Bad BMID 
Premature disconnection of charge cable 

J 

O 

P 

I 

G 

F 

Battery water usage too high 

Algorithm/capacity mismatch 
Incorrect equalization schedule 
Battery temperature too high 

J 

O 

H,P 

Battery temperatures too high 

Loose interconnection between batteries 
Pack/Algorithm mismatch 
Batteries underwatered 
Cell SOC mismatch 
Incorrectly installed temp sensor 

Q 

J 

P 

I 

F,G 

Charge connector arcs when 
disconnected 

Bad Control board 

B 

Noisy unit 

Loose Sheet metal 
Loose Fan blade or mount 
Noisy Transformer 
Miswiring of AC input 

R 
R 
A 
D 

Excess fumes during charging 

Algorithm overcharging batteries 
Underwatered batteries 

J 

P 

History files incorrect 

Bad or noisy control board 
Bad BMID 

B 

G 

6.2.4 

 

 

 

Summary of Contents for DVS 400

Page 1: ...09190 W 03 01 docx Operation and Maintenance Manual GSE Intelligent Fast Charging Systems DVS 400 English ...

Page 2: ...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 ser...

Page 3: ...m Installation 11 5 Operation 12 5 1 System Start Up 12 5 2 Charging 13 5 3 Equalization 15 5 4 Full Over Charging 15 5 5 Reduced Charging 15 5 6 Viewing Charge Data or Fault Warning Screens 15 5 7 Data Logs Charger Configuration and Advanced Programming Features 16 5 8 External Status Indicator Configuration Optional 18 6 DVS 400 Periodic Maintenance 18 6 1 DC Power Output Cable Service 18 6 1 1 ...

Page 4: ...ONT PANEL LAYOUT 14 FIGURE 5 4 CHARGE COMPLETE SCREENS 14 FIGURE 5 5 REPRESENTATIVE CHARGING DATA SCREENS 15 FIGURE 5 6 REPRESENTATIVE FAULT OR WARNING SCREENS 16 FIGURE 5 7 TOP LEVEL MENU FOR ADVANCED FEATURES 17 FIGURE 6 1 CORRECT PIN ALIGNMENT 19 FIGURE 6 2 INCORRECT PIN ALIGNMENT 19 List of Tables TABLE 5 1 LED LABELS AND MEANINGS 14 TABLE 6 1 PROBLEM SYMPTOMS AND ACTION KEY 20 TABLE 6 2 FAULT...

Page 5: ...DVS 400 Fast Charging System Operation and Maintenance Manual 09190 W 03 01 Page 5 of 27 Webasto Charging Systems Inc This Page Left Intentionally Blank ...

Page 6: ...which battery After completing a charge the system shuts off automatically The DVS 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 pac...

Page 7: ... or BatteryRx Installation Manual 3 Once BMID is installed the battery pack may be connected to the charger 4 If your BMID does not come pre configured you will need to initialize the new BMID Refer to BMID Programming and Advanced Features Manual 5 Once the BMID has been initialized the battery pack is ready to begin charging 1 2 Applicable Documents TITLE Part Number DVS 400 Installation Manual ...

Page 8: ...our 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 grou...

Page 9: ... 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 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 FIR...

Page 10: ...ce 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 all of the batteries in your fleet without needing to worry about mismatching batteries and chargers Each BMID is pre configured with the following information 1 An identification number which can help track the charging history of a spec...

Page 11: ...our pack 24V BMID P N 08660 W 36V 48V BMID P N 08661 W 72V 80VBMID P N 08662 W Contact Customer Service for Dual SBX or Euro cable kits Thermistor Options Choose the correct thermistor type for your battery Submersible thermistors are designed for installation through the battery case into the battery electrolyte of flooded battery cells Exterior thermistors are designed to be glued onto the exter...

Page 12: ... avoiding low voltage operation that can reduce vehicle performance 5 1 System Start Up Once the system has been properly installed mechanically and electrically it is ready to be powered When you first power up your DVS 400 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 DVS 400 will the...

Page 13: ...oltage OCV of the battery pack and calculating the State of Charge SOC to determine what the initial current should be to charge the pack properly Once the charge starts and the Charging screen is displayed the current is ramped up from zero to the target initial current while the charger monitors the pack voltage Figure 5 2 Connecting Status Screens Note that the screen examples shown above have ...

Page 14: ... If an equalization charge is scheduled for this battery pack the Charge Complete will not illuminate until the equalization has been completed The operator may stop charging at any time without waiting for the charge to complete by pressing the STOP button After a charge has been completed or stopped by the user the screen will indicate the method in which the charge was stopped and the data valu...

