Webasto ABC-600 Installation, Operation And Maintenance Manual
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Webasto ABC-600 Installation, Operation And Maintenance Manual

Webasto ABC-600 Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual
EV Test Systems
ABC-600
English

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  • Page 1 Installation, Operation and Maintenance Manual EV Test Systems ABC-600 English...

  • Page 2: Table Of Contents

    © 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: 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-600 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 RS-232 CAN Interface...
  • Page 4 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 17032-03-D Page 4 of 51 Webasto Charging Systems, Inc.
  • Page 5 ABC-600 Installation, Operation and Maintenance APPENDIX I: GLOSSARY OF TERMS APPENDIX II: DC I/O CONNECTOR ASSEMBLY APPENDIX III: ABC-600 REMOTE VOLTAGE SENSE OPERATION APPENDIX IV: ANALOG SIGNAL CONTROL APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING APPENDIX VI: EXTERNAL PARALLEL OPERATION 17032-03-D Page 5 of 51 Webasto Charging Systems, Inc.

  • Page 6: Warranty

    Warranty Webasto, Inc. – ABC-600 Limited Warranty Products manufactured by Webasto are warranted to the original user only to be free of defects in material and workmanship for a period of twelve (12) months from date of installation, but not more than eighteen (18) months from date of shipment. Webasto’s liability under this warranty shall be limited to repairing or replacing at Webasto’s option,...

  • Page 7: Safety Precautions - Read Before Use

    Installation, Operation and Maintenance Safety Precautions - Read Before Use The ABC-600 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 8 • • 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. 17032-03-D Page 8 of 51 Webasto Charging Systems, Inc.

  • Page 9: Introduction

    Independent Mode Control for each Channel. • The ABC-600 is an ideal test system for a wide range of DC loads other than those mentioned above, offering more capability than a traditional power supply system. The ABC-600 uses the bi-directional characteristic of the electric utility...

  • Page 10: Abc-600 Applications

    ABC-600 Installation, Operation and Maintenance 1.3 ABC-600 Applications The ABC-600 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-600. 1.3.1 Constant Voltage Source In Voltage Mode, the ABC-600 regulates the voltage of a given DC output channel.

  • Page 11: Battery Emulation

    ABC-600 Installation, Operation and Maintenance The ABC-600 was designed to handle the demands of EV battery pack cycling. Using the ABC-600 ROS or other software packages, USABC compliant tests can be developed and run to verify battery pack adherence to requirements. Repetitive use of these automated compliant test profiles can be used for comparative research as well as production level testing.

  • Page 12: System Description

    2.0 System Description 2.1 System Block Diagram The ABC-600 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 13 MAIN POWER or EMERGENCY OFF switch must be switched off to remove power DANGER from the system for at least five minutes prior to accessing the interior of the cabinet. 17032-03-D Page 13 of 51 Webasto Charging Systems, Inc.

  • Page 14: Dc Converter Functions & Controls

    The converter has the ability to operate in two different configurations: Independent Configuration Two loads can be connected and separately controlled. NOTE: The negative sides of the ABC-600 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 are utilized for parallel operation to provide higher current capability.
  • Page 15 ABC-600 Installation, Operation and Maintenance Figure 2.3 DC Converter Front Panel Figure 2.3 shows the ABC-600 DC Converter front panel. The displays and controls are described below: CONFIGURATION Used to select the load configuration and wiring connection. There is one button each for Parallel, RVS and Independent, respectively.

  • Page 16: Communication Between Ac Inverter And Dc Converter

    DC Converter and the ABC- 600 (ROS). The purpose of this interface is to provide status information and DC output measurements from the ABC-600 to the ROS and to accept commands from the ROS. For more information about the Remote Operation Interface, please refer to the Remote Operation System Manual, Webasto document number 06631.

  • Page 17: High Voltage Interlock (Front Panel)

    Installation, Operation and Maintenance 2.1.6 High Voltage Interlock (Front Panel) Each channel of the ABC-600 has a High Voltage Interlock Switch (HVIS) for added protection (Figure 2.4). The HVIS can put one channel of the ABC-600 into the Standby Mode without affecting the other channel.

