Webasto 900CE User manual

11477-03-D
Installation, Operation and Maintenance Manual
Power Processing Products
900CE
English

11477-03-D Page 2 of 56 Webasto Charging Systems, Inc.
© 2019 Webasto Charging Systems, Inc. All rights reserved.
P3™ 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. Specifications are subject to change without notice. Images of the
power cycling and test systems are representative; production models may vary. No portion of these materials may be
duplicated, used, or disclosed without prior written permission from Webasto Charging Systems, Inc.
Disclaimer: this manual includes the latest information available at the time of printing. Webasto Charging Systems, Inc.
Reserves the right to make changes to this manual and/or product without further notice. Changes or modifications to this
product not completed by an authorized service provider could void the product warranty.
These commodities, technology or software were exported from the United States in accordance with the Export
Administration Regulations. Diversion contrary to US law prohibited
Webasto Charging Systems, Inc.
[phone]
evtestsystems.com

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Warranty
Webasto 900CE 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 the date of installation,
but not more than 18 months from the 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.
Webasto’s factory, any product of Webasto’s manufacture. Webasto will not be liable for any
costs of removal, installation, transportation, or any other charges that may arise in
connection with a warranty claim. 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.
To obtain service under this warranty, the defective product must be returned to Webasto
with proof of purchase and installation date, failure date, and supporting installation data.
Any defective product to be returned to Webasto must be sent freight prepaid; documentation
supporting the warranty claim and/or a Return Material Authorization must be included if so
instructed.
WEBASTO WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE OR ANY
OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND
BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE.
Some jurisdictions do not allow the exclusion or limitation of incidental or consequential
damages and some jurisdictions do not allow limitations on how long implied warranties may
last. Therefore, the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights that vary from jurisdiction
to jurisdiction.

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WARNING
Before attempting to service the system:
1) Turn off the Main Disconnect Switch.
2) Depress and latch the Emergency Off switch for at least 5 minutes to allow the
high voltage to discharge.
3) Do not open the covers; there are no user serviceable parts inside.
CONTACT WEBASTO’S CUSTOMER SERVICE DEPARTMENT
PRIOR TO PERFORMING ANY SERVICE ON THE UNIT.

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Table of Contents
WARRANTY 4
WARNING 5
TABLE OF CONTENTS 6
SAFETY PRECAUTIONS - READ BEFORE USE 9
SYMBOL USAGE 9
GENERAL SAFETY WARNINGS AND PRECAUTIONS 9
1.0 INTRODUCTION 11
1.1 Overview 11
1.2 Scope of Manual 11
1.2.1 Manual Organization 11
1.3 900CE Applications 12
Constant Voltage Source 12
Constant Current Source 12
Battery Quick Charging 12
Battery Pack Cycling 12
Battery Emulation 13
Other Applications 13
2.0 SYSTEM DESCRIPTION 14
2.1 System Block Diagram 14
2.1.1 AC Inverter Functions & Controls 14
2.1.2 Isolation Fault Detection 16
2.1.3 DC Converter Functions & Controls 18
Independent Configuration 18
External Parallel Configuration 18
2.1.4 DC Side Connector Interface 20
Remote Operation Interface 21
900CE Remote Operation System (ROS) 21
HV Interlock (Front Panel) 21
RVS (Remote Voltage Sense) 22
CAN Operation (Optional) 22
Analog Signal Control 22
2.1.5 Remote Emergency Stop (Optional) 22
2.2 Technical Specifications 23
2.2.1 Utility Requirements 23
AC Output 23
DC Output 23
Operating range 23
Accuracy 24
Operating Environment 24
Physical Specification 24
3.0 INSTALLATION 24

