Webasto ABC-170CE User manual

29730-03-04
Installation, Operation, and Maintenance Manual
EV Test Systems
ABC-170CE
English

ABC-170CE Installation, Operation, and Maintenance
29730-03-04 Page 2 of 61 Webasto Charging Systems, Inc.
© 2021 Webasto Charging Systems, Inc. All rights reserved.
EV Test Systems is a product line of Webasto Charging Systems, Inc. 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
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These commodities, technology or software were exported from the United States in accordance with the Export
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Warranty
Webasto ABC-170CE 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 date of
installation, but not more than 18 months from 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 charge
which 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
may last. 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 which vary
from jurisdiction to jurisdiction.

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Danger
Before attempting to service the system:
1) Turn off the Main Disconnect Switch.
2) Depress and latch the Emergency Off switch for at least 5 minutes to allow high
voltage to discharge
Warning
Do not open covers. No user serviceable parts inside.

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Table of Contents
WARRANTY 3
TABLE OF CONTENTS 5
SAFETY PRECAUTIONS - READ BEFORE USE 8
SYMBOL USAGE 8
GENERAL SAFETY WARNINGS AND PRECAUTIONS 8
1.0 INTRODUCTION 10
1.1 Intended Use 10
1.2 Overview 10
1.3 Scope of Manual 11
1.3.1 Manual Organization 11
1.4 ABC-170CE Applications 12
Constant Voltage Source 12
Constant Current Source 12
Battery Quick Charging 12
Battery Pack Cycling 13
Battery Emulation 13
Other Applications 13
2.0 SYSTEM DESCRIPTION 14
2.1 System Block Diagram 14
2.1.1 AC Inverter Functions & Controls 14
2.1.2 DC Converter Functions & Controls 16
Independent Configuration 16
External parallel Configuration 16
2.1.3 Communication between AC Inverter and DC Converter 18
2.1.4 Remote Operation Interface 18
2.1.5 ABC-170CE Remote Operation System (ROS) 19
2.1.6 High Voltage Interlock (Front Panel) 19
2.1.7 Remote Voltage Sense (RVS) 19
2.1.8 Analog Signal Control 19
2.1.9 Optional Data Acquisition Interfaces 20
2.1.10 Optional CAN Interface 20
2.1.11 Remote Emergency Stop 20
2.2 Technical Specifications 21
DC Input/Output: Operating Range 21
Accuracy and Resolution 22
Utility Requirements 22
AC Power Quality at Rated Power 22
Communication 22
Operating Environment 22
Storage 22
Safety 23

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3.0 INSTALLATION 24
3.1 Preparation 24
3.1.2 Unpacking and Inspection 24
3.1.3 Location (only Indoor) 24
3.1.4 Equipment Needed 26
3.2 Cooling System Preparation 26
3.3 AC Input Connection 26
AC Input Connections 27
3.4 DC Input/Output Connectors 27
4.0 OPERATION 29
4.1 Planning 30
4.1.1 Choosing a Load Configuration 31
445 Vdc Upper Limit 32
Operating above 420 Volts in External Parallel Configuration 33
Operating Above 420 Volts in Independent Configuration 33
4.2 Independent Configuration 34
4.3 External Parallel Configuration 35
4.4 Choosing Operating Limits 36
General Limits Considerations 36
Operating Space 36
Second Boundary 36
Load 36
4.5 Operating the System 38
4.6 System Startup 40
4.7 Connecting the Load and Selecting the Configuration 40
4.8 Adjusting Operating Limits 41
4.9 Selecting Local or Remote Operation 42
4.10 Local Operation 42
4.10.1 Selecting Mode 42
4.10.2 Adjusting Setting 42
4.10.3 Changing Mode While Running a Test 43
4.10.4 Changing Operating Limits 43
4.10.5 Pausing a Test 44
4.10.6 Entering Remote Operation 44
4.10.7 Changing Load Configuration 45
4.11 Remote Operation 45
4.12 Turning off Power 46
5.0 MAINTENANCE 47
5.1 Preventative Maintenance 47
5.2 Fault Indications 48

