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Summary of Contents for Webasto 22615
- Page 1 Instructions, Field Installation Convert Ampro PC104 to ICOP VDX-6353RD, 50/60HZ ABC-150 English 22615-76_02.docx...
- 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.
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Page 3: Warranty
Webasto Limited Warranty Products manufactured by Webasto Inc. are warranted to the original user only to be free of defects in material and workmanship for a period of 12 months from the date of installation, but not more than 18 months from the date of manufacture. - Page 4 Introduction The #22615 kit is provided to allow the ABC-150 with Ampro PC104 computer board, to be converted to ICOP VDX-6353RD, and allowing communication via CAN or/and ROS that exits in the unit. The kit contains the following: Item Part No.
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Page 5: Hardware Installation
3. Locate the Ampro PC104 Computer Board (# 05176), and CAN Card (# 05890), if the unit has CAN card, in the lower left corner of the Display Assembly. Replace PAL U24 with # 22259 Figure 2. DC Control Board with CAN Card and Cable Installed 22615-76_02.docx... - Page 6 Figure 3. DC Control Board CAN Port Cable [Remove] Figure 4. User I/O Panel with CAN Port Location 5. Carefully remove the CAN Card from the Ampro PC104 Computer Board below, as shown in Figure 5. Figure 5. CAN Card 22615-76_02.docx...
- Page 7 6. Carefully remove the cables #05315, #05318, #05317, and #05316. Remove other cables connected to DC control board below, as shown in Figure 7. Keep and mark all cables so that can be easily put back later. Figure 7. Cable connections for DC Control DC Control Board with Ampro PC 104 Computer Board. 22615-76_02.docx...
- Page 8 Figure 8. Explode view of DC control board with Ampro PC 104 Computer Board. 8. Remove the Ampro PC104 Computer Board #05176 with RAM #05175 as shown in Figure 8. 9. Remove the NOMEX #08953 and mounting bracket #05344, as shown in Figure 8. 22615-76_02.docx...
- Page 9 9X 01626 21148 5X 05345 8X 01250 01626 21054 11379 11378 11354 2X 03280 14286 11352 3X03280 5X 03280 Figure 9. Explode view of DC control board with VDX-6353-D Computer Board. 14. Install PCBA DC CONTROL #04767 with U24 #22259. 22615-76_02.docx...
- Page 10 Interface Board #14286, as shown in Figure 11. Please note: PC104 Computer Board VDX-6353RD should be verified in factory that the Custom BIOS setup is complete. COM1; cable #21047 with red side (pin 1) flat ribbon plug into COM1 of PC104 Computer Board VDX- 6353RD. Figure 11. VDX-6353RD Controller 22615-76_02.docx...
- Page 11 17. Connect the cable #11388, #05317, #21047, #21050, #05318, and #01149 below, as shown Figure 12 and Figure 12. Side view of PC104 computer board VDX-6353RD with interface cables Figure 13. PC104 computer board VDX-6353RD with interface cables 22615-76_02.docx...
- Page 12 Remove Jumper connected between IRQ6 and PC-104 CAN IRQ9. Install board with jumper #05042 for cable J2-1 IRQ15, J2-2 IRQ14, J2-4 IRQ11, VDX-6353D Controller J2-6 IRQ9, (below CAN board) J2-9 IRQ5. Figure 16. ABC-150 Display Assembly - PC-104 CAN Location 22615-76_02.docx...
- Page 13 26. Change Dip switch settings (2 places) for Opto isolator #21128 (485OPDR) as shown below 1 and 2: OFF 3: ON 4, 5 and 6: OFF 7 and 8: ON For RS-485 2-Wire Half Duplex communication mode 9600 baud. 22615-76_02.docx...
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Page 14: Power Supply
BLK #22 AV #21119 AV #21120 TO J13 OF DC CONVERTER DATA IN (A) BOARD AV #21148 ASSY,REMOTE E-STOP AV #04419 +OUT RED #22 BLK #22 BLK #22 -OUT +12V/1.7A SUPPLY LINEAR POWER Figure 20. Wiring for Opto isolator 22615-76_02.docx... - Page 15 31. Based on ABC-150 Field Calibration Procedure in Appendix I, calibrate the unit. 32. Place the calibration label #07310 to the unit and fill the report, as shown in Appendix II. 22615-76_02.docx...
- Page 16 For 50Hz systems: 1. Use provided #23964 Interlock Loop cable assembly (Item Num 18). 2. Connect to P5 of PCBA AC Control Board Figure 14. Location of P5 in PCBA Inverter Control 22615-76_02.docx...
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Page 17: Appendix I: Abc-150 Field Calibration Procedure
3.4 Set Channel A in Voltage mode at 8V. Adjust R318 (AREMOTE) offset till DMM1 reads 8.0000.010V. 3.5 Command 420V from ROS. Adjust R50 such that both local and remote readings for 420 0.250V. This may require going back and forth between local and remote modes. 22615-76_02.docx... - Page 18 6.2 Put Channel A in voltage mode at 100V and Channel B in current mode at 0A. 6.3 Set the DMM to mV (1mV = 1A for the shunt rating: 500A/500mv) 6.4 Adjust R94 until the DMM connected to the current shunt must reads 0.000.01mVDC. 22615-76_02.docx...
- Page 19 Command 100A on Channel A and note the reading on the DMM (assume that the reading is 99.92mV) Divide this number by the shunt resistance and record the current value derived as shown below. 99.92 mV/ 0.9993335 m Ohm = 99.98A 22615-76_02.docx...
- Page 20 Use Label #07310, fill up the information, remove the old calibration label and install the label in the vicinity of nameplate of the unit. Due date is one year from the date of calibration. Calibration label is shown below. 22615-76_02.docx...
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Page 21: Appendix Ii: Abc-150 Calibration Data Sheet
Refer to procedure 04417-08 Test Equipment: Equipment Manufacturer Model Serial Calibration Validity Date DMM1 DMM2 Shunt Webasto Charging Systems INC. ABC-150 MONROVIA, CALIFORNIA UNIT SN: _______________ INFORMATION: AC CTRL BOARD WORK ORDER DC CTRL BOARD TEST DATE EPROM VER TESTER VOLTAGE CALIBRATION AND ACCURACY: + 250mV CH “A”... - Page 22 250.62 1.1A 0.9A -49.87A -50.125A 99.75A 100.25 -0.1A 0.1A -99.75A -100.25A 49.87A 50.125 -.1.1A -0.9A -250.62A 249.37A 9.9A 10.1A -10.1A -9.9A FUNCTION TEST: ANALOG “A” RVS CHANNEL “A” ANALOG “B” RVS CHANNEL “B” INTERLOCK “A” PARALLEL TEST INTERLOCK “B” 22615-76_02.docx...
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