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4.0 OPERATION 27
4.1 Planning 28
4.1.1 Choosing a Load Configuration 28
4.1.2 Operating Below 750 Volts 28
Operating Above 750 Volts In Parallel Configuration 29
Operating Above 750 Volts In Independent Configuration 29
4.3 External Parallel Configuration 32
4.4 Choosing Operating Limits 32
General Limit Considerations 33
Operating Space 33
Second Boundary 33
Load 33
4.5 Operating the System 35
4.6 System Startup 37
4.7 Connecting the Load and Selecting the Configuration 37
4.8 Adjusting Operating Limits 37
4.9 Selecting Local or Remote Operation 38
4.10 Local Operation 38
4.10.1 Selecting Mode 38
4.10.2 Adjusting Setting 39
4.10.3 Changing Mode While Running a Test 40
4.10.4 Changing Operating Limits 40
4.10.5 Pausing a Test 40
4.10.6 Entering Remote Operation 41
4.10.7 Changing Load Configuration 41
4.11 Remote Operation 41
4.12 Turning Off Power 42
5.0 MAINTENANCE 43
5.1 Preventative Maintenance 43
5.2 Fault Indications 44
APPENDIX I: GLOSSARY OF TERMS 47
APPENDIX II: DC I/O CONNECTOR ASSEMBLY 49
EQUIPMENT REQUIREMENTS: 49
General 49
Cable Assembly Procedures 50
APPENDIX III: 900CE REMOTE VOLTAGE SENSE OPERATION 51
APPENDIX IV: 900CE ANALOG SIGNAL CONTROL 53
INDEPENDENT MODE 53
PARALLEL MODE 54

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THE ANALOG VOLTAGE RESPONSE AND SCALING 54
APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING 56

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Safety Precautions - Read Before Use
The 900CE 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
Throughout this manual, take special note of the information marked with the following
symbols:
DANGER
Contains information about safety practices necessary to prevent
personal injury or death.
WARNING
Contains information about safety practices necessary to prevent
fire or equipment overheating.
NOTE
Offers helpful information for installation or usage, but does not
contain personnel or equipment safety related information.
GENERAL SAFETY WARNINGS AND PRECAUTIONS
WARNING
BEFORE YOU BEGIN
Read all instructions and cautionary markings on the 900CE
assembly.
Make sure you also read the IMPORTANT SAFETY
INSTRUCTIONS below.
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.

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DANGER
ELECTRIC SHOCK CAN KILL:
Touching live electrical parts can cause fatal shocks or severe
burns.
The input power circuitry and internal circuits are live whenever
input power is on.
An incorrectly installed or improperly grounded unit is a hazard.
Depress and latch the Emergency Off Switch for at least five (5)
minutes to allow high voltage to discharge.
WARNING
Battery testers should not rely solely on manual
operation or automated scripts for safety. Errors can
subject batteries to overcharging which can result in
battery damage or fire.
Batteries should be monitored by independent hardware for
one or more of these unsafe conditions:
•Over voltage
•Over temperature
•Excess pressure
•Excess gassing (H2)
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.

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1.0 Introduction
1.1 Overview
The 900CE is a bi-directional, computer-controlled two-channel DC power
processing system offering superior accuracy and flexibility. The system was
specifically designed for testing (i.e., “cycling”) electric and hybrid-electric vehicle
components and subsystems. Examples include APU’s, flywheels, motors,
inverters, batteries, fuel cells, capacitors, and more.
The 900CE 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
900CE uses the bi-directional characteristic of the electric utility (it can deliver
and absorb power) to meet the needs of both uni-directional and bi-directional
loads (as used in this manual, load refers to a device or system connected to the
900CE for the purpose of receiving and/or delivering DC power).
Power is transferred from the utility to the load, or vice-versa. Using the utility to
absorb power eliminates the need for external resistive loads and conserves
energy normally lost. In addition, the 900CE incorporates special power
processing algorithms, enabling the user to perform a wide variety of testing.
1.2 Scope of Manual
This manual contains a description of the 900CE and instructions for the
installation, operation and maintenance of the system.
1.2.1 Manual Organization
This manual is divided into five sections with several support appendices as
follows.
SECTION
DESCRIPTION
1.0
Provides system and application overview
2.0
Describes the system architecture and
function
3.0
Provides step-by-step instructions for
installing the 900CE
4.0
Discusses operation of the 900CE, using
typical 900CE applications as examples
5.0
Provides preventative maintenance
guidelines
Appendices
Defines 900CE terms and details of
application procedures