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APPENDIX I: GLOSSARY OF TERMS 51
APPENDIX II: DC I/O CONNECTOR ASSEMBLY 53
General 53
Assembly Procedures 53
Disassembly Procedures 54
APPENDIX III: REMOTE VOLTAGE SENSE OPERATION 55
APPENDIX IV: ANALOG SIGNAL CONTROL 57
APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING 59
APPENDIX VI: EXTERNAL PARALLEL OPERATION 60

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Safety Precautions - Read Before Use
The ABC-170CE is designed with the safety of the user as the highest priority.
However, installation must comply with all local codes, and the following safety
precautions must be read and observed.
SYMBOL USAGE
Throughout this manual, take special note of the information marked with the
following symbols:
DANGER
Contains information about safety practices necessary to prevent
personal injury or death.
WARNING
Contains information about safety practices necessary to prevent
fire or equipment overheating.
NOTE
Offers helpful information for installation or usage, but does not
contain personnel or equipment safety related information.
GENERAL SAFETY WARNINGS AND PRECAUTIONS
WARNING
BEFORE YOU BEGIN
Read all instructions and cautionary markings on the
ABC-600 assembly.
Make sure you also read the IMPORTANT SAFETY
INSTRUCTIONS below.
Be sure to 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.
DANGER
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 for at least five (5)
minutes to allow high voltage to discharge.

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WARNING
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:
Overvoltage
Overtemperature
Excess pressure
Excess gassing (H2)
The HV Interlock on the PPS is provided to allow a hardware
monitor to shut down the PPS in the event of an unsafe
battery condition.

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1.0 Introduction
1.1 Intended Use
The ABC-170CE is used to develop and test products that require additional
sinking power. The ABC-170CE was originally developed to test fuel cells in an
energy efficient manner, by returning clean AC power back to the utility grid.
ABC-170CE can be used to test batteries, hybrids and other electric vehicle
(EV) and hybrid electric vehicle (HEV) applications that require higher
discharging capability.
1.2 Overview
The ABC-170CE 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. Examples are auxiliary power unit,
flywheels, motors, inverters, batteries, fuel cells, capacitors, and more.
The capabilities are:
Greater Accuracy / Finer Control
Remote Voltage Sense Capability
Independent Hardware Channel Enable
Independent Mode Control for each Channel
The ABC-170CE is an ideal test system for a wide range of DC loads other than
batteries, offering more capability than a traditional power supply system. The
ABC-170CE 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 loads (as used in this manual, load refers to a device or system
connected to the ABC-170CE for the purpose of receiving and/or delivering
DC power).
Power is transferred from the utility to the load, or vice-versa. Using the utility
to absorb power eliminates the need for external resistive loads and conserves
energy normally lost. In addition, the ABC-170CE incorporates special power
processing algorithms, enabling the user to perform a wide variety of testing.

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1.3 Scope of Manual
This manual contains a description of the ABC-170CE and instructions for the
installation, operation and maintenance.
1.3.1 Manual Organization
This manual describes the installation and operation of the ABC-170CE power
processing system.
Section
Description
2.0
Outlines some typical ABC-170CE
applications and describes the system
architecture and function
3.0
Provides step-by-step instructions for
installing the ABC-170CE
4.0
Discusses operation of the ABC-170CE,
using typical ABC-170CE applications
as examples
5.0
Provides preventative maintenance
Glossary
ABC-170CE terms
DC I/O Connector
Assembly
DC I/O connection assembly instructions

