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

Webasto ABC-170 Hardwired Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual
EV Test Systems
ABC-170 Hardwired
English
11780-03-E

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Summary of Contents for Webasto ABC-170 Hardwired

  • Page 1 Installation, Operation and Maintenance Manual EV Test Systems ABC-170 Hardwired English 11780-03-E...
  • 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: 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. 11780-03-E Page 4 of 52 Webasto Charging Systems, Inc.

  • Page 5: Table Of Contents

    3.1.5 Equipment Needed 3.2 Cooling System Preparation 3.3 AC Input Connection AC Input Connections 3.4 DC Input/Output Connections 4.0 OPERATION 4.1 Planning 4.1.1 Choosing a Load Configuration 445 Vdc Upper Limit 11780-03-E Page 5 of 52 Webasto Charging Systems, Inc.
  • Page 6 APPENDIX II: DC I/O CONNECTIONS 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 11780-03-E Page 6 of 52 Webasto Charging Systems, Inc.

  • Page 7: Safety Precautions - Read Before Use

    Be sure to leave these instructions with the installed unit for future reference. Only qualified personnel should install, use or service this unit. Read and understand these Manufacturer’s instructions and your employer’s safety practices manual. 11780-03-E Page 7 of 52 Webasto Charging Systems, Inc.
  • 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. 11780-03-E Page 8 of 52 Webasto Charging Systems, Inc.

  • Page 9: Introduction

    The ABC-170 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-170. 11780-03-E Page 9 of 52 Webasto Charging Systems, Inc.
  • Page 10 Repetitive use of these automated compliant test profiles can be used for comparative research as well as production level testing. Battery Emulation 11780-03-E Page 10 of 52 Webasto Charging Systems, Inc.
  • Page 11 ABC-170 in a virtually limitless set of applications. The ABC-170 base unit can be customized for particular applications using ROS Scripts or Optional J1850 or CAN Communication capabilities. Contact Webasto customer service for more information.

  • Page 12: System Description

    AC Inverter as a true unity power factor interface regardless of line harmonics. Figure 2 shows the AC Inverter front panel. Each of the front panel controls and indicators are described below. 11780-03-E Page 12 of 52 Webasto Charging Systems, Inc.

  • Page 13: Dc Converter Functions & Controls

    2.1.2 DC Converter Functions & Controls The DC Converter monitors load connections, processes power from the Intermediate DC Bus for the load, and provides a local control interface for the user. 11780-03-E Page 13 of 52 Webasto Charging Systems, Inc.
  • Page 14 (e.g., a voltage higher than the user- defined limit). Figure 3 DC Converter Front Panel Figure 3 shows the ABC-170 DC Converter front panel. The displays and controls are described below. 11780-03-E Page 14 of 52 Webasto Charging Systems, Inc.
  • Page 15 OPERATION of the respected channel from the load. To re-initiate Remote mode operation, the user must manually push the flashing Remote A/B button to resume operation under ROS control. 11780-03-E Page 15 of 52 Webasto Charging Systems, Inc.

  • Page 16: Communication Between Ac Inverter And Dc Converter

    ABC-170 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 06631-03. 2.1.5 ABC-170 Remote Operation System (ROS) The ABC-170 ROS is a personal computer based system for controlling the ABC-170.

  • Page 17: Analog Signal Control

    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 18: Technical Specifications

    186 Amps RMS Frequency 60 ± 1 Hz Ground Connected to chassis AC Power Quality at Rated Power Power factor > 99% Harmonic Distortion < 3% THD, no individual harmonic greater than 3% 11780-03-E Page 18 of 52 Webasto Charging Systems, Inc.
  • Page 19 Automatic shutdown on loss of utility power UL recognized components used where possible Remote Emergency Stop Cabinets Dimensions: 72”L x 30”D x 67"H (183cm x 76cm x 170 cm) Weight: 2,500lb (1,136kg) 11780-03-E Page 19 of 52 Webasto Charging Systems, Inc.

  • Page 20: Installation

    Keep it in the original packing materials Store it at temperatures between 0 o C (32 o F) and 70 o C (158 o F) • Always protect the equipment from moisture, dust and weather • 11780-03-E Page 20 of 52 Webasto Charging Systems, Inc.

