Webasto 900EX User manual

Installation, Operation, and Maintenance Manual
EV Test Systems
900 EX

© 2019 WEBASTO CHARGING SYSTEMS, INC. ALL RIGHTS RESERVED.
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.
CORPORATE HEADQUARTERS
Webasto Charging Systems, Inc.
1333 S. Mayflower Ave. Suite 100
Monrovia, CA 91016
[phone]
www.evtestsystems.com

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A NOTE ABOUT CUSTOMER SUPPORT
To ensure superior service, please write down the unit’s serial number in the
owner’s record above and have it available when contacting Webasto customer
support. The serial number can be found on the nameplate rating label on the
upper left corner of the unit.
Webasto EV Test Systems
Customer Support
1-866-767-4242
[e-mail]
OWNER’S RECORD
Model:
900 EX
Serial number (s/n):
Purchase date:
22855-03-04

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SAVE THESE INSTRUCTIONS!
This manual contains important instructions for the installation, operation and
maintenance of the 900 EX.
CONTENTS
1INTRODUCTION............................................................................1
1.1 Symbol Usage .................................................................................. 2
1.2 General Safety Precautions............................................................... 3
2SYSTEM DESCRIPTION ..................................................................5
2.1 About the 900 EX ............................................................................ 6
2.2 900 EX Power Applications.............................................................. 6
2.3 System Components ........................................................................ 8
2.4 AC Inverter Functions & Controls ..................................................... 9
2.5 DC Converter Functions & Controls................................................ 13
2.6 Technical Specifications.................................................................. 17
3INSTALLATION ............................................................................19
3.1 On-Site Installation......................................................................... 20
4OPERATION ................................................................................23
4.1 Channel to Channel Operation....................................................... 25
4.2 Planning ........................................................................................ 25
4.3 Choosing a Load Configuration...................................................... 26
4.4 Choosing Operating Limits............................................................. 30
4.5 Operating the System .................................................................... 31
4.6 System Start-Up............................................................................. 33
4.7 Connecting Load & Selecting Configuration......................................33
4.8 Adjusting Operating Limits............................................................. 34
4.9 Selecting Local or Remote Operation ............................................. 35
4.10 Turning Off Power........................................................................ 40

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5MAINTENANCE...........................................................................41
5.1 Preventative Maintenance .............................................................. 42
5.2 Fault Indications............................................................................. 43
APPENDIX A
GLOSSARY OF TERMS.................................................................... 45
A.1 Glossary of Terms .......................................................................... 46
APPENDIX B
DC I/O CONNECTOR ASSEMBLY ....................................................51
B.1 Standard Unit with CAMLOCKS ..................................................... 52
B.2 No CAMLOCKS Unit...................................................................... 53
APPENDIX C
900 EX REMOTE VOLTAGE SENSE OPERATION ...............................55
C.1 Remote Voltage Sense (RVS) Operation.......................................... 56
APPENDIX D
HIGH VOLTAGE INTERLOCK WIRING .............................................. 59
APPENDIX E
INDEX.............................................................................................61

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Chapter 1
Introduction

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1.1 SYMBOL USAGE
The 900 EX is designed with safety as the highest priority. Installation must
comply with all local codes and the following safety precautions must be read
and observed.
Indicates information about safety practices which, if not
followed, may result in serious injury or death.
Indicates information about safety practices which, if
not followed, could result in personal injury, fire, or
equipment overheating.
Indicates helpful information for installation or usage,
but does not contain personnel or equipment safety-
related information.

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1.2 GENERAL SAFETY PRECAUTIONS
BEFORE YOU BEGIN
• Read all instructions and cautionary markings on
the 900 EX assembly.
• Read the important safety instructions below.
• 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.
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. Turn
off local disconnect on the left side of the unit.
Leave off for at least five (5) minutes to allow high
voltage to discharge.
• Do not operate the unit if there is physical damage
to the unit, coupler, or cable.
• Do not subject the cable to damage or stress.
• Do not step on the DC output cable.
• Do not operate the unit if any access panels are
open.
Inspect the equipment immediately upon receipt. If
the unit was damaged during shipment, keep the
shipping cartons and packing materials and file a claim
with the freight carrier and/or insurance company for
shipping damage. If shipping damage is discovered after
acceptance, file a claim for concealed damages.

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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 900 EX is provided to allow a
hardware monitor to shut down the 900 EX in the event
of an unsafe battery condition.
Before attempting to service the system, follow these
steps:
1. Turn off the Input Circuit Breaker or Main
Disconnect Switch.
2. Turn off local disconnect on the left side of the
unit.
3. Depress and latch the Emergency Off switch for at
least five (5) minutes to allow the high voltage to
discharge.
4. 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.
1-866-767-4242

Chapter 2
System Description

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2.1 ABOUT THE 900 EX
The 900 EX 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.
The 900 EX is an ideal test system for a wide range of DC loads, in addition
to batteries, offering more than a traditional power supply system. Examples
include Auxiliary Power Units (APU), flywheels, motors, inverters, batteries, fuel
cells, capacitors, and more. The 900 EX 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 operation.
Power is transferred from the utility to the load or from the load to the utility.
Using the utility to absorb power eliminates the need for external resistive loads
and conserves energy that is normally lost. In addition, the 900 EX incorporates
special power processing algorithms to perform a wide variety of tests.
2.2 900 EX POWER APPLICATIONS
The 900 EX is flexible and may be used for a variety of DC power applications
(see Table 1). This section describes a few typical applications to illustrate the
different features of the 900 EX.
Table 1. 900 EX Power Applications
Category Application 900 EX
Battery Testing and
Cycling
Battery Cell
Battery Module
Battery Management Systems
Battery Pack •
Production Testing •
Simulation Battery •
Powertrain •
Fuel Cell •
Hardware in the Loop •