  • Page 18: Optional Rs-232 Can Interface

    Installation, Operation and Maintenance 2.1.10 Optional RS-232 CAN Interface The CAN interface is a ROS-enabled interface with user programmable messages. Contact Webasto’s Customer Service Department 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 19: Dc Output

    UL recognized components used where possible • • Remote emergency stop Cabinets Dimensions 72”L x 34”W x 77"H (183cm L x 86cm W x 196cm H) Weight Approx. 3,500 lbs (1,588 Kg) 17032-03-D Page 19 of 51 Webasto Charging Systems, Inc.

  • Page 20: Installation

    ABC-600 Installation, Operation and Maintenance 3.0 Installation This section outlines the requirements and procedures for installing the ABC-600 system. Read this entire section before proceeding with installation. Installation should be completed by an experienced electrician and should conform to all Local and National Electrical Codes.

  • Page 21: Equipment Needed

    • 3.2 Cooling System Preparation Before operating the ABC-600, check the cooling system by opening the reservoir located inside the back panel door of the AC cabinet. Remove the cap from the top of the reservoir and set aside. If the cooling fluid is near the top of the reservoir, it is full.

  • Page 22: Ac Input Connections

    5. Attach the ground (earth) wire from the appropriate power ground to the grounding lug mounted on the wall of the ABC-600 input box. 6. Replace the input box cover and screw it into place.

  • Page 23: Operation

    PPS in the event of an unsafe battery condition. When the DC output external contact in the load opens in either Current or Power Mode, the user must put the ABC-600 in Standby Mode before reclosing the external contact. This can be done manually or in the ROS script.

  • Page 24: Planning

    Channel B in any other way. 4.1 Planning Before you begin a test with the ABC-600, you will need to decide on certain parameters. The following checklist may be used as a guideline for preparation. What load configuration is required?

  • Page 25: Choosing A Load Configuration

    Each of the configurations is described below in more detail. WARNING Load cables exceeding 10’ may cause loss of power. Figure 4.1 ABC-600 Operating Limits Note: Voltage refers to the limit on either channel and not the output. 17032-03-D Page 25 of 51...

  • Page 26: Independent Configuration

    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. 17032-03-D Page 26 of 51 Webasto Charging Systems, Inc.

  • Page 27: 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 External Parallel configuration, output current is shared between the two converters. 17032-03-D Page 27 of 51 Webasto Charging Systems, Inc.

  • Page 28: Choosing Operating Limits

    Installation, Operation and Maintenance 4.4 Choosing Operating Limits The ABC-600 allows the user 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, the user may want to set these more restrictive limits in order to protect the load or avoid unsafe conditions.
  • Page 29 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 ABC-600 DC Converter’s operating space must include this initial condition.

  • Page 30: Operating The System

    DC Converter front panel prompt the user to check or reset the operating limits and the control modes (voltage, current and power). Each step on the flowchart is discussed in detail below. 17032-03-D Page 30 of 51 Webasto Charging Systems, Inc.
  • Page 31 End of test program, panel Select standby mode enter standby mode Resume test, Enter same load remote configuration operation Change load configuration Figure 4.5 ABC-600 Operation Flow Chart 17032-03-D Page 31 of 51 Webasto Charging Systems, Inc.

  • Page 32: System Startup

    Installation, Operation and Maintenance 4.6 System Startup The AC Inverter contains the controls to start the ABC-600. To start the system: Confirm the red light of the OFF Switch is illuminated. If it is not illuminated, check the input power phase sequence and the Emergency Off switch.

  • Page 33: Adjusting Operating Limits

    Once the load has been connected, the load configuration has been chosen and the operating limits have been set, the ABC-600 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 34: Local Operation

    If the control setting cannot be adjusted to the desired value, check the operating limits and adjust as necessary (see Section 4.10.4 on Changing Operating Limits below). In particular, if the mode button is flashing for a 17032-03-D Page 34 of 51 Webasto Charging Systems, Inc.

  • Page 35: Changing Mode While Running A Test

    Voltage, Current or Power Modes can be entered. This sequence is required to make sure that you are aware of the limit settings and have confirmed that they are correct before applying power to the load again. 17032-03-D Page 35 of 51 Webasto Charging Systems, Inc.

  • Page 36: Entering Remote Operation

    Configuration, above and proceed through the remaining set-up steps. 4.11 Remote Operation Once in remote operation, all control can be done from the ABC-600 Remote Operation System (ROS). The ROS provides the complete set of ABC-600 front panel controls. Limit and mode selections are easily performed with a few clicks of the mouse.

