Webasto DVS100 MHE Intelligent Fast Charging Systems Installation Guide

Webasto DVS100 MHE Intelligent Fast Charging Systems

Product Information

Specifications

• Product Name: MHE Intelligent Fast Charging Systems DVS100/DVS150 CEC
• Region: North America
• Model Number: 12284-W-76-CEC-01
• Manufacturer: Webasto Charging Systems, Inc.

Getting Started
Before you begin, it is important to familiarize yourself with the cautions in Section 2 of the manual and read the installation instructions in Section 4 completely. Follow the steps below to quickly get your system up and running:

1. Ensure that the DVS siting requirements are followed (refer to Section 4.4).
2. Connect the 3-phase utility power to the DVS and apply power to the DVS (refer to Section 4.5).
3. Install the BMID on the battery pack (refer to Section 4).
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 Manual, P/N document #06701).
6. Once the BMID has been properly programmed, the battery pack is ready to begin charging.

Safety Precautions
The DVS is designed with the safety of the user as the highest priority. Installation must comply with all local codes, and the following safety precautions must be read and observed.

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 0death.
• WARNING: Contains information about safety practices necessary to prevent fire or equipment overheating.
• DANGER: Contains information to prevent shock hazards 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

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.

Frequently Asked Questions

• Q: Can I install the DVS without following the siting requirements?
• A: No, it is essential to follow the siting requirements mentioned in Section 4.4 of the installation instructions for proper functioning and safety.
• Q: How do I initialize a new BMID?
• A: To initialize a new BMID, refer to the BMID programming Manual, P/N document #06701, for detailed instructions.
• Q: What should I do if my BMID does not come pre-configured?
• A: If your BMID does not come pre-configured, you will need to initialize it following the instructions in the BMID programming Manual, P/N document #06701.

**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 DVS.

To get your system up and running quickly perform the following steps:

1. Ensure the DVS siting requirements are followed. (Section 4.4)
2. Connect the 3-phase utility power to the DVS, and apply power to the DVS. (Section 4.5)
3. Install the BMID on the battery pack. (Section 4)
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 Manual, P/N document #06701)
6. Once the BMID has been properly programmed, the battery pack is ready to begin charging.

Safety Precautions

Read before using
The DVS is designed with the safety of the user as the highest priority. Installation must comply with all local codes, and the following safety precautions must be read and observed.

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 hazards 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™ (DVS) 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.

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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.

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Cautions and Warnings

• 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 DVS. There are no user-serviceable parts inside. Refer all servicing to qualified service personnel. Opening the system or attempting installation or repair by other than qualified service personnel voids the warranty.
• Disconnect the battery charger from the 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 DVS 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 DVS and inspected frequently for wear, cuts, and abrasion. Do not use worn, damaged, undersized, or poorly spliced cables.
• The DVS 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 requirements of 29 CFR 1910.178 (g) (2). The charging areas shall comply with 29 CFR 1910.178 (g) (1), (8), (9), (10), (11) and (12). Personal protective equipment shall be used when and where required.

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• Do not install or place the unit on, over, or near combustible surfaces.
• Do not install the 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.
• 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 section.
• Protective bollards or Armco barriers should be installed where the charging equipment location is subject to damage from vehicle activity.
• Do not install a unit where it will be exposed to direct sunlight.
• To avoid shock hazards, 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 DVS.
• 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.

Technical Support
This manual is intended to provide an authorized, fully trained installation technician with the information and guidance necessary to safely install the DVS equipment. For assistance contact PosiCharge™ Customer Support at:

866-767-4242
E-mail: info@posicharge.com

List of Webasto-Provided Equipment

Optional
Cable Management Pole Assy (48”)| 2| 07233| Optional
Cable Management Pole (48”) and Pogo Stick| 2| 09258| Optional
Cable Management Pole (40”) and Pogo Stick| 2| 11752| Optional

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.

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 DVS 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 DVS. Choose the correct BMID and BMID programming for the nominal voltage and size of your pack.

Installation

This section outlines the requirements and procedures for installing the DVS. 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.

Preparation

Unpacking and Inspection
The DVS is provided fully assembled on a shipping pallet. It is surrounded by a protective shipping box. Remove the packaging and any other shipping materials before installation.

The following equipment is provided with each system:

• One DVS system
• DVS Installation Manual
• CD Manual

The following equipment is shipped to the truck retrofit location

• Two BMID systems with related connectors
• Two BMID thermistor kit
• The “BMID Programming” Manual

NOTE : Additional connector sets and BMID kits may be purchased from your authorized DVS Dealer.