Page 15: ...h Current setting of Equalization However this feature enables the user to set a time window when Full Over Charge can take place It also allows the user to control the length of time that the battery is Over Charged If the charger is actively charging during the time window set by the user and the feature is enabled Full Over Charging will be performed The time window as well as the length of Ove...

Page 16: ...re many of the charge parameters and review recorded data stored in the system s internal data logger All configuration programming is performed through menus that are accessible directly through the display and the keypad By pressing the Select key you will enter the top level menu of the advanced features menu see Figure 5 7 Details on how to access the advanced features and configuration menus ...

Page 17: ...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 Charge...

Page 18: ... 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 Customer Service 6 1 1 SBX SYX Connector Service The auxiliary contact pins in SBX and SYX connectors sometimes make intermittent contact when the vehicle is plugged in to the PosiCharge Charger This results in a BMID Comm...

Page 19: ...1 Red Aux Connector 1 Blk Aux Connector Additional kits or individual parts may be available Contact Customer Service for more information 6 2 Troubleshooting 6 2 1 How to Use This Section The following tables should be used in diagnosing trouble with your DVS 400 Fast Charging System Use Table 6 1 to relate symptoms to probable causes Find the symptom that best describes the problem in the first ...

Page 20: ...ch B E II Charger does not start charge when battery connected Output connector not completely connected BMID is bad or reading out of range Pilot line disconnected Bad Control board Loose or incorrect signal wiring Corrosion on the signal pins Battery over discharged F G F B F EE K Charger stops charge before complete Battery overheat Loss of communication line Bad cell within pack Algorithm capa...

Page 21: ...hm capacity mismatch Incorrect equalization schedule Battery temperature too high J O H P Battery temperatures too high Loose interconnection between batteries Pack Algorithm mismatch Batteries underwatered Cell SOC mismatch Incorrectly installed temp sensor Q J P I F G Charge connector arcs when disconnected Bad Control board B Noisy unit Loose Sheet metal Loose Fan blade or mount Noisy Transform...

Page 22: ... B 104 Battery Backup Failure Backup Battery disconnected or dead FF 105 Pilot Int Failure Pilot interrupts stopped occurring F 106 PS1 Overvoltage Powerstage 1 port A voltage too high S 107 PS1 Overcurrent Powerstage 1 port A current too high T 108 PS1 Undercurrent Powerstage 1 port A current too low U 109 PS1 Trans Failure Powerstage 1 port A transistor failure V 110 PS1 General Failure Powersta...

Page 23: ... Port A BMID not adequately configured for charger usage M 140 BMID Config Mismatch on Port A BMID data doesn t match battery parameters J 141 BMID Failure on Port A BMID reporting a critical failure G 142 BMID Temp Sensor Failure on Port A BMID temp sensor out of valid range G 143 Vbat Mismatch on Port A BMID and terminal voltages don t match KK 144 Battery Overdischarged on Port A Battery excess...

Page 24: ...ge port H The DVS 400 Fast Charging System contains built in safety systems which will fold back charge in response to high battery temperatures and stop charge completely if the batteries get above a manufacturer s specified threshold temperature If the charger has stopped because of a false reading of a high battery temperature check the installation of the BMID and the integrity of the thermist...

Page 25: ...er cables and verify that welded interconnects have not loosened R Tighten all screws and fasteners as needed S Check for opens in the charge path contactors output cables Check DVS 400 Control Board connectors P12 Output Voltage Sense and P15 To Contactors Check that all wire crimps are secure T Shut down the unit and check for shorts or problems in the output cable Check current sensors and chec...

Page 26: ...d down firmly to the front panel and are securely holding the control board at all locations Correct any problems found with the standoffs and cycle power to the DVS 400 If this does not correct the problem replace the door assembly Burned out LED s usually indicate a damaged membrane Replace the door assembly KK A power imbalance in 500A mode is indicated when the DVS 400 is delivering unequal cu...

Page 27: ...st Charge normal termination Finish current reached 11 FINISH AHR LIMIT Finish Charge Amp hours exceeded 12 FINISH BAT TEMP LIMIT Finish Charge battery temp limit 13 FINISH BMID COM LOST Finish Charge BMID communications lost 14 FINISH TIME LIMIT Finish Charge CV mode time limit exceeded 15 FINISH USER STOP Finish Charge user stopped stop button or disconnected 16 FULL AHR LIMIT Full Over charge A...

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