Webasto MT-30 User manual

MT-30 Installation Instructions
21324-76_02.docx Page 1 of 26 Webasto Charging Systems, Inc.
INSTRUCTIONS, FIELD
INSTALLATION, CONVERT AMPRO
PC104 TO VDX-6353RD, MT-30
Webasto Charging Systems, Inc.
1333 S. Mayflower Avenue, Suite 100
Monrovia, CA 91016 U.S.A.
Telephone [phone]
[email protected]
2020 Webasto Charging Systems, Inc.

MT-30 Installation Instructions
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Warranty
Webasto Charging Systems Limited Warranty
Products manufactured by Webasto Charging Systems, 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 shipment from Webasto Charging
Systems. Webasto Charging Systems's liability under this warranty shall be limited to repairing
or replacing at Webasto Charging Systems's option, without charge, F.O.B. Webasto Charging
Systems's factory or onsite at the option of Webasto Charging Systems, any product of Webasto
Charging Systems’s manufacture. Webasto Charging Systems 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 Charging Systems will not be liable for damage or wear to products
caused by abnormal operating conditions, accidents, abuse, misuse, unauthorized alteration or
repair, or if the product was not installed and operated in accordance with Webasto Charging
Systems’s printed installation and operating instructions.
To obtain service under this warranty, the defective product must be returned to Webasto
Charging 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.
WEBASTO CHARGING SYSTEMS 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; you may also have other rights that vary from jurisdiction to
jurisdiction.

MT-30 Installation Instructions
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Introduction
The Webasto US Los Angeles (WUSLA) #21324 kit is provided to allow the MT-30 with Ampro
PC104 computer board, to be converted to ICOP VDX-6353RD, and allowing communication via
CAN or/and ROS that existed in the unit.
Warning –Old MT-30 code used to set the MT-30 in Internal Parallel mode, this version of code
sets the MT-30 in External Parallel to allow the system to be in a 100% Duty Cycle. The kit
contains the following:
Item #
Part #
Description
Ref Des
Qty
1
07310
LABEL,CALIBRATION
1
2
05042
CONNECTOR, SHORTING JUMPER, SHROUD, 2PIN, 0.100(2.54), 2800VACrms, 3.0A,
-55-120C, UL E66906
3
3
06825
ASSY,MICROCIRCUIT,PROGRAMMED,AC INVERTER,MT-30
1
4
14286
PCBA,INTERFACE,PCM/PC-104,ABC
1
5
11352
STANDOFF,FEM/FEM,RND,4-40THR,0.625"L,0.187"OD,BRASS
1
6
11354
STANDOFF,MALE/FEMALE,HEX,4-40x0.625"L,1/4"OD,NYLON
1
7
11378
STANDOFF,FEM/FEM,HEX,4-40X0.625"L,1/4"OD,BRASS
3
8
11379
STANDOFF,MALE/FEMALE,HEX,6-32X0.625"L,1/4"OD,BRASS
2
9
11388
CABLE ASSY,PC104/CONVERTER CONTROL COM,AVP
1
10
29594
KIT,COMPUTER,SINGLE BOARD W PC/104
1
10.1
29595
COMP,SINGLE BRD PC/104 AND CUSTOM BIOS,VORTEX86DX 800 MHZ CPU W/256MB
MEMORY,3.78in(96mm)X3.55in(90.2mm),-20C-70C
1
10.2
21047
CABLE ASSY, 2mmx2mm MOLDED 26 PINS CONNECTOR WITH 1mm FLAT RIBBON
26C CABLE 7inL, 30V, -20C-85C (SHIPPED WITHIN ITEM 6).
1
10.3
21050
CABLE ASSY, 2mmx2mm MOLDED CONNECTORS WITH 1mm FLAT RIBBON 20C
CABLE 8inL, 30V, -20C-85C (SHIPPED WITHIN ITEM 6).
1
11
22259
ASSY,MACH211 PAL,U24,CNTL BD,DC,(VDX),P3
U24
1
12
22507
ASSY,FLASH STORAGE VDX-6353-D,HYB,MT-30
1
13
09434
NUT,6-32,HEX,W/TOOTH WASHER,ZN PL STL
2
14
22262
KIT,SW,ROS V6.0/CAN V1.7.1/HYBRID,P3
0
15
21117
ASSY,KIT,OPTO ISOLATOR (485OPDR),MT-30
1
15.1
21079
OPTOISOLATOR,RS-422/485 ISOLATED REPEATER, 4.173inDx0.992inWx3.118inH,
10-30Vdc 0.7W PWR SPLY, 35mm DIN RAIL MNTD,2KV,-40C-80C,UL,CE,FCC
1
15.2
03166
POWER SUPPLY,AC/DC,100-240VAC,47-63Hz,SINGLE,12VDC or 15VDC,1.7A or
1.5A,0.05% FOR 50% CHANGE,PANELor DESK-TOP,1.62inHx4.83inWx3.99inD,0-50C,NO
INTERNAL FUSE
1
15.3
03484
CABLE TIE,MOUNT,1.00(2.54)Lx1.00(2.54)Wx0.20(3.2)H ,ABS,0.50 lbs,BLACK,ACRYLIC
ADHESIVE BACKED
2
15.4
01150
CABLE TIE,MINI,3.1in,0.68inD,18 lbs,NATURAL,NYLON, BLACK
6
15.5
21119
CABLE ASSY,OPTO ISOLATOR (485OPDR) TO INVERTER CONTROL BD,P3
1
15.6
21475
CABLE ASSY,OPTO ISOLATOR (485OPDR) TO CONVERTER CONTROL BD,ABC-
150/170,MT-30
1
15.7
21433
CABLE ASSY,INPUT LINE,P9 DISTRIBUTION BOARD TO LINEAR POWER SUPPLY
INPUT,MT-30
1
15.9
01798-002-M
WIRE,22AWG,19/34,TIN CU,BLACK,IRRADIATED PVC,300V,105C,UL 1430
0.762 M
15.9
01798-002-M
WIRE,22AWG,19/34,TIN CU,RED,IRRADIATED PVC,300V,105C,UL 1430
0.762 M
15.10
04332
SCREW,MACH,STD,10-32x0.625in,CAP,SC HD,SS,BARE
2
15.12
01558
NUT,10-32,CLIP-ON,STEEL,ZN PL,FLOATING NUT RETAINER
2
15.13
03540
CLAMP,WIRE HARNESS,NYLON,0.5(12.7),ELASTIC RELEASE,SCREW MOUNT
1
18
23964
CABLE ASSY,INTERLOCK LOOP BACK,P3
1
Note 3: Item Num 18 only needed for 50Hz Systems

