Related Manuals for Webasto ABC-600NS
Summary of Contents for Webasto ABC-600NS
- Page 1 Installation, Operation and Maintenance Manual EV Test Systems ABC-600NS English 31565-03_01...
- 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.
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Page 3: Warranty
Warranty Webasto ABC-600NS 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 date of installation, but not more than 18 months from date of manufacture. Webasto's liability under this warranty shall be limited to repairing or replacing at Webasto's option, without charge, F.O.B. -
Page 4: Table Of Contents
SAFETY PRECAUTIONS - READ BEFORE USE SYMBOL USAGE GENERAL SAFETY WARNINGS AND PRECAUTIONS INTRODUCTION 1.1 Overview 1.2 Scope of Manual 1.2.1 Manual Organization 1.3 ABC-600NS Applications Constant Voltage Source Constant Current Source Battery Quick Charging Battery Pack Cycling Battery Emulation Other Applications 2.0 SYSTEM DESCRIPTION... - Page 5 APPENDIX I: GLOSSARY OF TERMS APPENDIX II: DC I/O CONNECTOR ASSEMBLY EQUIPMENT REQUIREMENTS: General Assembly Procedures Disassembly Procedures APPENDIX III: ABC-600NS REMOTE VOLTAGE SENSE OPERATION APPENDIX IV: ABC-600NS ANALOG SIGNAL CONTROL 31565-03_01 Page 5 of 51 Webasto Charging Systems, Inc.
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Page 6: Safety Precautions - Read Before Use
Safety Precautions - Read Before Use The ABC-600NS 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. SYMBOL USAGE... - Page 7 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. 31565-03_01 Page 7 of 51 Webasto Charging Systems, Inc.
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Page 8: Introduction
Examples are APU’s, flywheels, motors, inverters, batteries, fuel cells, capacitors, and more. The ABC-600NS is an ideal test system for a wide range of DC loads in addition to batteries; offering more capability than a traditional power supply system. The ABC-... -
Page 9: Constant Current Source
ABC-600NS will cease operation. Constant Current Source In Current Mode, the ABC-600NS regulates the current of a given DC output channel. As in constant Voltage Mode, the load may draw or provide current bi-directionally subject to user-defined limits. -
Page 10: Battery Emulation
Battery Emulation With its computer control capabilities, the ABC-600NS can be programmed to emulate a battery. The ABC-600NS would first be put into constant Voltage Mode at the desired state of charge. As current is drawn from the ABC-600NS, the voltage would be lowered; as if the “battery” was being discharged. -
Page 11: System Description
2.0 System Description 2.1 System Block Diagram The ABC-600NS architecture is shown in the following system block diagram (Figure 2.1). The AC Inverter connects to the utility via an isolation transformer. The DC Converter and AC Inverter transfer power via an Intermediate DC Bus and communicate via an RS-485 data bus. - Page 12 EMERGENCY Pressed it to remove input control power to the system. switch has a locking mechanism and must be rotated counterclockwise to enable the control power to power the system. 31565-03_01 Page 12 of 51 Webasto Charging Systems, Inc.
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Page 13: Dc Converter Functions & Controls
The internal contactors remain disconnected during load configuration or reconfiguration, and will also be disconnected in the event of a load fault 31565-03_01 Page 13 of 51 Webasto Charging Systems, Inc. - Page 14 Figure 2.3. DC Converter Front Panel The following displays and controls are operable in manual mode or through the ROS. The ABC-600NS starts up with both Channel A and Channel B in manual mode. Both the Remote A and the Remote B buttons are unlit in this mode.
