Webasto ABC-600 User manual

ABC-600 Installation Instructions
22394-76_02.docx Page 1 of 20 Webasto Charging Systems, Inc.
INSTRUCTIONS, FIELD
INSTALLATION, CONVERT PC104
PCM-3341 TO ICOP VDX-6353RD,
50/60HZ, ABC-600
Webasto Charging Systems, Inc.
1333 S. Mayflower Avenue, Suite 100
Monrovia, CA 91016 U.S.A.
Telephone [phone]
[e-mail]
2020 Webasto Charging Systems, Inc.

ABC-600 Installation Instructions
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Warranty
Webasto Charging Systems Limited Warranty
Products manufactured by Webasto Charging Systems, Inc., are warranted to the original user only
to be free of defects in material and workmanship for a period of 12 months from the date of
installation, but not more than 18 months from the date of shipment from Webasto Charging
Systems. Webasto Charging Systems's liability under this warranty shall be limited to repairing or
replacing at Webasto Charging Systems's option, without charge, F.O.B. Webasto Charging
Systems's factory or onsite at the option of Webasto Charging Systems, any product of Webasto
Charging Systems’s manufacture. Webasto Charging Systems will not be liable for any costs of
removal, installation, transportation, or any other charges that may arise in connection with a
warranty claim. Webasto Charging Systems will not be liable for damage or wear to products
caused by abnormal operating conditions, accidents, abuse, misuse, unauthorized alteration or
repair, or if the product was not installed and operated in accordance with Webasto Charging
Systems’s printed installation and operating instructions.
To obtain service under this warranty, the defective product must be returned to Webasto Charging
Systems with proof of purchase and installation date, failure date, and supporting installation data
if so requested. Any defective product to be returned to Webasto Charging Systems must be sent
freight prepaid; documentation supporting the warranty claim and/or a Return Material
Authorization must be included if so instructed.
WEBASTO CHARGING SYSTEMS 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; you may also have other rights that vary from jurisdiction to jurisdiction.

