Webasto 900 Installation, Operation And Maintenance Manual
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Webasto 900 Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual
EV Test Systems
900
English
11816-03-D
Page 1 of 58
Webasto Charging Systems, Inc.

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  • Page 1 Installation, Operation and Maintenance Manual EV Test Systems English 11816-03-D Page 1 of 58 Webasto Charging Systems, Inc.
  • Page 2 © 2019 Webasto Charging Systems, Inc. All rights reserved. EV Test 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.
  • Page 3 Webasto will not be liable for any costs of removal, installation, transportation, or any other charges that may arise in connection with a warranty claim. Webasto will not be liable for damage or wear to products caused by abnormal operating conditions, accident, abuse, misuse, unauthorized alteration or repair, or if the product was not installed in accordance with Webasto's printed installation and operating instructions.

  • Page 4: Warning

    2) Depress and latch the Emergency Off switch for at least 5 minutes to allow the high voltage to discharge. 3) Do not open the covers; there are no user serviceable parts inside. CONTACT WEBASTO’S CUSTOMER SERVICE DEPARTMENT PRIOR TO PERFORMING ANY SERVICE ON THE UNIT. 11816-03-D Page 4 of 58 Webasto Charging Systems, Inc.

  • Page 5: Table Of Contents

    2.1.3 DC Converter Functions & Controls Independent Configuration External Parallel Configuration 2.1.4 DC Side Connector Interface Remote Operation Interface 900 Remote Operation System (ROS) HV Interlock (Front Panel) RVS (Remote Voltage Sense) CAN Operation (Optional) Analog Signal Control 2.1.5 Remote Emergency Stop (Optional) 2.2 Technical Specifications...
  • Page 6 5.2 Fault Indications APPENDIX I: GLOSSARY OF TERMS APPENDIX II: DC I/O CONNECTOR ASSEMBLY II-1. STANDARD UNIT WITH CAMLOCKs EQUIPMENT REQUIREMENTS: General Assembly Procedures Disassembly Procedures II-2. NO CAMLOCKs UNIT EQUIPMENT REQUIREMENTS: 11816-03-D Page 6 of 58 Webasto Charging Systems, Inc.
  • Page 7 General Assembly Procedures APPENDIX III: 900 REMOTE VOLTAGE SENSE OPERATION APPENDIX IV: 900 ANALOG SIGNAL CONTROL INDEPENDENT MODE PARALLEL MODE THE ANALOG VOLTAGE RESPONSE AND SCALING APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING 11816-03-D Page 7 of 58 Webasto Charging Systems, Inc.

  • Page 8: Safety Precautions - Read Before Use

    Safety Precautions - Read Before Use The 900 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. SYMBOL USAGE...
  • Page 9 • Excess gassing (H • The HV Interlock on the PPS is provided to allow a hardware monitor to shut down the PPS in the event of an unsafe battery condition. 11816-03-D Page 9 of 58 Webasto Charging Systems, Inc.

  • Page 10: Introduction

    Examples include APU’s, flywheels, motors, inverters, batteries, fuel cells, capacitors, and more. The 900 is an ideal test system for a wide range of DC loads in addition to batteries; offering more capability than a traditional power supply system. The...

  • Page 11: Constant Current Source

    By setting the correct upper voltage limit and operating the system in constant Current Mode, the user can assure that the 900 will charge the battery at the desired current until its voltage rises to the limit and will then maintain that voltage. No manual adjustment is needed during the test.

  • Page 12: Other Applications

    Battery Emulation With its computer control capabilities, the 900 can be programmed to emulate a battery. To do so, the 900 would first be put into constant Voltage Mode at the desired state of charge. As current is drawn from the 900, the voltage would be lowered as if the “battery”...

  • Page 13: System Description

    RS-485 data bus. The DC Converter also communicates to the 900 Remote Operation System via an RS-232 data link. The DC Converter provides the DC interface to a load (or possibly two separate loads) in one of two operating modes.
  • Page 14 Ready Light (green) when the system power is on and the system is functioning normally. 11816-03-D Page 14 of 58 Webasto Charging Systems, Inc.