  • Page 21: Location (In-Door Only)

    3.3 AC Input Connection The unit should be installed electrically by a Licensed Electrician according to the local code and National Electric Code (NEC). 11780-03-E Page 21 of 52 Webasto Charging Systems, Inc.

  • Page 22: Ac Input Connections

    The appropriate wire for use with the DC Converter is 4/0 wire gauge welding cable with 600VDC minimum insulation. Welding cable is suggested due to the higher flexibility, but is not critical for proper operation of the unit. 11780-03-E Page 22 of 52 Webasto Charging Systems, Inc.

  • Page 23: Operation

    The High Voltage Interlock Connector may also be used to put the unit in Standby mode. When the High Voltage Interlock connection for a channel is opened, the associated channel goes into STANDBY mode. Refer to the manual and consult Webasto field support if necessary. 11780-03-E Page 23 of 52...

  • Page 24: Planning

    Will this test be controlled locally or remotely? Locally Remotely If remote operation, what test script will be used? What control mode is required? Voltage Mode Current Mode Power Mode Combination of above modes 11780-03-D Page 24 of 52 Webasto Charging Systems, Inc.

  • Page 25: Choosing A Load Configuration

    + 125 / -170 445 VDC upper limit available, see below Continuous power rating Volts Parallel Mode Independant Mode -700 -600 -500 -400 -300 -200 -100 Amperes Figure 6 ABC-170 Operating Limits (420VDC System) 11780-03-D Page 25 of 52 Webasto Charging Systems, Inc.

  • Page 26: 445 Vdc Upper Limit

    The voltage of the intermediate DC bus within the ABC-170 is higher, so both current and power must be restricted in order to protect electrical components (see Figure 7). 11780-03-D Page 26 of 52 Webasto Charging Systems, Inc.

  • Page 27: 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. 11780-03-D Page 27 of 52 Webasto Charging Systems, Inc.

  • Page 28: Independent Configuration

    A single load may be connected in INDEPENDENT configuration (i.e., either Load A or Load B) with no change in functionality. 11780-03-D Page 28 of 52 Webasto Charging Systems, Inc.

  • Page 29: External Parallel Configuration

    DC Converter will override the selected control mode and use the boundary condition as its internal control mode if necessary to stay within the operating space. 11780-03-D Page 29 of 52 Webasto Charging Systems, Inc.
  • Page 30 300 Vdc, a lower voltage limit of 100 Vdc, upper/lower current limits of ± 100 Adc, and upper/lower power limits of ± 20 kW. 11780-03-D Page 30 of 52 Webasto Charging Systems, Inc.
  • Page 31 +80 Adc. This operating point is inside the operating space so the DC Converter will operate along the +80 Ampere vertical line until the battery voltage has increased to 250 Vdc. 11780-03-D Page 31 of 52 Webasto Charging Systems, Inc.

  • Page 32: Operating The System

    ABC-170 is expecting the user to make a choice or verify a setting and will not allow certain other actions until that step is completed. In particular, the ABC-170 will not close the internal contactors to provide power until all necessary steps have been taken. 11780-03-D Page 32 of 52 Webasto Charging Systems, Inc.
  • Page 33 End of test program, panel Select standby mode enter standby mode Resume test, Enter same load remote configuration operation Change load configuration Figure 11 ABC-170 Operation Flow Chart 11780-03-D Page 33 of 52 Webasto Charging Systems, Inc.

  • Page 34: System Startup

    To set the limits push the UPPER or LOWER LIMITS button. The corresponding UPPER or LOWER LIMITS will be displayed on the front panel in the VOLTAGE, CURRENT, and POWER displays. While holding the LIMITS button down, increase or decrease the 11780-03-D Page 34 of 52 Webasto Charging Systems, Inc.

  • Page 35: Selecting Local Or Remote Operation

    To make small changes, press the button and release it as many times as needed. To make larger changes, press the button and hold it down until the desired setting is reached. 11780-03-D Page 35 of 52 Webasto Charging Systems, Inc.