ABC-600 Installation Instructions
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Introduction
The Webasto US Los Angeles (WUSLA) #22394-00X kit is provided to allow the ABC-600 with PC104 PCM-
3341 computer board, to be converted to ICOP VDX-6353RD, and allowing communication via CAN or/and
ROS that exits in the unit. The kit contains the following:
(This kit applies to ROS, CAN and Hybrid Systems)
Item
No.
Part No.
Description
Ref
Des
Qty
1
07310
LABEL,CALIBRATION
1
2
05042
CONNECTOR, SHORTING JUMPER, SHROUD, 2PIN, 0.100(2.54), 2800VACrms, 3.0A,
-55-120C, UL E66906
3
3
10302
ASSY,MICROCONTROLLER,AC INV CTRL,ABC-600
1
4
11388
CABLE ASSY,PC104/CONVERTER CONTROL COM
5
29594
KIT,COMPUTER,SINGLE BOARD W PC/104
1
5.1
29595
COMPUTER,SINGLE BOARD W PC/104 AND CUSTOM BIOS,VORTEX86DX 800 MHZ CPU
W/256MB MEMORY,3.78in(96mm)X3.55in(90.2mm),-20C-70C
1
5.2
21047
CABLE ASSY, 2mmx2mm MOLDED 26 PINS CONNECTOR WITH 1mm FLAT RIBBON 26C
CABLE 7inL, 30V, -20C-85C (SHIPPED WITHIN ITEM 6).
1
5.3
21050
CABLE ASSY, 2mmx2mm MOLDED CONNECTORS WITH 1mm FLAT RIBBON 20C CABLE
8inL, 30V, -20C-85C (SHIPPED WITHIN ITEM 6).
1
6
22259
ASSY,MACH211 PAL,U24,CNTL BD,DC,(VDX),P3
U24
1
7
See below
ASSY,FLASH STORAGE VDX-6353-D,HYB,ABC-600
1
8
22262
KIT,SW,ROS V6.0/CAN V1.7.1/HYBRID,P3
0
9
21130
ASSY, KIT, OPTO ISOLATOR (485OPDR)
1
9.1
21079
OPTOISOLATOR,RS-422/485 ISOLATED REPEATER, 4.173inDx0.992inWx3.118inH,
10-30Vdc 0.7W POWER SUPPLY, 35mm DIN RAIL MOUNTED,2KV ISOLATED,-40C-
80C,UL,CE,FCC
1
9.2
25663
POWER SUPPLY,AC/DC,100-240VAC,47-450Hz,SINGLE,12VDC,1.2 A,1.5%,DIN RAIL,
3.54in(90mm)Hx0.89in(22.5mm)Wx3.54in(90.0mm)D,-25 TO 50C,UL CSA,VDE,CE,RoHS
1
9.3
05355
ASSY,RAILING,DIN,MODIFIED,IPC/P3
1
9.4
08610
END STOP,TERM BLOCK,DIN RAIL MOUNT
1
9.5
21119
CABLE ASSY,OPTO ISOLATOR (485OPDR) TO INVERTER CONTROL BD,P3
1
9.6
21120
CABLE ASSY,OPTO ISOLATOR (485OPDR) TO CONVERTER CONTROL BD,P3
1
9.7
21121
CABLE ASSY,INPUT LINE,OPTO ISOLATOR (485OPDR),P3
1
9.9
01798-002
WIRE,22AWG,19/34,TIN CU,RED,IRRADIATED PVC,300V,105C,UL 1430
5.25”
9.10
01598
TERM BLOCK,TAB,2 SIDE,1 SCREW,
1.22(31)Lx0.41(10.3)Wx0.032(0.81)Tx0.250(6.3 5)TWx0.171(4.34)HS,FLAT
2
9.11
07493
SCREW,MACH,10-32x0.375,PHP,SQ CONE WASHER SEMS,ZNPL STL,60000PSI MIN
2
18
23964
CABLE ASSY,INTERLOCK LOOP BACK,P3
1
Note 1: Items 5.1 through 5.3 are part of Kit P/N: 29594 (Item 5).
Note 2: Items 9.1 through 9.11 are part of Kit P/N: 21130 (Item 9).
Note 3: Item Num 18 only needed for 50Hz
Note 4: See table below for part number
Kit
Part Number
Flash Storage
Part Number
900 System
Current Rating
22394-001
21417
300A
22394-003
22392
400A/200A

ABC-600 Installation Instructions
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Hardware Installation
DANGER
BEFORE performing the installation, TURN OFF the AC input circuit
breaker and DISCONNECT ALL loads from the unit’s output terminals.
WARNING
New PC104 requires installation of ROS/CAN software CD, WUSLA
#22262 Rev. A or higher, supplied with kit.
1. Turn the unit off and turn the utility power off.
2. Open the front panel on the DC side and AC side by removing the panel screws.
Figure 1. ABC-600 Front Panel

ABC-600 Installation Instructions
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3. Locate the PC104 PCM-3341 Computer Board (WUSLA #11342) and CAN Card (WUSLA #05890) (if the
unit has CAN card) in the Display Assembly, as shown in Figure 2.
Figure 2. DC Control Board (WUSLA #09842 or 05984 ) with CAN Card and Cable
Installed
DC Control board
WUSLA Part Number
ABC-600 System
09842
300A/300A
05984
400A/200A
4. Carefully remove the CAN Card from the PC104 PCM-3341 Computer Board below, as shown in Figure 3.
Figure 3. CAN Card (ESD CAN-PC104/331-2)
U24
PC104 PCM-3341
Computer Board
(below CAN board)
PC104 CAN
Card with
cable
05984 DC
control board
is shown