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1.3 900CE Applications
The 900CE 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 900CE.
Constant Voltage Source
In Voltage Mode, the 900CE regulates the voltage of a given DC output
channel. The load may draw current from the 900CE at the regulated
voltage and the voltage level may be varied on demand, as with a
conventional DC power supply. In addition, the 900CE allows the user to
define voltage, current and power limits to protect the load and maintain
safe operating conditions. The 900CE also allows for bi-directional power
flow (i.e., it allows the load to discharge current back to the utility), unlike
standard power supplies. However, if the utility voltage is interrupted while
running, the 900CE will cease operation.
Constant Current Source
In Current Mode, the 900CE regulates the current of a given DC output
channel. As in constant Voltage Mode, the load may draw or provide
current bi-directionally based on user-defined limits.
Battery Quick Charging
Battery charging algorithms vary considerably depending on many factors.
A basic quick charging algorithm involves charging the battery at a constant
current rate (i.e., the maximum charge rate) until a certain voltage level is
reached and then maintaining that voltage level while the charge rate
decreases to a trickle charge. This can be accomplished very simply with
the 900CE. By setting the correct upper voltage limit and operating the
system in constant Current Mode, the user can assure that the 900CE will
charge the battery at the desired current until its voltage rises to the limit
and will then maintain that voltage. No manual adjustment is needed
during the test.
More complicated battery charge algorithms can be achieved by modifying
the operating limits, modes and command values as the test proceeds.
Such algorithms can be implemented manually or they can be programmed
and run automatically using the 900CE Remote Operation System or other
scripting tool.
Battery Pack Cycling
Battery packs used in electric vehicles (EV) endure constantly changing
demands. As the vehicle accelerates and brakes, the battery may go from
rapid discharge to charge and back again in a matter of seconds. In
addition, the daily driving and charging of an electric vehicle puts the
battery through a large number of deep discharge cycles, resulting in
shortened battery life.
Because of these factors, EV battery pack testing is highly important but
also very difficult. Simulating the demands of an electric vehicle on a
battery pack requires computer-controlled testing with a highly accurate
and responsive battery cycling system.

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The 900CE was designed specifically to handle the demands of EV battery
pack cycling. Using the 900CE Remote Operating System, 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.
Battery Emulation
With its computer control capabilities, the 900CE can be programmed to
emulate a battery. To do so, the 900CE would first be put into constant
Voltage Mode at the desired state of charge. As current is drawn from the
900CE, the voltage would be lowered as if the “battery” were being
discharged.
Similarly, as the “battery”is charged, the voltage would be increased. The
algorithm to determine how voltage changes in response to charging and
discharging would be determined by the user, based on the size and type
of battery to be emulated, and then programmed into the 900CE Remote
Operation System or other scripting tool.
Other Applications
As the above examples illustrate, the 900CE is very flexible and versatile
and can be used for many other applications. Testing or emulation of
almost any DC power system can be achieved with the powerful computer-
controlled testing capabilities.
The 900CE can also be valuable for very simple applications, such as
discharging batteries and putting their power back onto the utility grid. With
a basic understanding of the system, users can employ the 900CE in a
virtually limitless set of applications.
The 900CE can be customized for particular applications with ROS scripts
or other optional communication capabilities. Contact Webasto’s
Customer Service Department for more information.

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2.0 System Description
2.1 System Block Diagram
The 900CE 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. The DC Converter also communicates to
the 900CE Remote Operation System via an RS-232 data link. The DC Converter
provides the DC interface to a load (or possibly two separate loads) in one of two
operating modes.
AC
Inverter
Unit
DC
Converter
Unit
Intermediate DC Bus
Load A
Load B
Optional Data Collection Systems:
•SmartGuard®
•National Instruments NIDAQ
•Custom
Isolation
Transformer
RS-232
Utility Interface
RS-485
PC
High Voltage Interlock A
High Voltage Interlock B
Figure 2.1 – 900CE System Block Diagram
2.1.1 AC Inverter Functions & Controls
The AC Inverter interfaces the utility to an internal Intermediate DC Bus.
The Intermediate DC Bus voltage is regulated by the AC Inverter based on
the maximum voltage expected by the DC Converter connected. The
range for the Intermediate DC Bus is 750 - 910 Volts DC.
Circuitry designed into the AC Inverter monitors the utility to detect any
abnormalities. This is accomplished by measuring the frequency and
amplitude of the utility, and verifying that it remains within the specified
range given in the Technical Specifications found below.
The AC Inverter operates under current control instead of the more
common phase control. This allows for a more robust interface to the utility
and linear response in the inverter dynamics. In addition, references for
the current are obtained from the utility waveforms, thereby maintaining the
AC Inverter as a true unity power factor interface regardless of line
harmonics.
•
Contact Webasto for
Additional Information

