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
21324-76_02.docx Page 2 of 26 Webasto Charging Systems, Inc.
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
21324-76_02.docx2 Page 3 of 26 Webasto Charging Systems, Inc.
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
21324-76_02.docx2 Page 4 of 26 Webasto Charging Systems, Inc.
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
21324-76_02.docx2 Page 5 of 26 Webasto Charging Systems, Inc.
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
21324-76_02.docx2 Page 6 of 26 Webasto Charging Systems, Inc.
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

MT-30 Installation Instructions
21324-76_02.docx2 Page 7 of 26 Webasto Charging Systems, Inc.
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.

MT-30 Installation Instructions
21324-76_02.docx2 Page 8 of 26 Webasto Charging Systems, Inc.
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.

MT-30 Installation Instructions
21324-76_02.docx2 Page 9 of 26 Webasto Charging Systems, Inc.
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.

MT-30 Installation Instructions
21324-76_02.docx2 Page 10 of 26 Webasto Charging Systems, Inc.
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