Webasto ABC-170CE Installation, Operation And Maintenance Manual
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Webasto ABC-170CE Installation, Operation And Maintenance Manual

Webasto ABC-170CE Installation, Operation And Maintenance Manual

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Installation, Operation, and Maintenance Manual
EV Test Systems
ABC-170CE
English
29730-03-04

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  • Page 1 Installation, Operation, and Maintenance Manual EV Test Systems ABC-170CE English 29730-03-04...
  • Page 2 © 2021 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: Warranty

    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 1) Turn off the Main Disconnect Switch. 2) Depress and latch the Emergency Off switch for at least 5 minutes to allow high voltage to discharge Warning Do not open covers. No user serviceable parts inside. 29730-03-04 Page 4 of 61 Webasto Charging Systems, Inc.

  • Page 5: Table Of Contents

    Independent Configuration External parallel Configuration 2.1.3 Communication between AC Inverter and DC Converter 2.1.4 Remote Operation Interface 2.1.5 ABC-170CE Remote Operation System (ROS) 2.1.6 High Voltage Interlock (Front Panel) 2.1.7 Remote Voltage Sense (RVS) 2.1.8 Analog Signal Control 2.1.9 Optional Data Acquisition Interfaces 2.1.10 Optional CAN Interface...
  • Page 6 4.10.4 Changing Operating Limits 4.10.5 Pausing a Test 4.10.6 Entering Remote Operation 4.10.7 Changing Load Configuration 4.11 Remote Operation 4.12 Turning off Power 5.0 MAINTENANCE 5.1 Preventative Maintenance 5.2 Fault Indications 29730-03-04 Page 6 of 61 Webasto Charging Systems, Inc.
  • Page 7 APPENDIX II: DC I/O CONNECTOR ASSEMBLY General Assembly Procedures Disassembly Procedures APPENDIX III: REMOTE VOLTAGE SENSE OPERATION APPENDIX IV: ANALOG SIGNAL CONTROL APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING APPENDIX VI: EXTERNAL PARALLEL OPERATION 29730-03-04 Page 7 of 61 Webasto Charging Systems, Inc.

  • Page 8: Safety Precautions - Read Before Use

    Installation, Operation, and Maintenance Safety Precautions - Read Before Use The ABC-170CE 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.
  • Page 9 Excess pressure  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. 29730-03-04 Page 9 of 61 Webasto Charging Systems, Inc.

  • Page 10: Introduction

     Independent Mode Control for each Channel The ABC-170CE is an ideal test system for a wide range of DC loads other than batteries, offering more capability than a traditional power supply system. The ABC-170CE uses the bi-directional characteristic of the electric utility (it can...

  • Page 11: Scope Of Manual

    ABC-170CE Installation, Operation, and Maintenance 1.3 Scope of Manual This manual contains a description of the ABC-170CE and instructions for the installation, operation and maintenance. 1.3.1 Manual Organization This manual describes the installation and operation of the ABC-170CE power processing system.

  • Page 12: Abc-170Ce Applications

    ABC-170CE Installation, Operation, and Maintenance 1.4 ABC-170CE Applications The ABC-170CE is flexible and may be used for a wide variety of DC power applications. This section describes a few typical applications to illustrate the different features of the ABC-170CE. Constant Voltage Source In Voltage Mode, the ABC-170CE regulates the voltage of a given DC input/output channel.

  • Page 13: Battery Pack Cycling

    The ABC-170CE would first be put into constant Voltage Mode at the desired state of charge. As current is drawn from the ABC-170CE, the voltage would be lowered as if the “battery” were being discharged.

  • Page 14: System Description

    2.0 System Description 2.1 System Block Diagram The ABC-170CE architecture is shown in the following system block diagram (Figure 2.1). The AC Inverter connects to the utility via an internally installed isolation transformer. The DC Converter and AC Inverter transfer power via an Intermediate DC Bus and communicate via an RS-485 data bus.
  • Page 15 “Main Power” or “Emergency Off” switch service must be switched off to remove power from the system for at least five minutes prior to accessing the interior of the cabinet. 29730-03-04 Page 15 of 61 Webasto Charging Systems, Inc.

