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

2
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