Webasto ABC-600 User manual

Installation, Operation and Maintenance Manual
EV Test Systems
ABC-600
English

ABC-600 Installation, Operation and Maintenance
17032-03-D Page 2 of 51 Webasto Charging Systems, Inc.
© 2019 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
Administration Regulations. Diversion contrary to US law prohibited
Webasto Charging Systems, Inc.
[phone]
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Table of Contents
TABLE OF CONTENTS 2
WARRANTY 6
SAFETY PRECAUTIONS - READ BEFORE USE 7
SYMBOL USAGE 7
GENERAL SAFETY WARNINGS AND PRECAUTIONS 7
1.0 INTRODUCTION 9
1.1 Overview 9
1.2 Scope of Manual 9
1.2.1 Manual Organization 9
1.3 ABC-600 Applications 10
1.3.1 Constant Voltage Source 10
1.3.2 Constant Current Source 10
1.3.3 Battery Quick Charging 10
1.3.4 Battery Pack Cycling 10
1.3.5 Battery Emulation 11
1.3.6 Other Applications 11
2.0 SYSTEM DESCRIPTION 12
2.1 System Block Diagram 12
2.1.1 AC Inverter Functions & Controls 12
2.1.2 DC Converter Functions & Controls 14
Independent Configuration 14
External Parallel Configuration 14
2.1.3 Communication Between AC Inverter and DC Converter 16
2.1.4 Remote Operation Interface 16
2.1.5 ABC-600 Remote Operation System (ROS) 16
2.1.6 High Voltage Interlock (Front Panel) 17
2.1.7 Remote Voltage Sense (RVS) 17
2.1.8 Analog Signal Control 17
2.1.9 Optional Data Acquisition Interfaces 17
2.1.10 Optional RS-232 CAN Interface 18
2.1.11 Remote Emergency Stop 18
2.2 Technical Specifications 18
2.2.1 Utility Requirements 18
AC Power Quality at Rated Power 18
DC Output 19
Accuracy 19
Communication 19
Operating Environment 19
Safety 19
Cabinets 19

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3.0 INSTALLATION 20
3.1 Preparation 20
3.1.1 System Requirements 20
3.1.2 Unpacking and Inspection 20
3.1.3 Storage 20
3.1.4 Location (in-door only) 20
3.1.5 Equipment Needed 21
3.2 Cooling System Preparation 21
3.3 AC Input Connection 21
AC Input Connections 22
3.4 DC Input/Output Connections 22
3.5 Air Intake 22
4.0 OPERATION 23
4.1 Planning 24
4.1.1 Choosing a Load Configuration 25
4.2 Independent Configuration 26
4.3 External Parallel Configuration 27
4.4 Choosing Operating Limits 28
Operating Space 28
Second Boundary 28
Load 28
4.5 Operating the System 30
4.6 System Startup 32
4.7 Connecting the Load and Selecting the Configuration 32
4.8 Adjusting Operating Limits 33
4.9 Selecting Local or Remote Operation 33
4.10 Local Operation 34
4.10.1 Selecting the Mode 34
4.10.2 Adjusting Setting 34
4.10.3 Changing Mode While Running a Test 35
4.10.4 Changing Operating Limits 35
4.10.5 Pausing a Test 35
4.10.6 Entering Remote Operation 36
4.10.7 Changing Load Configuration 36
4.11 Remote Operation 36
4.12 Turning Off Power 37
5.0 MAINTENANCE 38
5.1 Preventative Maintenance 38
5.2 Fault Indications 40

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APPENDIX I: GLOSSARY OF TERMS 42
APPENDIX II: DC I/O CONNECTOR ASSEMBLY 44
APPENDIX III: ABC-600 REMOTE VOLTAGE SENSE OPERATION 46
APPENDIX IV: ANALOG SIGNAL CONTROL 48
APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING 50
APPENDIX VI: EXTERNAL PARALLEL OPERATION 51