  • Page 36: Changing Mode While Running A Test

    NOTE: Before changing operating limits, be sure you have carefully considered the potential impact on the load. It is best to maintain an operating space that is as small as possible to prevent unwanted or unsafe operation. 11780-03-D Page 36 of 52 Webasto Charging Systems, Inc.

  • Page 37: Pausing A Test

    Limit and mode selections are easily performed with a few clicks of the mouse. The display indicates limits selected, operating mode and system status. Any test run locally from the front panel can be duplicated using the ROS. 11780-03-D Page 37 of 52 Webasto Charging Systems, Inc.

  • Page 38: Turning Off Power

    You must make sure that the AC circuit breaker is off and the system has been off with the OFF or EMERGENCY OFF button WARNING depressed for a minimum of five minutes before opening either cabinet for service. 11780-03-D Page 38 of 52 Webasto Charging Systems, Inc.

  • Page 39: Maintenance

    This section describes preventative maintenance. Preventative maintenance may require access to the interior of the unit and should only be performed by an Webasto authorized technician. The following warning should be observed for all such activity. WARNING: You must make sure that the AC circuit breaker is off and that tthe system has been turned off for a minimum of five minutes by depressing the OFF or EMERGENCY OFF button, before opening either cabinet for service.
  • Page 40 Tighten or replace any loose fittings. Replace any hoses that are damaged. If a leak is found in the pump, the heat sink, or the reservoir, contact Webasto for service or a replacement part. Once these procedures have been completed, refill the coolant system with Webasto approved coolant and allow it to stand for an extended period of time, checking frequently for leaks.

  • Page 41: Fault Indications

    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. 11780-03-D Page 41 of 52 Webasto Charging Systems, Inc.
  • Page 42 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. 11780-03-D Page 42 of 52 Webasto Charging Systems, Inc.

  • Page 43: Appendix I: Glossary Of Terms

    One of two load configurations (see also Independent). External parallel Control of the DC Converter is achieved from a remote Remote operation system via the Remote Operation Interface. Operation 11780-03-D Page 43 of 52 Webasto Charging Systems, Inc.
  • Page 44 (Also Converter B) The slave or right converter in the DC Converter. An operational mode in which the output terminals are Standby Mode internally disconnected and no power transfer occurs. Utility AC three phase power source. 11780-03-D Page 44 of 52 Webasto Charging Systems, Inc.

  • Page 45: Appendix Ii: Dc I/O Connections

    For Catalog Numbers of Leviton 16D24E (Webasto# 01578) and 16D24R (Webasto # 01579); provided with two copper shims for 2/0 cable and one copper shim for 3/0 or 4/0 cable. 3. Attach male and female contacts to cable ends by inserting the cable wire into the end of the contact and position the strain relief wire in the cable hole on the opposite side of the contact from the set screws.

  • Page 46: Disassembly Procedures

    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. 11780-03-D Page 46 of 52 Webasto Charging Systems, Inc.

  • Page 47: Appendix Iii: Remote Voltage Sense Operation

    Load in order to eliminate any shock hazard to the operator. It is highly recommended to use twisted pairs or shielded cabling for sensing and then routing them away from any noise emitting sources. 11780-03-D Page 47 of 52 Webasto Charging Systems, Inc.
  • Page 48 Figure 12 Connection Diagram for Independent Mode Operation with 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. 11780-03-D Page 48 of 52 Webasto Charging Systems, Inc.

  • Page 49: Appendix Iv: Analog Signal Control

    -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) 11780-03-D Page 49 of 52 Webasto Charging Systems, Inc.
  • Page 50 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 Power Mode 11780-03-D Page 50 of 52 Webasto Charging Systems, Inc.

  • Page 51: Appendix V: High Voltage Interlock Wiring

    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-170 from the load). Figure 13 High Voltage Interlock Connection Wiring 11780-03-D Page 51 of 52 Webasto Charging Systems, Inc.

  • Page 52: Appendix Vi: External Parallel Operation

    Using either configuration method still requires actively pressing the PARALLEL configuration button on the front panel. Figure 14 External Parallel Bus Bars Installed CONFIGURATION PRESS TO TOGGLE PARALLEL INDEPENDENT Figure 15 PARALLEL Configuration Selection 11780-03-D Page 52 of 52 Webasto Charging Systems, Inc.

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