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Webasto ABC-600 Installation Instructions Manual
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Webasto ABC-600 Installation Instructions Manual

Webasto ABC-600 Installation Instructions Manual

Convert pc104 pcm-3341 to icop vdx-6353rd
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ABC-600
Installation Instructions
INSTRUCTIONS, FIELD
INSTALLATION, CONVERT PC104
PCM-3341 TO ICOP VDX-6353RD,
50/60HZ, ABC-600
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.
22394-76_02.docx
Page 1 of 20
Webasto Charging Systems, Inc.

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Summary of Contents for Webasto ABC-600

  • Page 1 INSTALLATION, CONVERT PC104 PCM-3341 TO ICOP VDX-6353RD, 50/60HZ, ABC-600 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. 22394-76_02.docx Page 1 of 20 Webasto Charging Systems, Inc.

  • Page 2: Warranty

    Systems with proof of purchase and installation date, failure date, and supporting installation data if so requested. Any defective product to be returned to Webasto Charging Systems must be sent freight prepaid; documentation supporting the warranty claim and/or a Return Material Authorization must be included if so instructed.
  • Page 3 Installation Instructions Introduction The Webasto US Los Angeles (WUSLA) #22394-00X kit is provided to allow the ABC-600 with PC104 PCM- 3341 computer board, to be converted to ICOP VDX-6353RD, and allowing communication via CAN or/and ROS that exits in the unit. The kit contains the following:...

  • Page 4: Hardware Installation

    #22262 Rev. A or higher, supplied with kit. 1. Turn the unit off and turn the utility power off. 2. Open the front panel on the DC side and AC side by removing the panel screws. Figure 1. ABC-600 Front Panel 22394-76_02.docx Page 4 of 20...
  • Page 5 WUSLA Part Number ABC-600 System 09842 300A/300A 05984 400A/200A 4. Carefully remove the CAN Card from the PC104 PCM-3341 Computer Board below, as shown in Figure 3. Figure 3. CAN Card (ESD CAN-PC104/331-2) 22394-76_02.docx Page 5 of 20 Webasto Charging Systems, Inc.
  • Page 6 DC control board. Keep and mark all cables and hardware so that they can be easily put back later. Figure 5. Cable connections for DC Control Board (WUSLA #09842 or 05984) with PC104 PCM-3341 Computer Board 22394-76_02.docx Page 6 of 20 Webasto Charging Systems, Inc.
  • Page 7 8. Insert Compact Flash Storage Memory (See Note for proper WUSLA #), ASSY,FLASH STORAGE VDX- 6353-D,HYB,ABC-600, into #29595, COMPUTER,SINGLE BOARD W PC/104 AND WEBASTO CHARGING SYSTEMS BIOS, VORTEX86DX, as shown in Figure 6 for the model of HYB ABC-600. PC104 computer board VDX-6353RD (WUSLA...
  • Page 8 9. Carefully, install the PC104 computer board VDX-6353RD, WUSLA #29595 with the Compact Flash Storage Memory into the Interface Board WUSLA #14286, as shown in Figure 7. Please note: PC104 Computer Board VDX-6353RD should be verified in factory that the Webasto Charging Systems BIOS setup is complete. COM1; cable WUSLA #21047...
  • Page 9 WUSLA #04860. WUSLA #05984. Figure 9. Side View, PC104 computer board VDX-6353RD with interface cables 16. Connect other disconnected and marked cables back to DC Control Board (WUSLA #09842 or 05984 22394-76_02.docx Page 9 of 20 Webasto Charging Systems, Inc.
  • Page 10 J2-4 IRQ11, J2-6 IRQ9, J2-9 IRQ5. Figure 10. ABC-600 Display Assembly - PC104 CAN Location 18. On the DC Control Board (WUSLA #09842 or 05984 locate J2, as shown in Figure 10. Remove the jumper between IRQ6 and IRQ9, install jumper WUSLA #05042 into J2-1, J2-2, J2-4, J2-6, and J2-9.
  • Page 11 Figure 11. Location of U26 in PCBA Inverter Control 22. Replace U26 with (See Note for proper WUSLA #), ASSY, MICROCONTROLLER, AC INV CTRL, 420V/60Hz, ABC-600, in available kit. For 50Hz systems: a. Use provided #23964 Interlock Loop cable assembly (Item Num 18).
  • Page 12 ABC-600 Installation Instructions 23. Drill (2) 5/32” holes and tap for 10-32 screws to the rectangular steel tubing from the left inside of ABC-600, as shown in Figure 13. 24. Install Opto Photo Isolator WUSLA #21079 and Power Supply WUSLA #25663 available in Kit #21130 as shown in Figure 12 and 13.
  • Page 13 29. Install the wiring WUSLA #21121 between the input line of power supply WUSLA #19626 and AC Contactor Assembly Terminal block, where tab WUSLA #01598 added to position 1 and position 4, as shown in Figure Figure 15. Terminal Block in Assy AC Contactor 22394-76_02.docx Page 13 of 20 Webasto Charging Systems, Inc.
  • Page 14 32. Based on ABC-600 Field Calibration Procedure in Appendix I, calibrate the unit. 33. Place the Calibration Label #07310 to the unit and fill the calibration report as shown in Appendix II.

  • Page 15: Appendix I: Abc-600 Field Calibration Procedure

    3.3 Connect Remote Voltage Sense connector from the shunt to the Channel A RVS connector on the front panel of the ABC-600. Turn RVS mode ON. 3.4 Set Channel A in Voltage mode at 8V. Adjust R318 (AREMOTE) offset till DMM1 reads 8.0000.010V.
  • Page 16 4.3 Connect Remote Voltage Sense connector from the shunt to the Channel B RVS connector on the front panel of the ABC-600. Turn RVS mode ON. 4.4 Set Channel B in Voltage mode at 8V. Adjust R316 (BREMOTE) offset till DMM1 reads 8.0000.010V.
  • Page 17 8.5 Now command +150A on Channel B and adjust R85 on the DC Control board such that the current on the shunt reads Y, which is 149.94 in this example. 8.6 Verify the current calibration similar to Channel A section 7.6 for Channel B. 22394-76_02.docx Page 17 of 20 Webasto Charging Systems, Inc.
  • Page 18 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 22394-76_02.docx Page 18 of 20 Webasto Charging Systems, Inc.

  • Page 19: Appendix Ii: Abc-600 Calibration Data Sheet

    ABC-600 Installation Instructions Appendix II: ABC-600 Calibration Data Sheet Refer to procedure 09400-08 Test Equipment: Equipment Manufacturer Model Serial Calibration Validity Date DMM1 DMM2 DMM3 Shunt WEBASTO CHARGING SYSTEMS, INC. ABC-600/600CE MONROVIA, CALIFORNIA UNIT SN: _______________ INFORMATION: AC CTRL BOARD...
  • Page 20 200.50A 99.75A 100.25A -.75A -1.25A 49.75A 50.25A -9.75A -10.25A 9.75A 10.25A -49.75A -50.25A FUNCTION TEST: ANALOG “A” RVS CHANEL “A” ANALOG “B” RVS CHANEL “B” INTERLOCK “A” PARALLEL TEST INTERLOCK “B” 22394-76_02.docx Page 20 of 20 Webasto Charging Systems, Inc.