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1.4 ABC-170CE Applications
The ABC-170CE is flexible and may be used for a wide variety of DC power
applications. This section describes a few typical applications to illustrate the
different features of the ABC-170CE.
Constant Voltage Source
In Voltage Mode, the ABC-170CE regulates the voltage of a given DC
input/output channel. The load may draw current from the ABC-170CE at
the regulated voltage and the voltage level may be varied on demand, as
with a conventional DC power supply. In addition, the ABC-170CE allows
the user to define voltage, current, and power limits to protect the load
and maintain safe operating conditions. The ABC-170CE also allows for
bi-directional power flow (i.e., it allows the load to discharge current back
to the utility), unlike standard power supplies. However, during the
blackout, ABC-170CE does shutdown the operation automatically.
Constant Current Source
In Current Mode, the ABC-170CE regulates the current of a given DC
input/output channel. As in constant Voltage Mode, the load may draw or
provide current bi-directionally subject to user-defined limits.
Battery Quick Charging
Battery charging algorithms vary considerably depending on many
factors. A basic quick charging algorithm involves charging the battery at
a constant current rate (i.e., the maximum charge rate) until a certain
voltage level is reached and then maintaining that voltage level while the
charge rate decreases to a trickle charge. This can be accomplished very
simply with the ABC-170CE.
By setting the correct upper voltage limit and operating the system in
constant Current Mode, the user can assure that the ABC-170CE will
charge the battery at the desired current until its voltage rises to the limit
and will then maintain that voltage. No manual adjustment is needed
during the test.
More complicated battery charge algorithms can be achieved by
modifying the operating limits, modes and command values as the test
proceeds. Such algorithms can be implemented manually or they can be
programmed and run automatically using the ABC-170CE Remote
Operation System.

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Battery Pack Cycling
Battery packs used in electric vehicles (EV) endure constantly changing
demands. As the vehicle accelerates and brakes, the battery may go from
rapid discharge to charge and back again in a matter of seconds. In
addition, the daily driving and charging of an electric vehicle puts the
battery through a large number of deep discharge cycles, resulting in
shortened battery life.
Because of these factors, EV battery pack testing is highly important but
also very difficult. Simulating the demands of an electric vehicle on a
battery pack requires computer controlled testing with a highly accurate
and responsive battery cycling system.
The ABC-170CE was designed specifically to handle the demands of EV
battery pack cycling. Using the ABC-170CE Remote Operation System,
USABC compliant tests can be developed and run to verify battery pack
adherence to requirements. Repetitive use of these automated compliant
test profiles can be used for comparative research as well as production
level testing.
Battery Emulation
With its computer control capabilities, the ABC-170CE can be
programmed to emulate a battery. The ABC-170CE would first be put
into constant Voltage Mode at the desired state of charge. As current is
drawn from the ABC-170CE, the voltage would be lowered as if the
“battery” were being discharged.
Similarly, as the “battery” is charged, the voltage would be increased. The
algorithm to determine how voltage changes in response to charging and
discharging would be determined by the user, based on the size and type
of battery to be emulated, and then programmed into the ABC-170CE
Remote Operation System.
Other Applications
As the above examples illustrated, the ABC-170CE is very flexible and
versatile so it can be used for many other applications. Test or emulation
of most DC power system can be achieved with the powerful, computer
controlled testing capabilities.
The ABC-170CE may be valuable even for very simple application such
as discharging batteries and putting their power back onto the utility grid.
With a basic understanding of the system, users can employ the
ABC-170CE in a virtually limitless set of applications.
The ABC-170CE base unit can be customized for particular applications
using ROS Scripts or Optional J1850 or CAN Communication capabilities.
Contact Webasto customer service for more information.

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2.0 System Description
2.1 System Block Diagram
The ABC-170CE architecture is shown in the following system block diagram
(Figure 2.1). The AC Inverter connects to the utility via an internally installed
isolation transformer. The DC Converter and AC Inverter transfer power via an
Intermediate DC Bus and communicate via an RS-485 data bus. The DC
Converter also communicates to the ABC-170CE Remote Operation System
(ROS) via an RS-232 data link, or CAN data link depending on system
configuration. The DC Converter provides the DC interface to a load
(or possibly two separate loads) in one of two configurations.
AC
Inverter
Unit
DC
Converter
Unit
Intermediate DC Bus
Load A
Load B
Optional Data Collection Systems:
SmartGuard®
National Instruments NIDAQ
Custom
Isolation
Transformer
RS-232
Utility Interface
RS-485
ROS PC
High Voltage Interlock A
High Voltage Interlock B
Figure 2.1. ABC-170CE System Block Diagram
2.1.1 AC Inverter Functions & Controls
The AC Inverter regulates the Intermediate DC Bus based on the
maximum voltage expected by the DC Converter connected. The range
for the Intermediate DC Bus is 350 - 425 Volts DC for 125KW source and
170KW sink. And it can be raised up to 450 Volts DC for 40KW source
and 40KW sink.
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 the 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.