MT-30 Installation Instructions
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Microcontroller in AC inverter board
WUSLA Part
number
Frequency
Description
06825
50/60 Hz
ASSY,MICROCIRCUIT,PROGRAMMED,AC INVERTER,MT-30
Hardware Installation
DANGER
BEFORE performing the installation, TURN OFF the AC input circuit
breaker and DISCONNECT ALL loads from the unit’s output terminals.
WARNING
This version of code sets the MT-30 in External Parallel to allow the
system to be in a 100% Duty Cycle.
WARNING
New PC104 requires installation of ROS/CAN software CD,
WUSLA #22262 Rev. A or higher, supplied with kit.
1. Turn the unit off and turn the utility power off.
2. Open the front panel of the MT-30.
Figure 1. MT-30 Font Panel

MT-30 Installation Instructions
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3. Locate the Ampro PC104 Computer Board (WUSLA #05176), and CAN Card (WUSLA
#05890), if the unit has CAN card, in the lower right corner of the Display Assembly.
Figure 2. DC Control Board with CAN Card and Cable Installed
4. Remove the cable connected between the DC Control Board J21 below, as shown in Figure 3,
and the ECHO Port of the User I/O Panel, as shown in Figure 4, if the unit has the cable.
Figure 3. DC Control Board ECHO Port Cable [Remove]
Figure 4. User I/O Panel with ECHO Port Location
Replace PAL U24
with WUSLA
#22259

MT-30 Installation Instructions
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5. Carefully remove the CAN Card from the Ampro PC104 Computer Board below, as shown in
Figure 5.
Figure 5. CAN Card
Figure 6. DC Control Board and Ampro PC104 Without CAN Card

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6. Carefully remove the cables WUSLA #05315, WUSLA #05318, WUSLA #05317, and
WUSLA #05316. Remove other cables connected to DC control board below, as shown in
Figure 7. Keep and mark all cables so that can be easily put back later.
Figure 7. Cable connections for DC Control DC Control Board with Ampro
PC 104 Computer Board.

