Webasto 22615 User manual

22615-76_02.docx
Instructions, Field Installation
Convert Ampro PC104 to ICOP VDX-6353RD, 50/60HZ
ABC-150
English

22615-76_02.docx
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22615-76_02.docx
Warranty
Webasto 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 maylast. 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.

22615-76_02.docx
Introduction
The #22615 kit is provided to allow the ABC-150 with Ampro PC104 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:
Item
No.
Part No.
Description
Ref
Des
Qty
1
07310
LABEL,CALIBRATION,OUTDOOR
1
2
05042
CONNECTOR, SHORTING JUMPER, SHROUD, 2PIN, 0.100(2.54), 2800VACrms, 3.0A,
-55-120C, UL E66906
3
3
05449
ASSY,MICROCIRCUIT,PROGRAMMED,AC INVERTER,ABC-150/170
U26
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
1
10
29594
KIT,COMPUTER,SINGLE BOARD W PC/104
1
10.1
29595
COMPUTER,SINGLE BOARD W 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 10).
1
10.3
21050
CABLE ASSY, 2mmx2mm MOLDED CONNECTORS WITH 1mm FLAT RIBBON 20C CABLE
8inL, 30V, -20C-85C (SHIPPED WITHIN ITEM 10).
1
11
22259
ASSY,MACH211 PAL,U24,CONTROL BOARD,DC,(VDX-6353-D),P3
U24
1
12
22517
ASSY,FLASH STORAGE VDX-6353RD,HYB,ABC-150
1
13
09434
NUT,6-32,HEX,W/TOOTH WASHER,ZN PL STL
2
13
22262
KIT,SW,ROS V6.0/CAN V1.7.1/HYBRID,P3
0
15
21128
KIT,OPTO ISOLATOR (485OPDR),ABC-150/170
1
15.1
21079
OPTOISOLATOR,RS-422/485 ISOLATED REPEATER, 4.173inDx0.992inWx3.118inH,
10-30Vdc 0.7W POWER SUPPLY, 35mm DIN RAIL MOUNTED,2KV ISOLATED,-40C-
80C,UL,CE,FCC
1
15.3
05355
ASSY,RAILING,DIN,MODIFIED,IPC/P3
1
15.4
08610
END STOP,TERM BLOCK,DIN RAIL MOUNT
2
15.5
21119
CABLE ASSY,OPTO ISOLATOR (485OPDR) TO INVERTER CONTROL BD,P3
1
15.6
21120
CABLE ASSY,OPTO ISOLATOR (485OPDR) TO CONVERTER CONTROL BD,P3
1
15.8
01798-000
WIRE,22AWG,19/34,TIN CU,BLACK,IRRADIATED PVC,300V,105C,UL 1430
30”
15.9
01798-002
WIRE,22AWG,19/34,TIN CU,RED,IRRADIATED PVC,300V,105C,UL 1430
30”
15.11
03540
CLAMP,WIRE HARNESS,NYLON,0.5(12.7),ELASTIC RELEASE,SCREW MOUNT
1
15.12
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 v
6
15.13
01150
CABLE TIE,MINI,3.1in,0.68inD,18 lbs,NATURAL,NYLON, BLACK
8
15.14
09435
NUT,10-32,HEX,W/TOOTH WASHER,ZN PL STL
2
18
23964
CABLE ASSY,INTERLOCK LOOP BACK,P3
1
Note 1: Items 10.1 through 10.3 are part of Kit P/N: 29594 (Item 10).
Note 2: Items 15.1 through 15.14 are part of Kit P/N: 21128 (Item 15).
Note 3: Item Num 18 only needed for 50Hz

22615-76_02.docx
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
New PC104 requires installation of ROS/CAN software, # 22262
1. Turn the unit off and turn the utility power off.
2. Open the DC converter front panel of the ABC-150.
Figure 1. ABC-150 DC Converter Font Panel
3. Locate the Ampro PC104 Computer Board (# 05176), and CAN Card (# 05890), if the unit has CAN card, in
the lower left corner of the Display Assembly.
Figure 2. DC Control Board with CAN Card and Cable Installed
Replace PAL U24
with # 22259

22615-76_02.docx
4. Remove the cable connected between the DC Control Board J21 below, as shown in Figure 3, and the CAN
Port of the User I/O Panel, as shown in Figure 4, if the unit has the cable.
Figure 3. DC Control Board CAN Port Cable [Remove]
Figure 4. User I/O Panel with CAN Port Location
5. Carefully remove the CAN Card from the Ampro PC104 Computer Board below, as shown in Figure 5.
Figure 5. CAN Card

22615-76_02.docx
Figure 6. DC Control Board and Ampro PC104 Without CAN Card
6. Carefully remove the cables #05315, #05318, #05317, and #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.

22615-76_02.docx
7. Carefully remove mounting screws on the DC Control Board #04767 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 #05176 with RAM #05175 as shown in Figure 8.
9. Remove the NOMEX #08953 and mounting bracket #05344, as shown in Figure 8.

22615-76_02.docx
10. Refer to Figure 2, in DC Control Board #04767, locate U24. Carefully remove the U24 with PLCC Extraction
Tool (MCM electronics P/N D00038, order #22-11114).
11. Replace U24 with #22259 ASSY, MACH211 PAL, U24, CONTROL BOARD, DC, (VDX-6353RD), P3, in the
Kit. Label #04767 board with FSB-00145 and date.
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-D Computer Board.
14. Install PCBA DC CONTROL #04767 with U24 #22259.
11378
11379
05041
04860
21148
11354
01626
3X 05348
20X 03442
9X 01626
5X 05345 8X 01250
21054
2X 03280
5X 03280
11352
14286
3X03280

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15. Insert compact flash storage memory #22517, ASSY,CF,FLASH STORAGE VDX-6353RD,HYB,ABC-150
into the computer board #29594 (part of # 29595) ,as shown in Figure 10 for the model of HYB ABC-150.
Figure 10. VDX-6353D Controller with FLASH Card Exposed
16. Carefully, install the PC104 computer board VDX-6353RD, #29595, with the Comact Flash Storage Memory
installed, into the Interface Board #14286, as shown in Figure 11. Please note: PC104 Computer Board
VDX-6353RD should be verified in factory that the Custom BIOS setup is complete.
Figure 11. VDX-6353RD Controller
COM1; cable #21047 with
red side (pin 1) flat ribbon
plug into COM1 of PC104
Computer Board VDX-
6353RD.
PC104 computer board
VDX-6353RD (# 29594)
and Compact Flash card
with label