ABC-600 Installation Instructions
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Figure 4.
DC Control Board (WUSLA #09842 or 05984 ) with PC104 PCM-3341 Computer Board
5. Carefully remove the cables WUSLA #11376 and WUSLA #11377. Then remove the PC104 PCM-3341
Computer Board with compact flash memory, as shown in Figure 5. If it is necessary, remove other cables
connected to DC control board. Keep and mark all cables and hardware so that they can be easily put back
later.
Figure 5.
Cable connections for DC Control Board (WUSLA #09842 or 05984)
with PC104 PCM-3341 Computer Board

ABC-600 Installation Instructions
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6. In DC Control Board (WUSLA #09842 or 05984 ). , locate U24. Carefully remove the U24 in PCBA with
PLCC Extraction Tool (MCM electronics P/N D00038, order #22-11114).
7. Replace U24 with WUSLA #22259 ASSY, MACH211 PAL, U24, CONTROL BOARD, DC, (VDX-6553RD),
P3 in the Kit.
8. Insert Compact Flash Storage Memory (See Note for proper WUSLA #), ASSY,FLASH STORAGE VDX-
6353-D,HYB,ABC-600, into #29595, COMPUTER,SINGLE BOARD W PC/104 AND WEBASTO CHARGING
SYSTEMS BIOS, VORTEX86DX, as shown in Figure 6 for the model of HYB ABC-600.
Figure 6. PC104 computer board VDX-6353RD with FLASH Card Exposed
PC104 computer board
VDX-6353RD (WUSLA
#29595) and Compact Flash
card
With label (See Note
for proper WUSLA #)

ABC-600 Installation Instructions
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9. Carefully, install the PC104 computer board VDX-6353RD, WUSLA #29595 with the Compact Flash Storage
Memory into the Interface Board WUSLA #14286, as shown in Figure 7. Please note: PC104 Computer Board
VDX-6353RD should be verified in factory that the Webasto Charging Systems BIOS setup is complete.
Figure 7. PC104 computer board VDX-6353RD
10.Refer to Figure 8 and Figure 9; install the cable #21047 from J3 of Interface Board to COM1 and COM2 of
PC104 Computer board VDX-6353RD.
11. Refer to Figure 8 and Figure 9; install cable #21050 from J18 of PC104 Computer board VDX-6353RD to J4
of Interface Board WUSLA #14286.
12.Refer to Figure 8 and Figure 9; install cable #05317 from P10 of Interface Board WUSLA #14286 to J5 of DC
Control Board (WUSLA #09842 or 05984 ).
13.Refer to Figure 5 and Figure 9; install cable #01149 from J14 of DC Control Board to P1 DC Display board
WUSLA #04860.
14.Refer to Figure 8 and Figure 9; install cable #11388 from P11 of Interface Board WUSLA #14286 to J4 of DC
Control Board.
15.Install the ROS cable WUSLA #06504 to the ROS connector J20 on the DC Control Board to User I/O front
panel.
COM1; cable WUSLA #21047
with red side (pin 1) flat ribbon
plug into COM1 of PC104
Computer Board VDX-6353RD.

ABC-600 Installation Instructions
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Figure 8. PC104 computer board VDX-6353RD with interface cables
Figure 9. Side View, PC104 computer board VDX-6353RD with interface cables
16.Connect other disconnected and marked cables back to DC Control Board (WUSLA #09842 or 05984 ).
Cable WUSLA #21050 for
Parallel Port, from J18 of
PC104 Computer Board VDX-
6353RD (WUSLA #29595) to
J4 of Interface Board
(WUSLA #14286)
Cable WUSLA #21047 for
Serial Port, from COM1 &
COM2 of PC104 Computer
Board VDX-6353RD (WUSLA
#29595) to J3 of Interface Board
(WUSLA #14286).
U24,
WUSLA
#22259
Cable WUSLA
#11388 from P11 of
Interface Board
WUSLA #14286 to
J4 of DC Control
Board WUSLA
#05984.
Cable #05317 from P10 of
Interface Board WUSLA
#14286 to J5 of DC Control
Board
Cable #01149 from
J14 of DC Control
Board to P1 DC
Display board
WUSLA #04860.
WUSLA #05984.