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7. Carefully remove mounting screws on the DC Control Board WUSLA #06298 below, as
shown in Figure 8. Keep all screws and standoffs. Gently remove the DC Control Board.
Figure 8. Explode view of DC control board with Ampro PC 104 Computer
Board.
8. Remove the Ampro PC104 Computer Board WUSLA #05176 with RAM WUSLA #05175 as
shown in Figure 8.
9. Remove the NOMEX WUSLA #08953 and mounting bracket WUSLA #05344, as shown in
Figure 8.
10.Refer to Figure 2, in DC Control Board #06298, locate U24. Carefully remove the U24 with
PLCC Extraction Tool (MCM electronics P/N D00038, order #22-11114).
11.Replace U24 with WUSLA #22259 ASSY, MACH211 PAL, U24, CONTROL BOARD, DC,
(VDX-6353-RD), P3, in the Kit. Label #06298 board with FSB-00145 and date.

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12.Rearrange and install all nuts and standoffs below, as shown in Figure 9.
13.Carefully install the interface board #14286 below, as shown in Figure 9.
Figure 9. Explode view of DC control board with VDX-6353-RD Computer
Board.

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14.Install PCBA DC CONTROL #06298 with U24 #22259.
15.Insert compact flash storage memory WUSLA #22507, ASSY, CF, FLASH STORAGE VDX-
6353-RD, HYB, MT-30 into the computer board WUSLA #29595 (part of WUSLA #29594),
as shown in Figure 10 for the model of HYB MT-30.
Figure 10. VDX-6353RD Controller with FLASH Card Exposed
16.Carefully, install the PC104 computer board VDX-6353RD, WUSLA #29595 with the
Compact Flash Storage Memory installed, into the Interface Board WUSLA #14286, as
shown in Figure 11. Please note: PC104 Computer Board VDX-6353RD should be verified in
factory that the WUSLA BIOS setup is complete.
Figure 11. VDX-6353RD Controller
COM1; cable WUSLA
#21047 with red side (pin
1) flat ribbon plug into
COM1 of PC104
Computer Board VDX-
6353RD.
PC104 computer board
VDX-6353RD (WUSLA#
29595) and Compact Flash
card with label

MT-30 Installation Instructions
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17. Connect the cable WUSLA #11388, WUSLA #05317, WUSLA #21047, WUSLA #21050,
WUSLA #05318, and WUSLA #01149 below, as shown Figure12.
Figure 12. PC104 computer board VDX-6353RD with interface cables

MT-30 Installation Instructions
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18. Install the ROS cable WUSLA #06504 to the ROS connector J20 on the DC Control Board
to User I/O front panel below, as shown in Figures 13 and 14.
Figure 13. ROS Connection on DC Control Board
Figure 14. User I/O Panel with ROS Connection Location (External)
19.Connect all other disconnected and marked cables back to DC Control Board #06298.
ROS Cable
connected to DC
Control Board J20

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20.For the HYB or CAN unit, gently install CAN card back to DC Control Board, as shown in
Figure 15.
Figure 15. MT-30 Display Assembly - PC-104 CAN Location
21.In DC control board WUSLA #06298, locate J2 as shown in Figure 12. Remove the jumper
between IRQ6 and IRQ9, install jumper WUSLA #05042 into J2-1, J2-2, J2-4, J2-6, and J2-9.
22.Plug one end of the CAN cable WUSLA #05375 into the CAN card, as shown in Figure 15
above.
23.Connect the other end of the CAN Port Cable to the ECHO port (CAN Port) DB9 connector
on user I/O front panel, as shown in Figure 16.
Figure 16. User I/O Panel with CAN Port Label Location
24.Locate U26 in PCBA AC Inverter Control #06296 as shown in Figure 17. Carefully remove
U26 with PLCC Extraction Tool (MCM electronics P/N D00038, order #22-11114).
PC-104 CAN
board with
cable
VDX-6353D Controller
(below CAN board)
Remove Jumper
connected
between IRQ6 and
IRQ9. Install
jumper WUSLA
#05042 for
J2-1 IRQ15,
J2-2 IRQ14,
J2-4 IRQ11,
J2-6 IRQ9,
J2-9 IRQ5.
J2

MT-30 Installation Instructions
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Figure 17. Location of U26 in PCBA Inverter Control
25.Replace U26 with #06825 ASSY, MICROCIRCUIT, PROGRAMMED, AC INVERTER,
MT-30, in available kit.
For 50Hz systems:
a. Use provided #23964 Interlock Loop cable assembly (Item Num 18).
b. Connect to P5 of PCBA AC Inverter Control Board
U26 of PCBA
AC Inverter
Control