Equipment Access
Be sure to use the proper size driver bits when removing or installing screws to avoid stripping the heads. Screws should be started slowly after aligning the holes to avoid cross-threading.

**Wiring

**

General Guidelines

• Check the utility configuration tag on DVS to make sure that the rated input voltage matches the local utility voltage. See Table 4-1 for details.
• See Table 4-1 for Input/Output parameters.

Ground Wire
Green, or green with a yellow stripe, attached to the compression lug provided.

Charging Cables / Cable Management System
To avoid shock hazards, 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 the Product Warranty.
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Grounding

• DVS must be connected to an equipment-grounding conductor routed with the circuit conductors. Connections must comply with all local codes and ordinances.
• The DVS must be grounded by the Facilities Utility grounding method.
• See Table 4-1 for wiring size (AWG) and additional information.
• Use THHN or a similar type, 600V, 90° C, suitable for conduit use.
• Use copper conductors only.
• The minimum ground wire size is listed. Refer to local electrical codes for reference.

Hardware
The manufacturer does not supply all external mounting hardware. User- supplied hardware may be needed to complete the installation.

DVS Weight

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531lbs

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619lbs

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CAUTION

| 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 a vertical position.

The external dimensions of the DVS-100 and DVS-150 are:

• Base : 20.44 x 24.5 in (51.9 x 62.3cm)
• Height : 51.47 in (130.7cm)

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 a minimum of 7” above surrounding curbing or walkways for water flood control, see Figure 4-1 and 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 for servicing as required by local codes.
• Do not install a unit where it will be exposed to direct sunlight.

Figure 4-1 DVS-100 and DVS-150 Installation

1. A . 91.4cm (36 IN) MINIMUM WORKING CLEARANCE ON FRONT AND BACK, INCLUDING TOP.
2. B. PAD MUST BE A MINIMUM OF 17.8cm (7 IN) ABOVE SURROUNDING CURB OR WALKWAYS FOR WATER FLOOD CONTROL.
3. C. PAD SIZE MINIMUM FOR A SINGLE CHARGER 86.4cm (34″) X 72.4cm (28.5″) CONCRETE 3000 PSI MIN
4. D. CONCRETE PAD REQUIRED ONLY FOR WATER FLOOD CONTROL

Figure 4-2 Bolt Pattern for DVS-100 and DVS-150 Installation
(Dimensions in Inches)

Connecting AC (Utility) Power

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CAUTION

| Before 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.

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DANGER

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Incorrect power wire installation or failure to properly grounthe d unit may result in a severe shock hazard.

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CAUTION

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Use copper conductors only.

Utility power lines to DVS 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. See Table 4-1 for information on input current, utility requirements, and cable sizes. All phase wires must be rated for the full input AC as listed.

Table 4-1 Utility and Wiring Information

load
THD Max| 35%| 35%| 35%| 35%
Minimum Input Conductor Size (AWG)| 8| 10| 8| 8
Minimum Grounding Conductor Size (AWG)| 10| 10| 10| 10
Minimum Input Wire Terminal Torque (in-lb)| N/A| N/A| N/A| N/A
Minimum Ground Wire Terminal Torque (in-lb)| 35-44| 35-44| 35-44| 35-44
Output Cable Connector| 320 Anderson Euro| 320 Anderson Euro

Reference National Electrical Code. ANSI/NFPA 70.1999

Table 4-2 Output Characteristics for DVS

or

2 X 2/0

| 2 x 95MM² or 2 x 3/0
Minimum Output Wire Size (DC BUS -, AWG)| 2X70MM² or

2 X 2/0

| 2 x 95MM² or 2 x 3/0

Installation / Line Voltage Instructions
(480VAC)

1. Remove the screws and open the front door of the DVS.

2. Locate the AC Input Terminal Block and the Chassis Ground Connector. Refer to Figures 4-3 tthrough4-6.

3. Bring utility wires from the Utility Distribution Panel through the conduit, and route them to the AC Input Terminal Block and the Chassis Grounding Connector. Refer to Figures 4-3 tthrough4-6.
   NOTE: The grounding wire should have insulation that is green or green wita h yellow stripe.

4. Close the front door before switching on the utility power.

Installation / Line Voltage Changeover Instructions
(Dual voltage configuration 480/600VAC)

1. Remove the screws and open the front door of the DVS.

2. Locate the Transformer Taps Terminal Block and the (3) black wires, marked with the letters A, B, and C. Refer to Figures 4-3 tthrough4-6.