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Category Application 900 EX
Energy Storage
Charging and Testing
Fuel Cell •
Super & Ultra Capacitors •
Flywheels •
Power Generation
Equipment Testing
Electric Components •
Power Supplies •
Generators •
Stationary Power •
Inverters •
Military & Aerospace •
Life, Run-in, Burn-in •
Uninterruptable Power Supplies (UPS) •
Hybrid and Electric
Vehicle Testing
Powertrain •
Production Testing •
Medium & Heavy-duty EVs (buses,
trucks, military, locomotives)
•

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2.3 SYSTEM COMPONENTS
Figure 1 and Table 2 illustrate and describe the 900 EX system components.
Figure 1. System Components

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Table 2. System Components
Number Description
1 (HMI) User Interface Panel
2Remote Operation System (ROS) Serial Port
3 CAN BUS Port
4Remote Voltage Sense (RVS) - Channels A and B
5Multi-Unit Fiber (IN)
6 Multi-Unit Fiber (OUT)
7Ethernet Fiber
8Multi-Unit Interlock
9 High Voltage Interlocks - Channels A and B
10 DC Output - Camlocks Option
11 Isolation Fault Detection
12 AC Diagnostic Port
13 Remote E (Emergency) Stop
14 Local E (Emergency) Stop
15 Power Button
16 Utility IN
2.4 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.

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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 Section
2.6 Technical Specifications.
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.
Figure 2 shows the AC Inverter front panel. See Table 3 for a description of AC
Inverter panel functions.
Figure 2. AC Inverter Front Panel
The main circuit breaker must be switched off and locked
out by authorized factory personnel; and, either the Main
Power or Emergency Off switch service must be switched
off to remove power from the system for at least five (5)
minutes prior to accessing the interior of the cabinet.

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Table 3. AC Inverter Controls and Indicators
Panel Functions Description
Main Power On/Off Press to apply and remove power to the system.
The switch ON is illuminated with a green light
when control power is applied to the system. The
switch OFF is illuminated with a red light when the
control power is off, but input power is present.
Emergency Off Press to remove all power to the system except
input power. The switch has a locking mechanism
and must be rotated counterclockwise to power
the control system.
2.4.1 ISOLATION FAULT DETECTION
Internal Isolation is monitored with a separate circuit.
Prior to contactor closure, this circuit monitors the impedance between the
positive and negative intermediate busses and the chassis or earth ground. Once
the contactors have been closed and the Unit Under Test (UUT) is connected to
the 900 EX, the Isolation Monitor is disabled to prevent nuisance trips with low
impedance loads.
The Isolation Monitor has four indicator lights (i.e., Ready, Reset, - Bus Fault, + Bus
Fault) for displaying the state of the system (see Figure 3).
Figure 3. Isolation Fault Detection Panel

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Table 4 defines the indicator lights in each state.
Table 4. Indicator Lights Displaying State of System
State Ready Light
(green)
Reset light
(yellow)
-Bus Fault
(red)
+ Bus Fault
(red)
Standby 1 Hz Flash – – –
Standby
fault
– – On steady On steady
Monitor On steady – – –
+ Bus
Fault
– – – On steady
- Bus
Fault
– – On steady –
Operate On steady – – –
Reset – 1 Hz Flash – –
Reset
complete
–On steady – –
1. Standby. When a power processing session is started, 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 900 EX 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.
2. Standby Fault. When the Isolation monitoring circuit times out during
Standby (the DC bus failed to reach the threshold voltage within nine (9)
seconds), the circuit disables the 900 EX and illuminates both fault lights
(red).
3. 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.
4. + Bus Fault/- Bus Fault. If loss of internal isolation is detected, the isolation
fault detection circuit will prevent the 900 EX 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.
5. 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).
6. 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
restart 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

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will flash while 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 900 EX lockout has been released.
2.5 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. All
DC Converter configurations can be set either via the ROS computer, CAN Bus
Interface, Ethernet interface, or manually through the front panel (shown in
Figure 4).
Figure 4. DC Converter Front Panel
The DC Converter is composed of two separately controlled converters:
Converter A and Converter B. Each converter has its own output terminals.
The converter has the ability to operate in two different configurations:
1. Independent Configuration
Two loads can be connected and separately controlled.
2. External Parallel Configuration
This configuration is called parallel because the two converter circuits
internally function in parallel to provide higher current capability. When
operating in this mode, 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.

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The internal contactors remain disconnected during load configuration or
reconfiguration, and will also be disconnected in the event of a load fault
condition (e.g., a short circuit) or an unsafe operating condition (e.g., a voltage
higher than the user-defined limit).
2.5.1 DC SIDE CONNECTOR INTERFACE
All of the manual functions of the 900 EX are controllable with the ROS or other
scripting tool. In addition, there are serial data output, CAN Bus, and ethernet
connectors that are accessible on the DC Connector Panel (Figure 5). Details of
the connector pin outs and the function of each are described below.
Figure 5. Connector Panel with Jumper Connectors
2.5.1.1 REMOTE OPERATION INTERFACE
The Remote Operation Interface is an isolated input based on the RS-232
communication standard and allows communication between the DC Converter
and the 900 EX ROS. The purpose of this interface is to provide status
information and DC output measurements from the 900 EX to the ROS and to
accept commands from the ROS. For more information on the Remote Operation
Interface, please refer to the ROS Manual and/or CAN Interface document.
2.5.1.2 900 EX ROS
ROS is a personal computer-based system for controlling the 900 EX. The
system consists of the computer itself and any peripherals, and the 900 EX ROS
application.
This software provides a graphical user interface for controlling and monitoring
the operation of the 900 EX and a command language interpreter that allows for
simple implementation of complex test programs and communication with the