MT-30 Installation Instructions
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26.Change Dip switch settings (2 places) for Opto isolator WUSLA #21079 (485OPDR) as
shown below
1 and 2: OFF
3: ON
4, 5 and 6: OFF
7 and 8: ON
For RS-485 2-Wire Half Duplex communication mode 9600 baud.
27.Untighten (2) terminal block end stops and move circuit breaker to right so that the Opto
isolator can be mounted next to the circuit breaker and remove a terminal block end stop that
was in the left side of circuit breaker.
28.Install Opto photo isolator WUSLA #21079, in Kit #21117, terminal block end stop and cable
clamp WUSLA #03540, as shown in the Figure 18 and 19.
Figure 18. Installation location for Opto isolator
Figure 19. Installation of cable clamp.
Opto isolator
WUSLA
#21079
Wire clamp
WUSLA
#03540

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29. Install the linear power supply WUSLA #03166 in the left side up corner of MT-30 next to
the with two 10-32 clip on type floating nuts WUSLA #01558 and 10-32x5/8 screws WUSLA
#04332 , as shown in the Figure 20 and 21.
Figure 20. Linear power supply installation (view from outside)
Figure 21. Linear power supply installation (view from inside)
Power
supply

MT-30 Installation Instructions
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30.Install cable assy’s WUSLA #21119, #21475 and black and red twisted wires per system
schematic drawing 18824-30 (Figure 22 is for reference only).
BLK
GRN
ORG
GRY
BLU
RED
BRN
GRY
RED
BRN
VIO
ORG
VIO
GRY
YEL
VIO
BRN
RED
ORG
RED #22
ORG
RED #22
AV #21119
RED
BLU
BRN AV #21079
BLK #22
RED
BRN
BLU GRY AV #21475
32 1 5
2
4
5
1
-S
+S
3
4
+OUT
LINEAR POWER
SUPPLY
+12V/1.7A
AC INPUT
-OUT
BLK #22
1
6
AC
3X 7X
B
D
8
F
X
K
G
M
J
RS-422/RS-485
OPTICAL ISOLATOR
E
L
H
ISOLATED SIDE MODEL 485OPDR
BLK
WHT
Figure 22. Wiring for Opto isolator
31.Make sure that cable assy’s are all properly strain relieved with using cable ties, cable clamp
and wire mounts , as shown figure 23 and 24.
Figure 23. Wire mounts location
Wire mount
location

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Figure 24. Cable ties location
32.Plug cable assembly #21433 into P9 of the Distribution board, other side of the cable mount
to the terminal block of linear power supply WUSLA #03166 as shown figures 25 and 26.
Twisted pair of 22 AWG black and red wires is connected from linear power supply, as
shown in the following figures 26.
Figure 25. P9 of the Distribution board location
P9 location
Cable tie

MT-30 Installation Instructions
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Figure 26. Linear power supply connections
33.Connect twisted-pair #22 RED and BLK; connect RED to terminal J, and BLK to terminal M,
of the Opto photo isolator #21079.
34.Close the unit using all panel screws and restore power to the system.
35.Based on MT-30 Field Calibration Procedure in Appendix I, calibrate the unit.
36.Place the calibration label #07310 to the unit and fill the report, as shown in Appendix II.
Twisted pair #22
BLK and RED for
+5VDC (RED) and
return (BLK)
Input line
#21433 ends
are connected
to 240Vac
input of linear
power supply

MT-30 Installation Instructions
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Appendix I: Mt-30 Field calibration procedure
Use data sheets 06200-97 to record the data.
1.0 Calibration Equipment:
Equipment
Manufacturer
Model
Serial
Calibration
Validity Date
DMM1
Fluke
187
DMM2
Fluke
187
Shunt
EMPRO
5089-500-500
*EPROM (#06826)
Webasto Charging Systems
*Note: If the UUT has CAN card installed internally, then it is necessary to have EPROM chip to run
ROS, which is used in this calibration procedure.
2.0 Calibration Instructions:
2.1 Turn unit ON. Wait ten minutes before beginning calibration procedure.
2.2 Connect the shunt to UUT DC output, Channel A to Channel B.
2.3 Connect a DMM1 to voltage points and a DMM2 to the current points on the shunt
2.4 Connect ROS to the UUT.
2.5 Note: If the facility has ABC-150, then connect channel A of ABC-150 to channel A of
MT-30 and then to channel B. Channel A of MT-30 is rated + 330A and B is rated +
170A. If channel A is connected to B, the current calibration can be performed in the
range of –170A and +170A. If ABC-150 is used as a source or sink in parallel mode the
calibration can be performed for channel A of MT-30 over range of –330A to +330A.
The text marked with asterisk is for optional readings taken with ABC-150 as
source/sink.