Webasto PosiCharge DVS 330 Operation And Maintenance Manual Download Page 1 | Manualshive

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Operations and Maintenance Manual

GSE Intelligent Fast Charging System
DVS 330 380VAC/50Hz with Emergency OFF

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Summary of Contents for PosiCharge DVS 330

Page 1: ...Operations and Maintenance Manual GSE Intelligent Fast Charging System DVS 330 380VAC 50Hz with Emergency OFF ...

Page 2: ...e 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...

Page 3: ... AND ACCESSORIES 9 4 SYSTEM INSTALLATION 9 5 OPERATION 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 6 DVS MVS 330 PERIODIC MAINTENANCE 17 6 1 DC POWER OUTPUT CABLE INSPECTION AND SERVICE 17 6 2 INTAKE AND EXH...

Page 4: ...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 ACTI...

Page 5: ...s 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...

Page 6: ...ck 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 SAFE...

Page 7: ...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 fr...

Page 8: ...o 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 i...

Page 9: ...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 followi...

Page 10: ...g 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...

Page 11: ... 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...

Page 12: ... 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 Dow...

Page 13: ...he 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 cabl...

Page 14: ...s 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 windo...

Page 15: ...lt 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...

Page 16: ...he 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 Configurati...

Page 17: ...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...

Page 18: ...hat 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 tabl...

Page 19: ... 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 Cor...

Page 20: ...h 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 Tra...

Page 21: ...istor failure V 110 PS1 General Failure Powerstage 1 port A voltage mismatch fault W 111 Not used 112 PS2 Overvoltage Powerstage 2 port B voltage too high S 113 PS2 Overcurrent Powerstage 2 port B current too high T 114 PS2 Undercurrent Powerstage 2 port B current too low S 115 PS2 Trans Failure Powerstage 2 port B transistor failure V 116 PS2 General Failure Powerstage 2 port B voltage mismatch f...

Page 22: ...l voltages don t match KK 144 Battery Overdischarged on Port A Battery excessively discharged K 145 Not used 164 Invalid Pilot on Port B Battery connected with invalid pilot circuit MM 165 Chrg Vdc Port B Low Battery voltage too low for charger Z 166 Chrg Vdc Port B High Battery voltage too high for charger Z 167 BMID B Vbat Too Low Battery voltage too low for BMID L 168 BMID B Vbat Too High Batte...

Page 23: ... installed properly Refer to BMID manual G Visually inspect the BMID and the thermistor If the potting of the BMID looks cracked or the thermistor appears corroded avoid erratic charging by replacing these components even if functional problems have not yet occurred Temporarily attach another BMID or thermistor to the pack If the problem is resolved replace the bad component If the problem persist...

Page 24: ...he battery charge path for shorts or opens Check the battery for defective or damaged cells If no problems are found replace the BMID M This fault is usually the result of an unprogrammed BMID or an improperly programmed BMID Using the BMID Configuration menu verify that the BMID installed on the pack has the correct battery manufacturer type code the correct capacity of the cells and the correct ...

Page 25: ...ider X Indicates that the 150V DC Buss dropped below 110V or rose above 170V There may be a miss wire in the utility wiring to the Charger Contact your Authorized DVS MVS 330 Fast Charging System Service Provider Y If there is no sign of excessive heat a temperature fault may indicate a faulty temperature switch Contact your Authorized DVS MVS 330 Fast Charging System Service Provider Z Check to m...

Page 26: ...oblem is most likely in the high current path or the voltage sense path Check for continuity throughout the high current path from the power board to the battery in the vehicle Check that all cables connections are tight and that all contactors in the path are functioning properly If the problem persists contact your Authorized DVS MVS 330 Fast Charging System Service Provider LL If the voltage ob...

Page 27: ... 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 Amp hours exceeded 17 FULL BAT TEMP LIMIT Full Over cha...

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