  • Page 16: Dc Converter Functions & Controls

    Independent Configuration Two loads can be connected and separately controlled. (The negative sides of the ABC-170CE outputs are tied together when outputs are active, so the two outputs cannot be placed in series.) External Parallel Configuration The outputs for both channels must be utilized for parallel operation.
  • Page 17 ABC-170CE Installation, Operation, and Maintenance Figure 2.3 shows the ABC-170CE DC Converter front panel. Figure 2.3. DC Converter Front Panel The displays and controls are described below. CONFIGURATION (Yellow) is used to select the load configuration and wiring connection. There is one button each for Parallel, RVS and Independent, respectively.

  • Page 18: Communication Between Ac Inverter And Dc Converter

    2.1.4 Remote Operation Interface The Remote Operation Interface, based on the RS-232 communication standard, allows communication between the DC Converter and the ABC-170CE (ROS). The purpose of this interface is to provide status information and DC input/output measurements from the ABC-170CE to 29730-03-04 Page 18 of 61 Webasto Charging Systems, Inc.

  • Page 19: Abc-170Ce Remote Operation System (Ros)

    (Gnd) signal, which is the ground. A break in either one of these links will put that channel into the standby mode (open the output contactor and isolate the output of the ABC-170CE from the load). (See appendix V for proper wiring.)

  • Page 20: Optional Data Acquisition Interfaces

    National Instruments Analog/Digital I/O 2.1.10 Optional CAN Interface The CAN interface is a ROS enabled interface with user programmable messages. Contact Webasto Customer Service for more information 2.1.11 Remote Emergency Stop An interface is provided to allow an external switch to control the emergency stop function of the system.

  • Page 21: Technical Specifications

    The above ranges are the maximum allowed by the system on a continuous basis. Voltage, current, and power limits within the above ranges can be set by the user based on the load and test requirements, respectively. 29730-03-04 Page 21 of 61 Webasto Charging Systems, Inc.

  • Page 22: Accuracy And Resolution

    Keep it in the original packing materials  Store it at temperatures between 0 ° C (32 ° F) and 70 ° C (158 ° F)  Always protect the equipment from moisture, dust and weather 29730-03-04 Page 22 of 61 Webasto Charging Systems, Inc.

  • Page 23: Safety

    Emergency stop switch  HV Interlock  Automatic load connect and disconnect  Automatic shutdown on loss of utility power  UL Recognized Components used where possible  Remote Emergency Stop 29730-03-04 Page 23 of 61 Webasto Charging Systems, Inc.

  • Page 24: Installation

    WARNING: The connections made may contain high voltages. High voltages can injure personnel and damage equipment. A qualified electrician or technician should install the ABC-170CE. BEFORE you connect any wiring, TURN OFF the AC input circuit breaker and DISCONNECT ALL loads from the ABC-170CE output terminals.
  • Page 25 (Figure 3.1) Figure 3.1 Equipment Skid with Cutouts  In addition to casters, the unit is provided with the leveling pads. Lower the pads and level the unit at the installed location. 29730-03-04 Page 25 of 61 Webasto Charging Systems, Inc.

  • Page 26: Equipment Needed

    National Electric Code (NEC). The AC input connection consists of 3-wire 380/400/415 VAC power cables connected from the Utility to the ABC-170CE cabinet and a ground cable from an appropriate power ground. This connection is made at the top rear of the AC Inverter cabinet.

  • Page 27: Ac Input Connections

    Each receptacle mounted in this panel will accept the corresponding connectors provided with the unit. To connect a load to the ABC-170CE, you will first need to attach your own load cables to connectors. Appropriate wire for use with the DC Converter is 4/0 wire gauge welding cable with 600VDC minimum insulation.
  • Page 28 To test that the fitting is securely locked into the jacket, use the following procedure. First, make sure that the ABC-170CE main power is off. Next insert the connector as far as possible into a receptacle on the DC input/output panel.

  • Page 29: Operation

    In Current or Power Mode, when the DC input/output external contact in load opens, the user must put the ABC-170CE in standby mode before reclose the external contact. It can be done manually or in the ROS script. Failing to put ABC-170CE in standby mode after the external contact is opened, may cause serious damage to the equipment.