  • Page 15: Isolation Fault Detection

    Prior to contactor closure, this circuit monitors the impedance between the positive and negative busses and the chassis. Once the contactors have been closed and the Unit Under Test (UUT) is connected to the 900, the isolation monitor is disabled to prevent nuisance trips with low impedance loads.
  • Page 16 While this is happening, the Ready light (green) is flashing. The 900 will stay in this state until the voltage threshold is reached, or for a maximum of nine (9) seconds, after which the unit declares a Standby Fault.

  • Page 17: Dc Converter Functions & Controls

    (e.g., a short circuit) or an unsafe operating condition (e.g., a voltage higher than the user-defined limit). 11816-03-D Page 17 of 58 Webasto Charging Systems, Inc.
  • Page 18 Ensure that the user has the ROS (or other scripting tool) computer operational and connected to the 900 and that the remote button lights up (yellow). CONFIGURATION The 900 starts up in Independent mode as its default.

  • Page 19: Dc Side Connector Interface

    ROS control. 2.1.4 DC Side Connector Interface All of the manual functions of the 900 are controllable with the Remote Operation System or other scripting tool. In addition, there are serial data output and monitoring connectors that are accessible on the DC Connector Panel (Figure 2.5).

  • Page 20: Remote Operation Interface

    HV Interlock (Front Panel) Each channel of the 900 has a High Voltage Interlock Switch (HVIS) for added protection (Figure 2.6). The HVIS can put one channel of the 900 into Standby Mode without affecting the other channel. It is designed to be used as part of an automated test setup.

  • Page 21: Rvs (Remote Voltage Sense)

    Department for additional information. RVS (Remote Voltage Sense) To increase voltage accuracy at the Load, the 900 can feed back on a remote voltage measurement. The RVS mode is activated by pressing the RVS button on the front panel. This feature can be used in Voltage mode and Power mode.

  • Page 22: Remote Emergency Stop (Optional)

    2.1.5 Remote Emergency Stop (Optional) Within the 900, there is a provision to allow installation of an external switch to control the emergency stop function of the system. To enable a system provided with this option, an electrical connection must be made between Pins 1 and 4 of this interface (Figure 2.8).

  • Page 23: Technical Specifications

    Power Independent 8 to 750 V ±530 ADC ±250 kW 751 to 825 V ±400 ADC ±225 kW 826 to 900 V ±300 ADC ±200 kW Parallel 8 to 749 V ±999 ADC ±250 kW 750 to 824 V ±800 ADC ±225 kW...

  • Page 24: Operating Environment

    (higher temperatures can be sustained at a lower continuous power rating) Humidity 0-90% non-condensing Physical Specification Dimensions: 36”(92cm) D x 72”(183cm) W x 77”(196cm) H Weight 3,500 lbs (1588 kg) All specifications are subject to change without notice. 11816-03-D Page 24 of 58 Webasto Charging Systems, Inc.

  • Page 25: Installation

    The 900 is designed with safety of the customer as the highest priority. The following safety precautions must be read and observed. Installation must comply with all local codes and the National Electrical Code (NEC). The 900 is designed to operate in a 0- 35°C lab environment that is free of significant airborne particulate.
  • Page 26 If you discover shipping damage after acceptance, file a claim for concealed damages. 11816-03-D Page 26 of 58 Webasto Charging Systems, Inc.

  • Page 27: Operation

    900 into Standby Mode before closing the external contact. It can be achieved manually or via instructions in a script. Failure to put the 900 in Standby Mode after the external contact is opened may cause serious damage to the equipment.

  • Page 28: Planning

    Damage to the DC power stage can occur if Channel A is connected to Channel B in any other way than the methods described above. 4.1 Planning Before you begin a test with the 900, you will need to decide on certain parameters. The following checklist may be used as a guideline for...

  • Page 29: Operating Above 750 Volts In Parallel Configuration

    826-900 ±300 ADC ±300 ±200 kW The user may always specify limits that are more restrictive than these system limits. See Figure 4.1 for a graphical representation of the 900 limits. 11816-03-D Page 29 of 58 Webasto Charging Systems, Inc.
  • Page 30 Figure 4.1 – 900 Operating Limits Note: Voltage refers to limit on either channel and not the output. 11816-03-D Page 30 of 58 Webasto Charging Systems, Inc.