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Figure 2.2 shows the AC Inverter front panel.
Figure 2.2. AC Inverter Front Panel
Each of the front panel controls and indicators are described below.
MAIN POWER Pressed to apply and remove power to the system.
The switch ON is illuminated with green light when
control power is applied to the system. The switch OFF
is illuminated with red light when the control power is off
but input power is present.
EMERGENCY OFF Pressed to remove input control power to the system.
The EMERGENCY OFF switch has a locking
mechanism and must be rotated counterclockwise to
enable the control power to repower the system.
NOTE: 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 minutes prior to accessing the interior
of the cabinet.

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READY light (Green) when the system power is on and the system is
functioning normally.
FAULT lights (Red) when a fault has been detected. The four lights
are AC Inverter Fault, DC Converter Fault, Utility Fault,
and Communication Fault. (Refer to Table 5.1 in
Section 5 of this manual to determine the definition of
any faults indicated.)
2.1.2 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
for the user.
The DC Converter is composed of two separately controllable converters,
converter A and converter B. Each converter has its own set of front
panel meters, mode select switches and output terminals. The converter
has the ability to operate in two different configurations:
Independent Configuration
Two loads can be connected and separately controlled. (The negative
sides of the ABC-170CE outputs are tied together when outputs are
active, so the two outputs cannot be placed in series.)
External Parallel Configuration
The outputs for both channels must be utilized for parallel operation.
Channel A front panel limits and controls are used for this mode
of operation.
The DC Converter can present the power to the load using a variety of
control algorithms (modes). It can be operated as a constant current
source, a constant voltage source or a constant power source. In
addition, limits value for voltage, current, and power are specified by the
operator to additionally constrain the output.
The DC Converter incorporates safety features that minimize the
possibility of an improperly connected load or hazardous voltage
exposure. The DC Converter monitors internal switches, which indicate
when 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 if one
of the connectors is removed from the unit, the internal contactors will
open automatically disconnecting the output from the load.
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).

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Figure 2.3 shows the ABC-170CE DC Converter front panel.
Figure 2.3. DC Converter Front Panel
The displays and controls are described below.
CONFIGURATION
(Yellow) is used to select the load configuration and wiring
connection. There is one button each for Parallel, RVS and
Independent, respectively.
Without external cables connected to the channels, all
yellow lights are flashing. Once the external cable plugged
into the CAM Lock, the unit starts up in Independent Mode
with the yellow light on. To change it to parallel Mode with
external cables plugged to both channels, pressed the
Parallel (yellow) button to enable the parallel operation.
Once a valid configuration has been selected, only the
appropriate button will remain lit (not flashing). Then,
customer can pressed RVS button to enable Remote
Voltage Sensing in either mode.

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LIMITS (yellow) is used to set upper and lower operating limits for
each converter. The user presses either the UPPER or the
LOWER button to view the existing limits and holds the
button down while pressing the Up arrow and Down arrow
buttons to adjust those limits.
Upper and lower limit buttons are included for each
converter (A and B). When these buttons are flashing, the
DC Converter is prompting the user to check the operating
limits and adjust them if necessary.
MODE A mode determines what control algorithm a converter will
use. The choices are VOLTAGE, CURRENT, POWER
control (green), or STANDBY (red).
When all four of these buttons on one converter (A or B)
are flashing, the DC Converter is prompting the user to
choose a mode. When a mode has been selected, only the
appropriate button will be lit (not flashing) for that
converter. Another mode button may also be flashing at
the same time if the DC Converter is at an operating limit
for one of the parameters that is not
being controlled.
STATUS Each channel will display (remote) status independently
(Remote A and Remote B). When operating remotely, the
REMOTE button will be lit for that channel. When the
system is initially powered up, it begins in local operation.
PROTECTED REMOTE OPERATION
While operating in Remote mode, the operator can change
the status of the ABC-170CE to standby by pushing the
Standby button. This action will cause the output contactor
to open, isolating the output of the respected channel from
the load. To re-initiate Remote mode operation, the
operator must manually push the flashing Remote A/B
button, which will resume operation under ROS control.
2.1.3 Communication between AC Inverter and DC Converter
The AC Inverter and DC Converter communicate over an RS-485
high-speed multiplexed data bus. The communication bus does not intend
to be accessed by the user at any time. The AC Inverter sends
information about its status and mode of operation to the DC Converter.
The DC Converter sends fault status information and communicates to
the Remote Operation System (ROS) via an RS232 link.
2.1.4 Remote Operation Interface
The Remote Operation Interface, based on the RS-232 communication
standard, allows communication between the DC Converter and the
ABC-170CE (ROS). The purpose of this interface is to provide status
information and DC input/output measurements from the ABC-170CE to