  • Page 30: Planning

    Damage to the DC power stage will occur if Channel A is connected to Channel B in any other way than that described above. 4.1 Planning Before you begin a test with the ABC-170CE, you will need to decide on certain parameters. The following checklist may be used as a guideline for preparation:...

  • Page 31: Choosing A Load Configuration

    4.1.1 Choosing a Load Configuration Some loads and test plans may require a particular configuration of the ABC-170CE load connections. For example, if the test requires current values over 265 Amperes in either direction, External parallel configuration must be used.

  • Page 32: 445 Vdc Upper Limit

    "Caution" Because of the control strategy required to maintain a broad range of accurate power transfer on the ABC-170CE, it is recommended that the system be used with loads of 20 ohms or lower. Higher impedance loads may be used, however they should be equipped with appropriate transient suppressers to eliminate voltage spikes.

  • Page 33: Operating Above 420 Volts In External Parallel Configuration

    <445 v ±90 A ±90 A ±40 kW <445 v 435-445 v ±90 A ±90 A ±40 kW Users may always specify limits that are more restrictive than these system limits. 29730-03-04 Page 33 of 61 Webasto Charging Systems, Inc.

  • Page 34: Independent Configuration

    A single load may be connected in the independent configuration (i.e., either Load A or Load B) with no change in functionality. 29730-03-04 Page 34 of 61 Webasto Charging Systems, Inc.

  • Page 35: External Parallel Configuration

    A and B. Output cables must be connected together at the load, or at separate junction points and then to the load. In the external parallel configuration, the output current is shared between the two converters. 29730-03-04 Page 35 of 61 Webasto Charging Systems, Inc.

  • Page 36: Choosing Operating Limits

    Installation, Operation, and Maintenance 4.4 Choosing Operating Limits The ABC-170CE allows you to set temporary upper and lower operating limits for voltage, current, and power that are more restrictive than the absolute limits defined above. In many cases, you may want to use these more restrictive limits in order to protect the load or avoid unsafe conditions.
  • Page 37 100 Adc, and upper/lower power limits of ± 20 kW. Upper OPERATING Lower Power Upper SPACE Lower Voltage -400.00 -300.00 -200.00 -100.00 0.00 100.00 200.00 300.00 400.00 Amps Figure 4.5. Example of a User-defined Operating Space 29730-03-04 Page 37 of 61 Webasto Charging Systems, Inc.

  • Page 38: Operating The System

    B is restricted to a lower power limit of [-170 - (-y)]KW. 4.5 Operating the System The ABC-170CE is designed for easy operation. The flowchart (Figure 4.6) on the following page describes the typical procedures that you should follow for any test.
  • Page 39 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 ABC-170CE 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 40: System Startup

    ABC-170CE Installation, Operation, and Maintenance 4.6 System Startup The AC Inverter contains the controls to start the ABC-170CE. To start the system: 1. Confirm the EMERGENCY OFF button is not actuated (depressed) on the AC Inverter front panel. To deactivate, rotate the switch counterclockwise.

  • Page 41: Adjusting Operating Limits

    Once the load has been connected, you may select the desired configuration. Even if there is only one valid configuration for the load connections, the ABC-170CE requires you to select it in order to confirm the choice. When a valid configuration has been selected, the Operating Limits buttons will flash.

  • Page 42: 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 ABC-170CE is ready to run. At this point, the unit is in Local mode operation by default. If ROS is running, Remote Operation of each channel can be initiated;...

  • Page 43: Changing Mode While Running A Test

    While holding the limits button down, use Up Arrow () or Down Arrow () buttons next to the displays to change voltage, current or power limits as desired.  Repeat for lower limits and for a second load, if necessary. 29730-03-04 Page 43 of 61 Webasto Charging Systems, Inc.

  • Page 44: Pausing A Test

    Once Standby Mode is entered, remote operation can be initiated via ROS. REMOTE A or REMOTE B LED will now be lit and that channel is ready to be controlled remotely. See Section 4.11, Remote Operation below for more information. 29730-03-04 Page 44 of 61 Webasto Charging Systems, Inc.

  • Page 45: 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 ABC-170CE Remote Operation System (ROS). The ROS provides the complete set of ABC-170CE front panel controls. Limit and mode selections are easily performed with a few clicks.