  • Page 37: Turning Off Power

    4.12 Turning Off Power To shut down the ABC-600 at any time, press the Main Power OFF switch or depress the EMERGENCY OFF button (both located on the AC Inverter Front Panel). However, in the event of a normal, non-emergency shut down, it is recommended that the DC Converter be placed in Standby Mode (STANDBY button(s) lit, while other mode buttons are unlit) first before turning off the power.

  • Page 38: Maintenance

    (5) minutes before opening either cabinet for service. 5.1 Preventative Maintenance The ABC-600 requires very little regular maintenance. Occasional preventative maintenance as described below should keep the system in good operating condition for many years. Important Note: Coolant used in this product is 25% Peak™...
  • Page 39 Also check the cooling system hoses for cracks or hardening. If a leak appears to have developed, DO NOT OPERATE THE ABC-600. Note the • leak location and then drain the coolant from the system as described above.

  • Page 40: Fault Indications

    Utility Failure, Utility Frequency is incorrect  Three Pulses Utility Failure, Utility Amplitude is incorrect  Four Pulses Utility Cutout, Utility Power has been removed  Communication Fault Indicator On Steady ROS Communication Failure  17032-03-D Page 40 of 51 Webasto Charging Systems, Inc.
  • Page 41 Channel A Current - Display Board Status Unit Over Temperature  RS485 Communication Fault *  * 5.1V & 0.4A is the standard fault condition indicated when power is removed from the system. 17032-03-D Page 41 of 51 Webasto Charging Systems, Inc.

  • Page 42: Appendix I: Glossary Of Terms

    A mode of control in which an isolated analog signal is used to Control modify a command sent by ROS. Battery Cycler A term for the ABC-600 that refers to its use in battery charge and discharge cycling. Configuration The wiring arrangement used for a particular load or loads. Also the selection on the DC Converter front panel that matches the physical load connections.
  • Page 43 System receives data and status information from the ABC-600 and sends operating limit and control commands to the ABC-600. Remote Voltage A connector input to allow the ABC-600 to monitor and regulate Sense Voltage directly on the Load. Side A (Also Converter A) The master or left converter in the DC Converter.

  • Page 44: 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. 17032-03-D Page 44 of 51 Webasto Charging Systems, Inc.
  • Page 45 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. 17032-03-D Page 45 of 51 Webasto Charging Systems, Inc.

  • Page 46: Appendix Iii: Abc-600 Remote Voltage Sense Operation

    Remote Voltage Sense Operation: Independent Mode The output voltage of each channel of the ABC-600 can be regulated directly at the load, eliminating excessive voltage drop across the cables, which carry high current between the ABC- 600CE and the Load, while maintaining greater voltage accuracy. This is accomplished by utilizing the V Sense connectors provided on the front panel user I/O strip.
  • Page 47 Figure III-1 Connection Diagram for Independent Mode Operation w/Remote Voltage Sensing External Parallel Mode In External Parallel Mode, only the RVS connector on channel A is used. The outputs of both channels are connected to the load. 17032-03-D Page 47 of 51 Webasto Charging Systems, Inc.

  • Page 48: Appendix Iv: Analog Signal Control

    Analog signal to control the output current or power. The Analog signal scales the output current or power of the ABC-600 based on the table listed below. Also provided below is the graphical representation in both Current and Power Mode.
  • Page 49 Output Power = Power + PLower limit PLower limit <= Output Power =< PUpper limit Power commanded by the user via Front panel or ROS (See Figure IV-2) ABC-600 in Power Mode with Analog Input Figure IV-2 Power Mode 17032-03-D Page 49 of 51...

  • Page 50: Appendix V: High Voltage Interlock Wiring

    Pin 4 (Gnd) is the Ground signal of the +5 V voltage source A break in any of these links will put that channel into Standby Mode (open the output contactor and isolate the output of the ABC-600 from the load). Front Panel...

  • Page 51: Appendix Vi: External Parallel Operation

    ABC-600 Installation, Operation and Maintenance Appendix VI: External Parallel Operation CONFIGURATION PRESS TO TOGGLE PARALLEL INDEPENDENT OUTPUT B COMMON NEGATIVES OUTPUT A Load A 17032-03-D Page 51 of 51 Webasto Charging Systems, Inc.

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