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
product not completed by an authorized service provider could void the product warranty.
These commodities, technology or software were exported from the United States in accordance with the Export
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Webasto Charging Systems, Inc.
[phone]
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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.

ABC-170CE Installation, Operation, and Maintenance
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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.