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the ROS and to accept commands from the ROS. For more information
about the Remote Operation Interface, please refer to the Remote
Operation System Manual, Webasto document number 20011-03.
2.1.5 ABC-170CE Remote Operation System (ROS)
The ABC-170CE Remote Operation System (ROS) is a personal
computer based system for controlling the ABC-170CE. The system
consists of the computer itself and any peripherals, and the ABC-170CE
ROS application.
This software provides a graphical user interface for controlling and
monitoring the operation of the ABC-170CE, a command language
interpreter that allows for simple implementation of complex test
programs, communication with the ABC-170CE system, and the option of
integrating external data acquisition devices into the system.
2.1.6 High Voltage Interlock (Front Panel)
Each channel of the ABC-170CE has a High Voltage Interlock Switch
(HVIS) for added protection (Figure 2.4). The HVIS can put one channel
of the ABC-170CE into the standby mode without affecting the
other channel.
Pin 1 (+V) is a system supplied +5 voltage source that is to be connected
to Pin 2 (+sense). The Pin 3 (-sense) has to be connected to the Pin 4
(Gnd) signal, which is the ground. A break in either one of these links will
put that channel into the standby mode (open the output contactor and
isolate the output of the ABC-170CE from the load). (See appendix V for
proper wiring.)
NOTE: If this feature is not used then it is necessary to have mating
connectors with jumper wire provided installed on this for proper
functioning of unit.
2.1.7 Remote Voltage Sense (RVS)
To increase voltage accuracy at the Load, activate the Remote Voltage
Sense. This feature shall be activated via ROS by pressing the button
labeled RVS on the top left side of the screen, or by pressing the RVS
button on the front panel (RVS cable must also be in place for both
channels). The RVS feature can be used in voltage mode as well as
power mode (Figure 2.4). (See Appendix III for proper wiring and use of
this feature.)
2.1.8 Analog Signal Control
The ABC-170CE provides a method for modifying the commands sent
from ROS with an analog signal. This is controlled from the BNC
connector on the connector strip (Figure 2.4). (See Appendix IV for
proper wiring and use of this feature.)
NOTE: Analog Signal must be isolated.

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Figure 2.4. Front Panel User I/O
2.1.9 Optional Data Acquisition Interfaces
The Remote Operation System can be provided with optional interface
systems that facilitate data collection during testing.
The following interfaces are available:
SmartGuard®
BYTE-PIPE
National Instruments Analog/Digital I/O
2.1.10 Optional CAN Interface
The CAN interface is a ROS enabled interface with user programmable
messages. Contact Webasto Customer Service for more information
2.1.11 Remote Emergency Stop
An interface is provided to allow an external switch to control the
emergency stop function of the system. To enable the system an
electrical connection must be made between pins 1 and 4 of this interface
(Figure 2.5).
NOTE:If remote switch is not used then it is necessary to have mating
connector installed with wire jumper on pin 1 and 4 for proper functioning
of unit.
*
1
2
3
4
1
2
3
4
AC Unit
Lower Rear Panel
*Note: The external switch must be closed to
allow power to be supplied to the system.
Amp P/N:
206430-1
Amp P/N: 206429-1, Connector
Figure 2.5. Remote Emergency Stop