  • Page 31: Independent Configuration

    4.2 Independent Configuration When the 900 is powered up, it is always in the Independent Configuration. Output A and Output B operate completely independently, allowing Load A and Load B to be controlled separately. Each load is connected from the positive terminal to the negative terminal of the appropriate output.

  • Page 32: Choosing Operating Limits

    Figure 4.3 – Parallel Configuration 4.4 Choosing Operating Limits The 900 allows the user to set temporary upper and lower operating limits for voltage, current and power that are more restrictive than the absolute system limits defined above. In many cases, the user may want to use these more restrictive limits in order to protect the load or avoid unsafe conditions.

  • Page 33: Operating Space

    4. The operating limits may not be outside the maximum limits of the DC Converter for the chosen configuration (as shown in Tables and Figure 4.1). 5. The upper limit for any parameter may not be lower than the lower limit for that parameter. 11816-03-D Page 33 of 58 Webasto Charging Systems, Inc.
  • Page 34 Prior to connection, no current is flowing in the terminals, and the voltage is by definition zero. If the resistive load is to be energized successfully, the 900 DC Converter's operating space must include this initial condition.

  • Page 35: Operating The System

    The flashing LEDs are controlled so that the user is reminded to check or reset all settings in the appropriate order. In general, whenever there are flashing LEDs, the 900 is expecting the user to make a choice or verify a setting and will not allow certain other actions until that step is completed.
  • Page 36 End of test program, Select standby mode enter standby mode Resume test Enter remote Same load configuration operation Change load configuration Figure 4.5 – 900 Operation Flow Chart 11816-03-D Page 36 of 58 Webasto Charging Systems, Inc.

  • Page 37: System Startup

    4.6 System Startup The DC Converter contains the controls to start the 900. To start the system: 1. Normally, the RED light on the MAIN POWER OFF button on the Webasto inverter front panel will be illuminated to confirm that input power is available.

  • Page 38: Adjusting Operating Limits

    Refer to Section 4.1.1 Choosing a Load Configuration above to determine which load connections to use. The 900 will power on to operate in Independent Mode as its default. To switch to Parallel Mode, press the PARALLEL button after connecting the load.

  • Page 39: Selecting Local Or Remote Operation

    Once the load has been connected, the load configuration has been chosen, and the operating limits have been set, the 900 is ready to run. At this point, the unit is in Local/Independent Mode operation by default. If ROS is running Remote Operation of each channel, it can be initiated;...

  • Page 40: Changing Mode While Running A Test

    Changing the operating limits is done in the same way as setting them initially. • Press the UPPER LIMIT button to view the defined upper operating limits. 11816-03-D Page 40 of 58 Webasto Charging Systems, Inc.

  • Page 41: Pausing A Test

    Once Standby Mode is entered, remote operation can be initiated via ROS. The REMOTE A or REMOTE B LED will now be lit and the system is ready to be controlled remotely. See Section 4.11, Remote Operation below to continue. 11816-03-D Page 41 of 58 Webasto Charging Systems, Inc.

  • Page 42: Changing Load Configuration

    Configuration above and proceed through the remaining setup steps. 4.11 Remote Operation Once in remote operation, all control can be done from the 900 Remote Operating System (ROS) or other scripting tool. The ROS provides the complete set of 900 front panel controls. Limits and mode selection is easily performed with a few clicks of the mouse.

  • Page 43: Turning Off Power

    4.12 Turning Off Power To shut down the 900 at any time, the user may press the OFF switch or depress the EMERGENCY OFF button (both on the AC inverter front panel). However, in the event of a normal, non-emergency shutdown, it is...

  • Page 44: Maintenance

    “Webasto approved coolant” hereunder). The system’s cooling system may deteriorate and cause failure if any other cooling fluid is used. Contact Webasto’s Customer Service Department if you need help in procuring Peak. Remove dust and dirt from the system every six months. Avoid •...