ABC-600 Installation Instructions
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17.Gently install CAN card back to DC Control Board, as shown in Figure 10.
Figure 10. ABC-600 Display Assembly - PC104 CAN Location
18.On the DC Control Board (WUSLA #09842 or 05984 ), locate J2, as shown in Figure 10. Remove the
jumper between IRQ6 and IRQ9, install jumper WUSLA #05042 into J2-1, J2-2, J2-4, J2-6, and J2-9.
19.Plug one end of the CAN cable WUSLA #05375 into the CAN card, as shown in Figure 10.
20.Connect the other end of the CAN Cable to the CAN Port DB9 connector on user I/O front panel.
PC104 CAN board
with cable
PC104 computer board VDX-
6353RD (below CAN board)
Remove Jumper
connected
between IRQ6 and
IRQ9. Install
jumper WUSLA
#05042 for
J2-1 IRQ15,
J2-2 IRQ14,
J2-4 IRQ11,
J2-6 IRQ9,
J2-9 IRQ5.

ABC-600 Installation Instructions
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21.Locate U26 in PCBA AC Inverter Control #06197, as shown in Figure 11. Carefully remove U26 with PLCC
Extraction Tool (MCM electronics P/N D00038, order #22-11114).
Figure 11. Location of U26 in PCBA Inverter Control
22.Replace U26 with (See Note for proper WUSLA #), ASSY, MICROCONTROLLER, AC INV CTRL,
420V/60Hz, ABC-600, in available kit.
For 50Hz systems:
a. Use provided #23964 Interlock Loop cable assembly (Item Num 18).
b. Connect to P5 of PCBA AC Inverter Control Board
Figure 12. Location of P5 in PCBA Inverter Control
U26 of PCBA
AC Inverter
Control

ABC-600 Installation Instructions
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23. Drill (2) 5/32” holes and tap for 10-32 screws to the rectangular steel tubing from the left inside of ABC-600,
as shown in Figure 13.
24.Install Opto Photo Isolator WUSLA #21079 and Power Supply WUSLA #25663 available in Kit #21130 as
shown in Figure 12 and 13.
25.Make sure that both sets of dip switches are set, as shown in Figure 12.
Figure 12. Kit, Opto Isolator WUSLA #21130
Figure 13. Installation location for Kit WUSLA #21130
INSTALL
WUSLA
#21130 IN
THE LEFT
SIDE OF
CABINET.
Set DIP switch:
1 and 2 OFF
3 ON
4, 5, 6 OFF
7 and 8 ON.
CABINET.

ABC-600 Installation Instructions
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26.Refer to the schematics diagram, as shown in Figure 14, for the wiring added to WUSLA #21079.
Figure 14. Schematic diagram for installation of Opto Isolator Kit
27.Install the wiring WUSLA #21119 to P4 of AC Inverter PCBA WUSLA #06197.
28.Install the wiring WUSLA #21120 to J13 of DC control PCBA.
29.Install the wiring WUSLA #21121 between the input line of power supply WUSLA #19626 and AC Contactor
Assembly Terminal block, where tab WUSLA #01598 added to position 1 and position 4, as shown in Figure
15:
Figure 15. Terminal Block in Assy AC Contactor

ABC-600 Installation Instructions
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30.Connect twisted-pair #22 RED (WUSLA #01798-002) and BLK (WUSLA #01798-000); connect RED to
terminal J, and BLK to terminal M, of the Opto Photo Isolator #21079.
31.Before closing the unit mark the back of the Control Panel with FSB-00145 and date. Close the unit using all
panel screws, and restore power to the system.
32.Based on ABC-600 Field Calibration Procedure in Appendix I, calibrate the unit.
33.Place the Calibration Label #07310 to the unit and fill the calibration report as shown in Appendix II.

