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Webasto MT-30 Instructions Manual
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Webasto MT-30 Instructions Manual

Webasto MT-30 Instructions Manual

Field installation, convert ampro pc104 to vdx-6353rd
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MT-30
Installation Instructions
INSTRUCTIONS, FIELD
INSTALLATION, CONVERT AMPRO
PC104 TO VDX-6353RD, MT-30
Webasto Charging Systems, Inc.
1333 S. Mayflower Avenue, Suite 100
Monrovia, CA 91016 U.S.A.
Telephone 1–866–767–4242
IPCService@webasto.com
2020 Webasto Charging Systems, Inc.
21324-76_02.docx
Page 1 of 26
Webasto Charging Systems, Inc.

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Summary of Contents for Webasto MT-30

  • Page 1 MT-30 Installation Instructions INSTRUCTIONS, FIELD INSTALLATION, CONVERT AMPRO PC104 TO VDX-6353RD, MT-30 Webasto Charging Systems, Inc. 1333 S. Mayflower Avenue, Suite 100 Monrovia, CA 91016 U.S.A. Telephone 1–866–767–4242 IPCService@webasto.com 2020 Webasto Charging Systems, Inc. 21324-76_02.docx Page 1 of 26 Webasto Charging Systems, Inc.

  • Page 2: Warranty

    12 months from the date of installation, but not more than 18 months from the date of shipment from Webasto Charging Systems. Webasto Charging Systems's liability under this warranty shall be limited to repairing or replacing at Webasto Charging Systems's option, without charge, F.O.B.
  • Page 3 Warning – Old MT-30 code used to set the MT-30 in Internal Parallel mode, this version of code sets the MT-30 in External Parallel to allow the system to be in a 100% Duty Cycle. The kit contains the following:...

  • Page 4: Hardware Installation

    BEFORE performing the installation, TURN OFF the AC input circuit DANGER breaker and DISCONNECT ALL loads from the unit’s output terminals. This version of code sets the MT-30 in External Parallel to allow the WARNING system to be in a 100% Duty Cycle.
  • Page 5 ECHO Port of the User I/O Panel, as shown in Figure 4, if the unit has the cable. Figure 3. DC Control Board ECHO Port Cable [Remove] Figure 4. User I/O Panel with ECHO Port Location 21324-76_02.docx2 Page 5 of 26 Webasto Charging Systems, Inc.
  • Page 6 5. Carefully remove the CAN Card from the Ampro PC104 Computer Board below, as shown in Figure 5. Figure 5. CAN Card Figure 6. DC Control Board and Ampro PC104 Without CAN Card 21324-76_02.docx2 Page 6 of 26 Webasto Charging Systems, Inc.
  • Page 7 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. 21324-76_02.docx2 Page 7 of 26 Webasto Charging Systems, Inc.
  • Page 8 PLCC Extraction Tool (MCM electronics P/N D00038, order #22-11114). 11. Replace U24 with WUSLA #22259 ASSY, MACH211 PAL, U24, CONTROL BOARD, DC, (VDX-6353-RD), P3, in the Kit. Label #06298 board with FSB-00145 and date. 21324-76_02.docx2 Page 8 of 26 Webasto Charging Systems, Inc.
  • Page 9 12. Rearrange and install all nuts and standoffs below, as shown in Figure 9. 13. Carefully install the interface board #14286 below, as shown in Figure 9. Figure 9. Explode view of DC control board with VDX-6353-RD Computer Board. 21324-76_02.docx2 Page 9 of 26 Webasto Charging Systems, Inc.
  • Page 10 14. Install PCBA DC CONTROL #06298 with U24 #22259. 15. Insert compact flash storage memory WUSLA #22507, ASSY, CF, FLASH STORAGE VDX- 6353-RD, HYB, MT-30 into the computer board WUSLA #29595 (part of WUSLA #29594), as shown in Figure 10 for the model of HYB MT-30.
  • Page 11 Installation Instructions 17. Connect the cable WUSLA #11388, WUSLA #05317, WUSLA #21047, WUSLA #21050, WUSLA #05318, and WUSLA #01149 below, as shown Figure12. Figure 12. PC104 computer board VDX-6353RD with interface cables 21324-76_02.docx2 Page 11 of 26 Webasto Charging Systems, Inc.
  • Page 12 Figure 13. ROS Connection on DC Control Board Figure 14. User I/O Panel with ROS Connection Location (External) 19. Connect all other disconnected and marked cables back to DC Control Board #06298. 21324-76_02.docx2 Page 12 of 26 Webasto Charging Systems, Inc.
  • Page 13 J2-6 IRQ9, J2-9 IRQ5. Figure 15. MT-30 Display Assembly - PC-104 CAN Location 21. In DC control board WUSLA #06298, locate J2 as shown in Figure 12. Remove the jumper between IRQ6 and IRQ9, install jumper WUSLA #05042 into J2-1, J2-2, J2-4, J2-6, and J2-9.
  • Page 14 Control Figure 17. Location of U26 in PCBA Inverter Control 25. Replace U26 with #06825 ASSY, MICROCIRCUIT, PROGRAMMED, AC INVERTER, MT-30, in available kit. For 50Hz systems: a. Use provided #23964 Interlock Loop cable assembly (Item Num 18). b. Connect to P5 of PCBA AC Inverter Control Board 21324-76_02.docx2...
  • Page 15 WUSLA #03540, as shown in the Figure 18 and 19. Opto isolator WUSLA #21079 Figure 18. Installation location for Opto isolator Wire clamp WUSLA #03540 Figure 19. Installation of cable clamp. 21324-76_02.docx2 Page 15 of 26 Webasto Charging Systems, Inc.
  • Page 16 MT-30 Installation Instructions 29. Install the linear power supply WUSLA #03166 in the left side up corner of MT-30 next to the with two 10-32 clip on type floating nuts WUSLA #01558 and 10-32x5/8 screws WUSLA #04332 , as shown in the Figure 20 and 21.
  • Page 17 31. Make sure that cable assy’s are all properly strain relieved with using cable ties, cable clamp and wire mounts , as shown figure 23 and 24. Wire mount location Figure 23. Wire mounts location 21324-76_02.docx2 Page 17 of 26 Webasto Charging Systems, Inc.
  • Page 18 Twisted pair of 22 AWG black and red wires is connected from linear power supply, as shown in the following figures 26. P9 location Figure 25. P9 of the Distribution board location 21324-76_02.docx2 Page 18 of 26 Webasto Charging Systems, Inc.
  • Page 19 34. Close the unit using all panel screws and restore power to the system. 35. Based on MT-30 Field Calibration Procedure in Appendix I, calibrate the unit. 36. Place the calibration label #07310 to the unit and fill the report, as shown in Appendix II.