  • Page 46: Turning Off Power

    4.12 Turning off Power To shut down the ABC-170CE at any time, you may turn off the MAIN POWER OFF switch or depress the EMERGENCY OFF button (both on the AC Inverter). However, in the event of a normal, non-emergency shut down, it is...

  • Page 47: Maintenance

    OFF or EMERGENCY OFF button, before opening either cabinet for service. 5.1 Preventative Maintenance The ABC-170CE requires very little regular maintenance. Occasional preventative maintenance as described below should keep the system in good operating condition for many years.

  • Page 48: Fault Indications

    To aid fault diagnosis, fault indicators have been built into the design of the ABC-170CE. 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 5.2 for information.
  • Page 49 Processor ‘ok’ @ time of fault 5.1V (see Display Board Status below)*  6.8V Failed Start-Up  6.9V Out of space  7.0V Transistor Fault  7.1V Voltage drop Across Contactors > 10V 29730-03-04 Page 49 of 61 Webasto Charging Systems, Inc.
  • Page 50 Channel A Current - Display Board Status  Unit Overtemperature  RS485 Communication Fault * * 5.1V & 0.4A is the standard fault condition indicated when power is removed from the system. 29730-03-04 Page 50 of 61 Webasto Charging Systems, Inc.
  • Page 51 ROS. Available on a DC Upgrade System only. Battery Cycler A term for the ABC-170CE that refers to its use in battery charge and discharge cycling. Configuration The wiring arrangement used for a particular load or loads.
  • Page 52 ABC-170CE and sends operating limit and control commands to the ABC-170CE. Remote Voltage Sense A connector input to allow the ABC-170CE to monitor and regulate Voltage directly on the Load. Available only on a DC Upgrade System.
  • Page 53 Insert the thermoplastic head screw into the port in the sleeve, use a screwdriver to thread into place, and secure the contact in the sleeve. 29730-03-04 Page 53 of 61 Webasto Charging Systems, Inc.
  • Page 54 2. To reassemble, follow the above assembly instructions. NOTE: These simple and easy procedures for assembly or disassembly offers the user the flexibility to change or replace contacts and/or insulator sleeves in the field. 29730-03-04 Page 54 of 61 Webasto Charging Systems, Inc.
  • Page 55 Remote Voltage Sense Operation: Independent Mode The output voltage of each channel of the ABC-170CE can be regulated directly at the load eliminating excessive voltage drop across the cables, which carry high current between the ABC- 170CE 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 56 + Sense B = = = V Sense Twisted pair / shielded Fuse 4 Plcs Load A Load B Figure III.1. Connection diagram for independent mode operation with Remote Voltage sensing 29730-03-04 Page 56 of 61 Webasto Charging Systems, Inc.
  • Page 57 -4.5 V <= (Analog V) <= -5.0 V Output Current = Current + ILower limit ILower limit <= Output Current =< IUpper limit Current commanded by the user via Front panel or ROS (See Figure IV-1) 29730-03-04 Page 57 of 61 Webasto Charging Systems, Inc.
  • Page 58 PLower limit <= Output Power =< PUpper limit Power commanded by the user via Front panel or ROS (See Figure IV-2) ABC-170 in Power Mode with Analog Input (Figure IV.2) Figure IV.2 Power Mode 29730-03-04 Page 58 of 61 Webasto Charging Systems, Inc.
  • Page 59 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 the standby mode (open the output contactor and isolate the output of the ABC-170CE from the load). Figure V.1 High-Voltage Interlock Connector Wiring...
  • Page 60 ABC-170CE Installation, Operation, and Maintenance Appendix VI: External Parallel Operation CONFIGURATION PRESS TO TOGGLE PARALLEL INDEPENDENT OUTPUT B COMMON NEGATIVES OUTPUT A Load A Figure VI.1 External Parallel Operation 29730-03-04 Page 60 of 61 Webasto Charging Systems, Inc.
  • Page 61 ABC-170CE Installation, Operation, and Maintenance Webasto Charging Systems, Inc. 1333 S. Mayflower Ave., Ste 100 Monrovia, CA 91016 Corporate headquarters: Friedrichshafener Str. 9 82205 Gilching Germany 29730-03-04 Page 61 of 61 Webasto Charging Systems, Inc.

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