3. Locate the Auxiliary Transformer Input Terminal Block. Refer to Figure 4-3.

4. Refer to the label that is located above the Transformer Taps Terminal Blocks to determine if the charger is connected to the available line voltage (480 or 600 VAC).

5. Bring utility wires from the Utility Distribution Panel through the conduit, and route them to the AC Input Terminal Block and the Chassis Grounding Connector. Refer to Figures 4-3 tthrough4-6.
   NOTE : The grounding wire should have insulation that is green or green with h yellow stripe.

6. Close the front door before switching on the utility power.

WARNING| ENSURE GOOD ELECTRICAL CONNECTION BY TIGHTENING ALL THE SCREWS PROPERLY
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Figure 4-3 DVS-100 and DVS-150 Location of Transformer Taps Terminal Block

Figure 4-4 DVS-100 and DVS150 Location of Chassis Ground Connector

Figure 4-5 Dual Voltage Systems (480/600VAC) – Location of Auxiliary Transformer Terminal Block

Note : If the charger has an ADK transformer, the blue input wire stays on the 480V.

DC Output Cable Installation

Figure 4-6 DC Output Cable Installation

To install output cable(s):

1. Install output cable(s) ensuring mounting screws and lock washers are properly installed and tightened. Recommended torque: 8.47 Nm (75 in-lbs).

2. A proper cable management system is required to relieve stress on the output connector mounting hardware.
   Note:

3. Do not remove the connector key(s) from the connector.

4. Minimum bend radii of 3.5 in are required for the output cables.

Checklist

DVS – INSTALLATION AND OPERATIONAL CHECKOUT

DVS| DVS| DVS| DVS|
Serial #| Serial #| Serial #| Serial #
__

| __

| __

| __

V _| V _| V _| V _| VERIFY AND RECORD SW VERSION
| | | | CHECK UNIT IS SECURELY MOUNTED
__



| __



| __



| __



| CHECK AC CIRCUIT BREAKER RATING DVS100 RATING IS 40 AAC @ 480VAC DVS100 RATING IS 30 AAC @ 600VAC DVS150 RATING IS 50 AAC @ 480VAC

DVS150 RATING IS 40 AAC @ 600VAC

__

__



| __

__



| __

__



| __

__



| UTILITY CONNECTIONS PROPERLY INSTALLED WITH ALL FASTENERS TIGHTENED:

CHECK AC TERMINAL BLOCK CHECK CHASSIS GND CONNECTOR

CHECK INPUT AND OUTPUT WIRES OF AC CONTACTOR ARE SECURE

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__



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__



| __

__



| __

__



| ALL DC BUS CONNECTIONS PROPERLY INSTALLED WITH ALL FASTENERS TIGHTENED:

CHECK DC OUTPUT NEGATIVE CHECK DC OUTPUT POSITIVE CHECK DC FUSE

CHECK SHUNT RESISTOR

| | | | CHECK OUTPUT CABLE STRAIN RELIEFS ARE SECURED
| | | | BMID COMMUNICATION WIRING IS SECURE AND PROPERLY CONNECTED
| | | | CHECK DC POWER SUPPLY CONNECTION
| | | | CHECK CONTROLLER BOARD CONNECTORS ARE SECURELY AND PROPERLY INSTALLED.
| | | | CHECK BASSI CONTROLLER BOARD CONNECTORS ARE SECURELY AND PROPERLY INSTALLED.
| | | | FRONT PANEL LEDs WORK PROPERLY
| | | | DISPLAY IS FULLY OPERATIONAL
| | | | ALL FRONT PANEL CONTROL BUTTONS ARE FUNCTIONAL
| | | | THE LATEST APPLICATION CODE HAS BEEN LOADED
| | | | ALL SCREWS AND WASHERS ARE PROPERLY INSTALLED ON THE DOOR AND BACK PANEL
| | | | VERIFY DVS CHARGES PROPERLY WHEN CONNECTED TO VEHICLE
| | | | ALL HIGH-CURRENT CABLES IN THE CHARGING PATH ARE SECURELY FASTENED
SYSTEM CHECKED BY

– NAME / SIGNATURE

| /| DATE:|
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CUSTOMER / LOCATION| /| DATE:

© 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 by the Export Administration Regulations. Diversion contrary to US law is prohibited. B PosiCharge™ systems, a product line of Webasto Charging Systems, Inc..

1.866.767.4242 | info@posicharge.com | @posicharge | posicharge.com © 2019 Webasto Charging Systems Inc.

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