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Page 15: Dc Side Connector Interface
ROS control. 2.1.3 DC Side Connector Interface All of the manual functions of the ABC-600NS are controllable with the Remote Operation System. In addition, there are serial data output and monitoring connectors, which are accessible on the DC Connector Panel (Figure 2.4). -
Page 16: Remote Operation Interface
ABC-600 Remote Operation System Manual and CAN Interface document. ROS Isolated RS-232 Port The ABC-600NS has serial ROS data out via the Isolated RS-232 Port. The pinouts for this feature are detailed in Figure 2.5: Figure 2.5. ROS ISOLATED PORT... -
Page 17: Hv Interlock (Front Panel)
RVS (Remote Voltage Sense) To increase voltage accuracy at the Load, the ABC-600NS can feed back on a remote voltage measurement. The RVS mode is activated by pressed the front panel button. The RVS feature can be used in voltage mode as well as power mode. -
Page 18: Optional Data Acquisition Interfaces
2.1.4 Remote Emergency Stop Within the ABC-600NS, there is a provision to allow installation of an external switch to control the emergency stop function of the system. To enable a system provided with this option, an electrical connection must be made between pins 1 and 4 of this interface (Figure 2.7). -
Page 19: Technical Specifications
± 300 mA or .35% of <130 mA RMS mV or reading .15% The power accuracy at each point is a simple multiple of the voltage and current accuracy for that point (with offsets). 31565-03_01 Page 19 of 51 Webasto Charging Systems, Inc. -
Page 20: Communication
Humidity 0-90% non-condensing Cabinets Dimensions, each cabinet: ~ 36” (92 cm) x 72” (182 cm) x 72” (182 cm) Weight ~ 3500 lbs (1588 Kg) 31565-03_01 Page 20 of 51 Webasto Charging Systems, Inc. -
Page 21: Installation
The ABC-600NS is designed with safety of the customer as the highest priority. However, the following safety precautions must be read and observed. Installation must comply with all local codes. The ABC-600NS is designed to be operated in a 0-35 C Lab environment, free of significant airborne particulate. - Page 22 If you discover shipping damage after acceptance, file a claim for concealed damage. 31565-03_01 Page 22 of 51 Webasto Charging Systems, Inc.
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Page 23: Operation
READ THIS ENTIRE SECTION BEFORE PROCEEDING When the DC output external contact in the load opens in either Current or Power Mode, the user must put the ABC-600NS 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-600NS, 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: Independent Configuration
Note: Voltage refers to limit on either channel and not output. 4.2 Independent Configuration When the ABC-600NS is powered up, it is always in the INDEPENDENT configuration. Output A and 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. - Page 26 ABC-600NS Installation, Operation and Maintenance CONFIGURATION PRESS TO TOGGLE EXTERNAL PARALLEL OUTPUT B COMMON NEGATIVES OUTPUT A Load A Load B Figure 4.2. Independent Configuration 31565-03_01 Page 26 of 51 Webasto Charging Systems, Inc.
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Page 27: External Parallel Configuration
Figure 4.3. Parallel Configuration 4.4 Choosing Operating Limits The ABC-600NS 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 28: General Limits Considerations
Converter for the chosen configuration (as shown in the Tables and Figure 4.1). 5. The upper limit for any parameter may not be lower than the lower limit for that parameter. 31565-03_01 Page 28 of 51 Webasto Charging Systems, Inc. - 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-600NS DC Converter's operating space must include this initial condition.
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Page 30: Operating The System
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-600NS 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 31 C h a n g e lo a d c o n fig u ra tio n Figure 4.5. ABC-600 Operation Flow Chart 31565-03_01 Page 31 of 51 Webasto Charging Systems, Inc.