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Warranty
Webasto, Inc. – ABC-600 Limited Warranty
Products manufactured by Webasto are warranted to the original user only to be free of
defects in material and workmanship for a period of twelve (12) months from date of
installation, but not more than eighteen (18) months from date of shipment. 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.
This warranty is subject to the following terms and limitations:
i) Replacement of expendable items, such as fuses, switches and connectors, is
not covered by this warranty.
ii) This warranty shall be voided by damage or wear to products caused by
abnormal operating conditions (including exposure to acid, chemical fumes,
metallic dust or extreme temperatures), accident, abuse, misuse, unauthorized
alteration or repair, or if the product was not installed, operated and maintained
in accordance with Webasto’s printed installation and operating instructions.
iii) This warranty does not include the costs of removal, installation, transportation,
or any other charges that may arise in connection with a warranty claim.
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. THE PURCHASER ASSUMES RESPONSIBILITY FOR ALL INJURY
AND PROPERTY DAMAGE RESULTING FROM THE HANDLING, POSSESSION OR
USE OF THE PRODUCT. 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. NO REPRESENTATIONS BEYOND THE ABOVE WARRANTY BY WEBASTO
REPRESENTATIVES SHALL HAVE ANY VALIDITY UNLESS CONFIRMED IN WRITING
BY AN OFFICER OF WEBASTO, INC.
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 that vary from
jurisdiction to jurisdiction.

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Safety Precautions - Read Before Use
The ABC-600 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:
•Over voltage
•Over temperature
•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 Overview
The ABC-600 is a bi-directional, computer-controlled two-channel DC power
processing system. The system was specifically designed for testing (i.e.,
“cycling”) electric and hybrid-electric vehicle components and subsystems,
including auxiliary power units, flywheels, motors, inverters, batteries, fuel cells,
capacitors and more.
The ABC-600 offers:
•Remote Voltage Sense Capability,
•Independent Hardware Channel Enable,
•Independent Mode Control for each Channel.
The ABC-600 is an ideal test system for a wide range of DC loads other than
those mentioned above, offering more capability than a traditional power supply
system. The ABC-600 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-600 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-600 incorporates special power
processing algorithms, enabling the user to perform a wide variety of testing.
1.2 Scope of Manual
This manual contains a description of the ABC-600 and instructions for the
installation, operation and maintenance.
1.2.1 Manual Organization
This manual describes the installation and operation of the ABC-600 power
processing system.
SECTION
DESCRIPTION
1.0
Provides system and application overview.
2.0
Describes the system architecture and
function.
3.0
Provides step-by-step instructions for
installing the ABC-600.
4.0
Discusses operation of the ABC-600,
using typical ABC-600 applications as
examples.
5.0
Provides preventative maintenance
guidelines.
Appendices
Defines ABC-600 terms and details of
application procedures.

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1.3 ABC-600 Applications
The ABC-600 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-600.
1.3.1 Constant Voltage Source
In Voltage Mode, the ABC-600 regulates the voltage of a given DC output
channel. The load may draw current from the ABC-600 at the regulated
voltage and the voltage level may be varied on demand, as with a
conventional DC power supply. In addition, the ABC-600 allows the user
to define voltage, current, and power limits to protect the load and maintain
safe operating conditions. The ABC-600 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, if the utility voltage is interrupted
while running, the ABC-600 will cease operation.
1.3.2 Constant Current Source
In Current Mode, the ABC-600 regulates the current of a given DC output
channel. As in constant Voltage Mode, the load may draw or provide
current bi-directionally subject to user-defined limits.
1.3.3 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-600.
By setting the correct upper voltage limit and operating the system in
constant Current Mode, the ABC-600 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-600 Remote Operation System (ROS)
or other software packages.
1.3.4 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.

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The ABC-600 was designed to handle the demands of EV battery pack
cycling. Using the ABC-600 ROS or other software packages, 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.
1.3.5 Battery Emulation
With its computer control capabilities, the ABC-600 can be programmed to
emulate a battery. The ABC-600 would first be put into constant Voltage
Mode at the desired state of charge. As current is drawn from the
ABC-600, the voltage is 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-600 Remote
Operation System.
1.3.6 Other Applications
As the above examples illustrated, the ABC-600 is very flexible and
versatile so it can be used for many other applications. Test or emulation
of most DC power systems can be achieved with the powerful, computer-
controlled testing capabilities.
The ABC-600 may be valuable even for very simple applications such as
discharging batteries and putting their power back onto the utility grid.
The ABC-600 base unit can be customized for particular applications using
ROS Scripts, Window-based languages such as LabVIEW or CAN
Communication capabilities. Contact Webasto’s Customer Service
Department for more information.