ABC-600 Installation Instructions
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Appendix I: ABC-600 Field calibration procedure
Field Calibration Procedure
Use data sheets 09400-97 to record the data.
1.0 Calibration Equipment:
Equipment
Manufacturer
Model
Serial
Calibration
Validity Date
DMM1
Fluke
187
DMM2
Fluke
187
Shunt
AMPRO
5089-500-500
EPROM
Webasto Charging
Systems
Current ROS
EPROM
*Note: If the UUT (Unit Under Test) has CAN card installed internally, then it is necessary to have EPROM chip to
run ROS, which is used in this calibration procedure.
2.0 Calibration Instructions:
2.1 Turn unit ON. Wait ten minutes before beginning calibration procedure.
2.2 Connect the shunt to UUT DC output, Channel A to Channel B.
2.3 Connect a DMM1 to voltage point and a DMM2 to the current points on the shunt
2.4 Connect ROS to the UUT.
3.0 Channel A Voltage Calibration:
3.1 Set Channel A for the following limits:
Voltage: 600V, 0V Current: +20A, -20A Power: +1Kw, -1Kw
3.2 Set Channel A in Voltage mode at 8V. Adjust R314 (ALOCAL) offset till DMM1 reads 8.0000.010V.
3.3 Connect Remote Voltage Sense connector from the shunt to the Channel A RVS connector on the front panel
of the ABC-600. Turn RVS mode ON.
3.4 Set Channel A in Voltage mode at 8V. Adjust R318 (AREMOTE) offset till DMM1 reads 8.0000.010V.
3.5 Command 600V from ROS. Adjust R50 such that both local and remote readings for 600 0.250V. This may
require going back and forth between local and remote modes.

ABC-600 Installation Instructions
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4.0 Channel B Voltage Calibration:
4.1 Set Channel B for the following limits:
Voltage: 600V, 0V Current: +20A, -20A Power: +1Kw, -1Kw
4.2 Set Channel B in Voltage mode at 8V. Adjust R312 (BLOCAL) offset till DMM1 reads 8.0000.010V.
4.3 Connect Remote Voltage Sense connector from the shunt to the Channel B RVS connector on the front panel
of the ABC-600. Turn RVS mode ON.
4.4 Set Channel B in Voltage mode at 8V. Adjust R316 (BREMOTE) offset till DMM1 reads 8.0000.010V.
4.5 Command 600V from ROS. Adjust R55 such that both local and remote readings for 600 0.250V. This may
require going back and forth between local and remote modes.
5.0 Channel A Current Offset Calibration:
5.1 Set channel A and B for the following limits:
Voltage: 600V, 0V Current: +200A, -200A Power: +75Kw, -75Kw
5.2 Put Channel B in voltage mode at 100V and Channel A in current mode at 0A.
5.3 Set the DMM to mV (1mV = 1A for the shunt rating: 500A/500mv)
5.4 Adjust R71 till the DMM connected to the current shunt must reads 0.000.01mVDC.
6.0 Channel B Current Offset Calibration:
6.1 Set channel A and B for the following limits:
Voltage: 600V, 0V Current: +200A, -200A Power: +75Kw, -75Kw
6.2 Put Channel A in voltage mode at 100V and Channel B in current mode at 0A.
6.3 Set the DMM to mV (1mV = 1A for the shunt rating: 500A/500mv)
6.4 Adjust R94 till the DMM connected to the current shunt must reads 0.000.01mVDC.