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Page 32: System Startup
ABC-600NS Installation, Operation and Maintenance 4.6 System Startup The AC Converter contains the controls to start the ABC-600NS. 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 33: Adjusting Operating Limits
To save the existing limits as the defaults for future use, press both UPPER and LOWER LIMITS buttons at the same time. Each NOTE time the ABC-600NS main power is turned on, the new default limits will be set. 31565-03_01 Page 33 of 51 Webasto Charging Systems, Inc. -
Page 34: 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-600NS is ready to run. At this point, the unit is in Local/Independent mode operation by default. If ROS is running Remote Operation of each channel, it can be initiated;... -
Page 35: Changing Mode While Running A Test
limits. 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. 31565-03_01 Page 35 of 51 Webasto Charging Systems, Inc. -
Page 36: 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 to continue. 31565-03_01 Page 36 of 51 Webasto Charging Systems, Inc. -
Page 37: Changing Load Configuration
Remote Operation System. 4.12 Turning Off Power To shut down the ABC-600NS at any time, the user may press 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 recommended... - Page 38 User must make sure that the AC circuit breaker is off and the system has been off with the ON/OFF or EMERGENCY OFF WARNING button in the OFF POSITION for a minimum of five minutes before opening cabinet for service. 31565-03_01 Page 38 of 51 Webasto Charging Systems, Inc.
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Page 39: Maintenance
Coolant used in this product is 25% Peak™ and 75% distilled water (referred as “Webasto approved coolant” hereunder). Cooling system may deteriorate and cause failure if any other cooling fluid is used. Contact Webasto Service Department if you need help in procuring “Peak”. - Page 40 After all of the coolant mixture has drained, close the valve and proceed to refill the coolant. With the pump off, fill reservoir (with Webasto approved coolant) until coolant is within 1” of the top of the reservoir. Turn the pump on and continue filling with coolant until reservoir remains full within 1”...
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Page 41: Fault Indications
Ripple currents can be verified at this same time. However, it is important that the load used while measuring ripple current is NOT a second ABC-600NS system. Use a battery or resistive load to obtain accurate ripple measurements. 5.2 Fault Indications To aid fault diagnosis, fault indicators have been built into the design of the ABC- 600NS. - Page 42 If a DC Fault is suspected (is the light lit?), measure the Detection voltage on the Channel A terminal block Communication Fault Indicator On Steady A communication fault has occurred 31565-03_01 Page 42 of 51 Webasto Charging Systems, Inc.
- Page 43 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. 31565-03_01 Page 43 of 51 Webasto Charging Systems, Inc.
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Page 44: Appendix I: Glossary Of Terms
A subassembly of the ABC-600NS on the left side of the cabinet. Converts AC to DC to regulate the Intermediate DC Bus. Battery Cycler A term for the ABC-600NS that refers to its use in battery charge and discharge cycling. Ch A (Also Converter A) The master or left converter in the DC Converter. - Page 45 ABC-600NS Installation, Operation and Maintenance Remote Operation The interface between the ABC-600NS and a remote operation Interface system. The physical interface is located on the left side of the DC Converter. The interface also specifies message structure and contents of messages exchanged between the ABC-600NS and the Remote Operation System.
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Page 46: Appendix Ii: Dc I/O Connector Assembly
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. 31565-03_01 Page 46 of 51 Webasto Charging Systems, Inc. -
Page 47: Disassembly Procedures
Remote Operation Interface for loss of communication. NOTE When the DC Converter is placed in remote operation, it waits to activate the time-out timer until the first message has been received from the Remote Operation System. 31565-03_01 Page 47 of 51 Webasto Charging Systems, Inc. -
Page 48: Appendix Iii: Abc-600Ns Remote Voltage Sense Operation
ABC-600NS 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 49 2) Parallel Mode In parallel mode only the RVS connector on channel A is used with the load connected up as in Figure 4.3. Figure A3.1 Connection diagram for RVS in Independent Mode. 31565-03_01 Page 49 of 51 Webasto Charging Systems, Inc.
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Page 50: Appendix Iv: Abc-600Ns Analog Signal Control
ABC-600NS Installation, Operation and Maintenance Appendix IV: ABC-600NS Analog Signal Control Signal Specification: Isolated source Absolute maximum range: +/-5VDC Operating mode: Power / Current under manual or remote operation Minimum resolution: 25mVDC ABC-600 Operation with Analog Signal Control – WITH ROS CONTROL The Analog control signal enables the user to program / control the output current or power on each channel of the ABC-600 independently. - Page 51 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 31565-03_01 Page 51 of 51 Webasto Charging Systems, Inc.