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2.0 System Description
2.1 System Block Diagram
The ABC-600 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-600 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-600 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.
Circuitry designed into the AC Inverter monitors the utility to detect
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.
•
Contact Webasto for
Additional Information

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Figure 2.2 AC Inverter Front Panel
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 2.2 shows the AC Inverter front panel. Each of the front panel
controls and indicators are described below.
MAIN POWER
Press the ON switch to apply input power to the system; the ON bulb is
illuminated with a green light. Press the OFF switch to remove power from
the system; the OFF switch is illuminated with a red light to indicate that
control power is off but input power is available.
EMERGENCY OFF
Press to remove all power from the system except for AC input power. The
switch has a locking mechanism and must be rotated counterclockwise to
energize the control system.
DANGER
The main circuit breaker must be switched off and locked out by
authorized perso
nnel and either the MAIN POWER or
EMERGENCY OFF switch 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)
Illuminates when the system power is on and the system is functioning
normally.
Fault Lights (Red)
Illuminate when a fault has been detected. The four lights are AC Inverter
Fault, DC Converter Fault, Utility Fault and Communication Fault. (Refer to
Tables 5.1 and 5.2 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.
NOTE: The negative sides of the ABC-600 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 are utilized for parallel operation to provide
higher current capability. Channel A front panel limits and controls are used
for this mode of operation.
The DC Converter can apply 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. The user can specify
limits to the values for the current, voltage and power, which additionally
constrain the output.
The internal contactors will 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 DC Converter Front Panel
Figure 2.3 shows the ABC-600 DC Converter front panel. The displays and
controls are described below:
CONFIGURATION
Used to select the load configuration and wiring connection. There is one
button each for Parallel, RVS and Independent, respectively.
The unit starts up in Independent Mode. To change to Parallel Mode, press
the PARALLEL (yellow) button to enable parallel operation. Once a valid
configuration has been selected, only the appropriate button will remain lit
(not flashing). Then the user can press the RVS button to enable Remote
Voltage Sensing in either mode, if desired.
LIMITS
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 () or 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
Mode determines what control algorithm a converter will use. The choices
are VOLTAGE, CURRENT, POWER control (green), or STANDBY (red).
Standby Mode opens the output contactor, isolating the output of the ABC-
600 from the load.
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

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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 user can change the status of the
ABC-600 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 user
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 a RS-485 high-
speed multiplexed data bus. The communication bus is not 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 a RS-232 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-
600 (ROS). The purpose of this interface is to provide status information
and DC output measurements from the ABC-600 to 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 06631.
2.1.5 ABC-600 Remote Operation System (ROS)
The ABC-600 ROS is a personal computer-based system for controlling
the ABC-600. The system consists of the computer itself and any
peripherals, and the ABC-600 ROS application.
This software provides a graphical user interface for controlling and
monitoring the operation of the ABC-600, a command language interpreter
that allows for simple implementation of complex test programs,
communication with the ABC-600 system, and the option of integrating
external data acquisition devices into the system.

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2.1.6 High Voltage Interlock (Front Panel)
Each channel of the ABC-600 has a High Voltage Interlock Switch (HVIS)
for added protection (Figure 2.4). The HVIS can put one channel of the
ABC-600 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 standby mode. (See Appendix IV for proper wiring.)
NOTE: If this feature is not used, then it is necessary to install the
interlock connectors (provided) for the unit to function properly.
2.1.7 Remote Voltage Sense (RVS)
To increase voltage accuracy at the Load, activate the Remote Voltage
Sense. This feature can 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 II for proper wiring and use of this
feature.)
2.1.8 Analog Signal Control
The ABC-600 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 III for proper wiring and
use of this feature).
NOTE: The Analog Signal must be isolated.
ANALOG
INPUT
ANALOG
INPUT
HV
INTLK
HV
INTLK
Figure 2.4 Front Panel User I/O
2.1.9 Optional Data Acquisition Interfaces
The Remote Operation System (ROS) can be provided with optional
interface systems that facilitate data collection during testing. The following
interfaces are available:
•SmartGuard®
•National Instruments Analog/Digital I/O