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Figure 2.2 – AC Inverter Front Panel
Figure 2.2 shows the AC Inverter front panel. Each of the front panel
controls and indicators are described below.
MAIN POWER Press the ON switch to apply input power to the system;
the ON bulb is illuminated with a green light. Press the
OFF switch to remove power from the system; the OFF
switch is illuminated with a red light to indicate that control
power is off but input power is available.
EMERGENCY Press to remove all power from the system except for AC
INPUT OFF power. The switch has a locking mechanism and must be
rotated counterclockwise to energize the control system.
NOTE: The main circuit breaker must be switched off
and locked out by authorized personnel and
either the “Main Power” or “Emergency Off”
switch must be switched off to remove power
from the system for at least five minutes prior to
accessing the interior of the cabinet.
Ready Light (Green) Illuminates when the system power is on and the
system is functioning normally.

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Fault Lights (Red) Illuminates when a fault has been detected. The four
lights are AC Inverter Fault, DC Converter Fault, Utility Fault
and Communication Fault. (Refer to Tables 5.1 and 5.2 in
Section 5 of this manual to determine the definition of any
faults indicated.)
2.1.2 Isolation Fault Detection
Internal Isolation is monitored with a separate circuit (See Figure 2.3).
Prior to contactor closure, this circuit monitors the impedance between the
positive and negative busses and the chassis. Once the contactors have
been closed and the Unit Under Test (UUT) is connected to the 900CE, the
isolation monitor is disabled to prevent nuisance trips with low impedance
loads.
Figure 2.3 – Isolation Fault Detection Panel

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The isolation monitor has four indicator lights for displaying the state of the
system to the users. The lights indicate the following states:
State
Ready Light
(green)
Reset Light
(yellow)
-Bus Fault
(red)
+ Bus Fault
(red)
Standby
1 Hz Flash
-
-
-
Standby Fault - -
On
Continuousl
y
On
Continuousl
y
Monitor
On
Continuously
- - -
+ Bus Fault - - -
On
Continuousl
y
- Bus Fault - -
On
Continuousl
y
-
Operate
On
Continuously
- - -
Reset
-
1 Hz Flash
-
-
Reset Complete -
On
Continuously
- -
Standby When the 900CE is first powered up, the isolation
monitoring circuit monitors the DC bus voltage to ensure
that it has risen to a sufficient level to prevent nuisance
isolation monitor trips. While this is happening, the Ready
light (green) is flashing. The 900CE will stay in this state
until the voltage threshold is reached, or for a maximum of
nine (9) seconds, after which the unit declares a Standby
Fault.
Standby Fault When the Isolation monitoring circuit times out
during Standby (the DC bus failed to reach the threshold
voltage within nine seconds), the circuit disables the
900CE and illuminates both fault lights (red).
Monitor After the bus voltage has risen to its set point, the isolation
monitoring circuit evaluates the isolation level of the high
voltage power system. If no faults are detected, the system
displays the Ready light (green) with steady illumination.
The system is now ready to be used.
+Bus Fault/ If loss of internal isolation is detected, the isolation fault
-Bus Fault detection circuit will prevent the 900CE from operating.
The + or – bus fault indicators (red) will be illuminated to
aid in determining the cause of the fault. The system will
remain in this state until manually reset or reset by a power-
down of the system.