  • Page 20: Appendix I: Mt-30 Field Calibration Procedure

    2.5 Note: If the facility has ABC-150, then connect channel A of ABC-150 to channel A of MT-30 and then to channel B. Channel A of MT-30 is rated + 330A and B is rated + 170A. If channel A is connected to B, the current calibration can be performed in the range of –170A and +170A.
  • Page 21 3.3 Connect Remote Voltage Sense connector from the shunt to the Channel A RVS connector on the front panel of the MT-30. Turn RVS mode ON. 3.4 Set Channel A in Voltage mode at 5V. Adjust R318 (AREMOTE) offset till DMM1 reads 5.0000.010V.
  • Page 22 6.3 Set DMM to mV (1mV = 1A for the shunt rating 500A/500mV) 6.4 Adjust R94 for DMM1 till the readings are 10mV or less apart. Also, the DMM connected to the current shunt must read 0.000.01mVDC. 21324-76_02.docx2 Page 22 of 26 Webasto Charging Systems, Inc.
  • Page 23 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 21324-76_02.docx2 Page 23 of 26 Webasto Charging Systems, Inc.
  • Page 24 Use Label WUSLA #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. CALIBRATION Date 21324-76_02.docx2 Page 24 of 26 Webasto Charging Systems, Inc.

  • Page 25: Appendix Ii: Wusla-900 Calibration Data Sheet

    Refer to procedure 06200-08 Test Equipment: Equipment Manufacturer Model Serial Calibration Validity Date DMM1 DMM2 Shunt WEBASTO CHARGING SYSTEMS, INC. MT-30 MONROVIA, CALIFORNIA UNIT SN: _______________ INFORMATION: AC CTRL BOARD SN WORK ORDER DC CTRL BOARD SN TEST DATE EPROM VER TESTER VOLTAGE CALIBRATION AND ACCURACY: + 250mV CH “A”...

  • Page 26: Function Test

    100.15A -0.125A 0.125A -99.85A -100.15A 49.875A 50.125A -.1.125A -0.875A *-169.74A -170.26A 10.125A 9.875A -10.125A -9.875A FUNCTION TEST: ANALOG “A” RVS CHANNEL “A” ANALOG “B” RVS CHANNEL “B” INTERLOCK “A” INTERLOCK “B” 21324-76_02.docx2 Page 26 of 26 Webasto Charging Systems, Inc.