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2.1.10 Optional RS-232 CAN Interface
The CAN interface is a ROS-enabled interface with user programmable
messages. Contact Webasto’s Customer Service Department 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 the remote switch is not used, then it is necessary to have
mating connectors installed with wire jumpers on pins 1 and 4 for
the unit to function properly.
*
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
2.2 Technical Specifications
2.2.1 Utility Requirements
Frequency
Voltage (3-Phase)
+10% / -15%, <5%
imbalance
Current
50Hz ± 1 Hz
380/400/415 Volts RMS
250/240/230 Amps RMS
60Hz ± 2 Hz
440/480 Volts RMS
218/200 Amps RMS
Ground: Connected to chassis
AC Power Quality at Rated Power
Power factor > 99%
Harmonic Distortion IEEE 519 Compliant

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DC Output
Operating Range
Configuration
Voltage
Current
Power
Independent
8 to 600 VDC
–300 to +300 ADC
±150 kW
External Parallel
8 to 600 VDC
–600 to +600 ADC
±150 kW
The above ranges are the maximum allowed by the system on a continuous
basis. Voltage, current, and power limits within the above ranges can be
set by the user based on the load and test requirements, respectively.
Accuracy
Configuration
Voltage
Current
Current Ripple
Independent
±250 mV or .15%
±250 mA or .25%
< 65mA RMS
External
Parallel
±250 mV or .15%
±300 mA or .35%
< 130mA RMS
Communication
ROS to DC Converter
RS-232
External CAN Bus
CAN
Internal System Communication Bus
RS-485
Operating Environment
Temperature 0-35 degrees Celsius (higher temperature can be
sustained at a lower continuous power rating)
Humidity 0-90% non-condensing
Safety
•Emergency stop switch
•HV interlock
•Automatic load connect and disconnect
•Automatic shutdown on loss of utility power
•UL recognized components used where possible
•Remote emergency stop
Cabinets
Dimensions 72”L x 34”W x 77"H (183cm L x 86cm W x 196cm H)
Weight Approx. 3,500 lbs (1,588 Kg)

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3.0 Installation
This section outlines the requirements and procedures for installing the ABC-600
system. Read this entire section before proceeding with installation. Installation
should be completed by an experienced electrician and should conform to all
Local and National Electrical Codes.
Before an installation is attempted, the following WARNING must be observed:
DANGER
The connections made may contain high voltages. High voltage can cause
personal injury and damage equipment. A qualified electrician or technician
should install the ABC-600. BEFORE connecting any wiring, TURN OFF
the AC input circuit breaker and DISCONNECT ALL loads from the unit’s
output terminals.
3.1 Preparation
3.1.1 System Requirements
See Section 2.2.1 (Utility Power Requirements)
3.1.2 Unpacking and Inspection
The following equipment is provided with each system.
NOTE: Any variations on the packing slip will supersede this list.
•One ABC-600 system.
•Installation, Operation & Maintenance Manual.
•Additional accessories for RVS & HV interlock connections.
Inspect the equipment immediately upon receipt. If anything has been
damaged during shipment, keep the shipping cartons and packing
materials and file a claim with the carrier and/or insurance company for
shipping damage. If shipping damage is discovered after acceptance, file
a claim for concealed damages.
3.1.3 Storage
If the equipment is not installed immediately:
•Keep it in the original packing materials
•Store it at temperatures between 0oC (32oF) and 70oC (158oF)
•Always protect the equipment from moisture, dust and weather
3.1.4 Location (in-door only)
When planning the ABC-600 installation location, remember to:
•Avoid temperature and humidity extremes (see Technical
Specifications in Section 2).
•Provide shelter from the elements (especially moisture and dust).