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Operate If no faults have been detected, following connection to a
UUT, the system disconnects the isolation monitoring,
allows the output contactors to close, and continues to
display the ready light (green).
Reset After a fault has been detected and the cause of the fault
corrected, the unit must be reset. This can be done either
by a power-down and re-start of the unit (as would have to
be done to perform any work inside the unit) or by manually
pressing the RESET button (yellow). To clear the fault
manually, hold the reset button down for eight (8) seconds.
The light will flash while you are holding down the button.
Once the fault is cleared, the light will return to a steady
yellow indicating the circuit is ready to resume monitoring
and the 900CE lockout has been released.
2.1.3 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. All DC converter configurations can be set either via the ROS
computer or manually through the front panel (shown in Figure 2.4).
The DC Converter is composed of two separately controllable converters,
converter A and converter B. Each converter has its own set of front panel
meters, mode select switches and output terminals.
The converter has the ability to operate in two different configurations:
Independent Configuration
Two loads can be connected and separately controlled.
External Parallel Configuration
This configuration is called parallel because internally the two converter
circuits function in parallel to provide higher current capability. When
operating in this mode, the user must use the output on both channel
terminals.
The DC Converter incorporates safety features to minimize the possibility
of an improperly connected load, or hazardous voltage exposure. The DC
Converter monitors internal switches, which indicate where load
connectors are inserted, and verifies that the load connections and the
chosen configuration are compatible.
If the load configuration requested does not match the load connections,
the requested configuration will not be acknowledged. Additionally, the
output terminals will automatically be disconnected, using internal
contactors, if one of the connectors is pulled from the unit.
The internal contactors remain disconnected during load configuration or
reconfiguration, and will also be disconnected in the event of a load fault

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condition (e.g., a short circuit) or an unsafe operating condition (e.g., a
voltage higher than the user-defined limit).
Figure 2.4 – DC Converter Front Panel
The following displays and controls are operable in manual mode or
through a scripting tool, like the ROS. The 900CE starts up with both
Channel A and Channel B in manual mode. Both the Remote A and the
Remote B LEDs are unlit in this mode. To toggle to remote operation, press
the button for the corresponding channel. Ensure that you have the ROS
(or other scripting tool) computer operational and connected to the 900CE
and that the remote button lights up (yellow).
CONFIGURATION The 900CE starts up in Independent mode as its
default. To change this configuration, press either
the External Parallel buttons (yellow) to enable
External Parallel Operation or the RVS button
(yellow) to enable RVS (Remote Voltage Sensing) in
either mode. If both buttons are unlit, the unit is in
default Independent mode.

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.
LIMITS Upper and lower limit buttons are included for each
converter (A and B). The user presses either the
UPPER or the LOWER button to view the existing
limits and holds the button down while pressing the
Up arrow and Down arrow buttons to adjust those
limits.
.
When these buttons are flashing, the DC Converter
is prompting the user to check the operating limits
and adjust them if necessary.
MODE Determines what control algorithm (mode) a
converter will use. The choices are VOLTAGE,
CURRENT, POWER control (green), or STANDBY
(red).
When all four of these buttons on one converter (A
or B) are flashing, the DC Converter is prompting the
user to choose a mode. When a mode has been
selected, only the appropriate button will be lit (not
flashing) for that converter. During operation (after
the mode has been selected), a flashing mode
button indicates that a user limit has been reached
and that the 900CE is now regulating to the set limit
rather than to the command in the selected mode.
STATUS Each channel will display (local or remote) status
independently (Remote A and Remote B). When
operating remotely, the REMOTE button will be lit for
that channel. When the system is initially powered
up, it begins in local operation. (See Section 4.3.1
for a special configuration option.)
PROTECTED While operating in Remote mode, the operator can
REMOTE change the status of 900CE to Standby by
OPERATION pressing the Standby button.
Pressing this button will open the output contactor
and isolate the output of the respective channel from
the load. To re-initiate remote mode operation, the
operator must manually push the flashing remote
A/B button, which will resume operation under ROS
control.
2.1.4 DC Side Connector Interface
All of the manual functions of the 900CE are controllable with the Remote
Operation System or other scripting tool. In addition, there are serial data
output and monitoring connectors that are accessible on the DC Connector
Panel (Figure 2.5). Details of the connector pin outs and the function of
each are described below.