  • Page 45: Fault Indications

    5.2 Fault Indications To aid fault diagnosis, fault indicators have been built into the design of the 900. If a system shuts down due to a fault condition, look at the front panel to see if any of the fault lights are lit or fault codes displayed and refer to Tables 5.1 and...
  • Page 46 A communication fault has occurred  Isolation Fault Indicator ±Bus Fault On Steady Loss of isolation between the positive or negative  Isolation Fault Detection Reset Flashing Isolation fault has been latched  11816-03-D Page 46 of 58 Webasto Charging Systems, Inc.
  • Page 47 Channel A Current - Display Board Status Unit Over Temperature  RS-485 Communication Fault*  *5.1V & 0.4A is the standard fault condition indicated when power is removed from the system. 11816-03-D Page 47 of 58 Webasto Charging Systems, Inc.

  • Page 48: Appendix I: Glossary Of Terms

    A subassembly of the 900 on the left side of the cabinet. AC Inverter Converts AC to DC to regulate the Intermediate DC Bus. A term for the 900 that refers to its use in battery charge and Battery Cycler discharge cycling.
  • Page 49 A computer-based system that interacts with the 900 via the Remote Operation Remote Operation Interface. The remote operation system System (ROS) receives data and status information from the 900 and sends operating limit and control commands to the 900. (Also Converter A)

  • Page 50: Appendix Ii: Dc I/O Connector Assembly

    4. Insert the cable end into the conductor pin. Verify that the foil completely covers the cable where the set screws are to be inserted. 5. Install the 5/8-18 set screws and torque to 150 in-lbs. 11816-03-D Page 50 of 58 Webasto Charging Systems, Inc.

  • Page 51: Disassembly Procedures

    NOTE: The simple and easy procedure for assembly or disassembly offers the user the flexibility to change or replace contacts and/or insulator sleeves in the field as well as easily reusing component parts. 11816-03-D Page 51 of 58 Webasto Charging Systems, Inc.

  • Page 52: Ii-2. No Camlocks Unit

    1. Strip cable insulation back 1 inch from end 2. Tighten the cable into the solid copper lug with half inch (1/2”) stud size. 3. Connect the lug with marked cable to the DC terminals respectively. 11816-03-D Page 52 of 58 Webasto Charging Systems, Inc.

  • Page 53: Appendix Iii: 900 Remote Voltage Sense Operation

    Remote Voltage Sense (RVS) Operation: 1) Independent Mode The output voltage of each channel of the 900 can be regulated directly at the load, eliminating excessive voltage drop across the cables, which carry high current between the 900 and the load and yet maintain greater voltage accuracy. This is accomplished by utilizing the V Sense connectors provided on the front panel user I/O strip.
  • Page 54 Figure A3.1 – Connection Diagram for RVS in Independent Mode 2) Parallel Mode In Parallel Mode, only the RVS connector on channel A is used with the load connected up as in Figure 4.3. 11816-03-D Page 54 of 58 Webasto Charging Systems, Inc.

  • Page 55: Appendix Iv: 900 Analog Signal Control

    Appendix IV: 900 Analog Signal Control Equipment Requirements: • Analog Signal Generator or variable power supply • Interface connections by panel mount terminal block for signal generator (power • supply) User I/O Terminal On 900 The user input output terminal block connections are: Independent Mode Apply 0 to 5V to “Load SIM A+”...

  • Page 56: Parallel Mode

    Output Power = Power Command *[|Analog V| / 4.5] -4.5 V <= (Analog V) <= -5.0 V Output Power = Power Command Load_Sim Profile for Positive Power Command Analog Signal (V) 11816-03-D Page 56 of 58 Webasto Charging Systems, Inc.
  • Page 57 Load_Sim Profile for Negative Power Command Analog Signal (V) 11816-03-D Page 57 of 58 Webasto Charging Systems, Inc.

  • Page 58: Appendix V: High Voltage Interlock Wiring

    Pin 4 (GND) is the Ground signal of the +5 V voltage source. A break in either one of these links will put that channel into Standby Mode (open the output contactor and isolate the output of the 900 from the load). High Voltage Interlock Connector Wiring...

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