ABC-600 Installation Instructions
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7.0 Channel A Current Gain Calibration:
7.1 Set channel A and B for the following limits:
Voltage: 600V, 0V Current: +200A, -200A Power: +75Kw, -75Kw
7.2 Put Channel B in voltage mode at 100V and Channel A in current mode at 0A.
7.3 Set the DMM to mV (1mV = 1A for the shunt rating: 500A/500mv)
7.4 Command -150A on Channel A and note the current reading from the shunt (A1). Now command +150A on
Channel A and note the current reading on the shunt (A2). Add the two readings and divide the result by two (S).
For example, the reading for –150A could be –149.33A and the reading for +150A could be +149.41. The
Absolute difference divided by two will be
C = -149.33 + 149.41 = 0.04
2
Add the number to +150A and multiply this resulting number by the shunt calibration factor noted on
the shunt (Rs). In this example:
Y = {+150 + 0.04} = 150.04A x 0.9993335 mOhm = 149.9 mV
7.5 Now command +150A on Channel A and adjust R62 on the DC Control board such that the current on the
shunt reads Y which is 149.94 in this example.
7.6 Verify the current calibration on the following points:
0A, 1A, 10A, 50 A, 100A, 250A and -1A, -10A, -50 A, -100A, -250A.
Example for recording values on the data sheet:
Command 100A on Channel A and note the reading on the DMM (assume that the reading is 99.92mV)
Divide this number by the shunt resistance and record the current value derived as shown below.
99.92 MV/ 0.9993335 M OHM = 99.98A
8.0 Channel B Current Gain Calibration:
8.1 Set channel A and B for the following limits:
Voltage: 600V, 0V Current: +200A, -200A Power: +75Kw, -75Kw
8.2 Put Channel A in voltage mode at 100V and Channel B in current mode at 0A.
8.3 Set the DMM to mV (1mV = 1A for the shunt rating: 500A/500mv)
8.4 Repeat section 7.4 for Channel B.
8.5 Now command +150A on Channel B and adjust R85 on the DC Control board such that the current on the
shunt reads Y, which is 149.94 in this example.
8.6 Verify the current calibration similar to Channel A section 7.6 for Channel B.

ABC-600 Installation Instructions
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9.0 Install Calibration Sticker
Use Label WUSLA #07310, fill up the information, remove the old calibration label and install the label in the
vicinity of nameplate of the unit. Due date is one year from the date of calibration.
Calibration label is shown below.
CALIBRATION
By
Due
Date

ABC-600 Installation Instructions
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Appendix II: ABC-600 Calibration Data Sheet
Refer to procedure 09400-08
Test Equipment:
Equipment
Manufacturer
Model
Serial
Calibration
Validity Date
DMM1
DMM2
DMM3
Shunt
WEBASTO CHARGING SYSTEMS, INC. ABC-600/600CE
MONROVIA, CALIFORNIA UNIT SN: _______________
INFORMATION:
AC CTRL BOARD
SN
WORK ORDER
DC CTRL BOARD
SN
TEST DATE
EPROM VER
TESTER
VOLTAGE CALIBRATION AND ACCURACY: + 250mV or + .15% of reading.
COMMAND
CH “A” RVS
CH “A” LOCAL
CH “B” RVS
CH “B” LOCAL
8V
100V
300V
400V
600V

ABC-600 Installation Instructions
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OUTPUT “A” CALIBRATION: OFFSET AT 0A & GAIN AT 150A
A1 = @ -150A
A2 = @ 150A
S = A1+A2
C = S/2
I = (150 + C) *
Rs
VERIFY CURRENT OUTPUT “A”: +250mA OR +.25% OF READING)
.75A
1.25A
-99.75A
-
100.25A
199.50A
200.50A
-.25A
.25A
-
199.50A
-
200.50A
99.75A
100.25A
-.75A
-1.25A
49.75A
50.25A
-9.75A
-10.25A
9.75A
10.25A
-49.75A
-50.25A
OUTPUT “B” CALIBRATION: OFFSET AT 0A & GAIN AT 150A
B1 = @ -150A
B2 = @ 150A
S = B1 + B2
C = S/2
I = (150 + C) *
Rs
VERIFY CURRENT OUTPUT “B”: +250mA OR +.25% OF READING)
.75A
1.25A
-99.75A
-
100.25A
199.50A
200.50A
-.25A
.25A
-
199.50A
-
200.50A
99.75A
100.25A
-.75A
-1.25A
49.75A
50.25A
-9.75A
-10.25A
9.75A
10.25A
-49.75A
-50.25A
FUNCTION TEST:
ANALOG “A”
RVS CHANEL “A”
ANALOG “B”
RVS CHANEL “B”
INTERLOCK “A”
PARALLEL TEST
INTERLOCK “B”