Webasto ABC-600NS User manual

31565-03_01
Installation, Operation and Maintenance Manual
EV Test Systems
ABC-600NS
English

31565-03_01 Page 2 of 51 Webasto Charging Systems, In .
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 Administration
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Warranty
Webasto ABC-600NS 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 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 vary from jurisdiction to jurisdiction.

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TABLE OF CONTENTS
WARRANTY 3
TABLE OF CONTENTS 4
SAFETY RECAUTIONS - READ BEFORE USE 6
SYMBOL USAGE 6
GENERAL SAFETY WARNINGS AND RECAUTIONS 6
1.0 INTRODUCTION 8
1.1 Overview 8
1.2 Scope of Manual 8
1.2.1 Manual Organization 8
1.3 ABC-600NS Applications 8
Constant Voltage Source 8
Constant Current Source 9
Battery Quick Charging 9
Battery Pack Cycling 9
Battery Emulation 10
Other Applications 10
2.0 SYSTEM DESCRI TION 11
2.1 System Block Diagram 11
2.1.1 AC Inverter Functions & Controls 11
2.1.2 DC Converter Functions & Controls 13
Independent Configuration 13
External Parallel Configuration 13
2.1.3 DC Side Connector Interface 15
Remote Operation Interface 16
ROS Isolated RS-232 Port 16
ABC-600 Remote Operation System 16
HV Interlock (Front Panel) 17
RVS (Remote Voltage Sense) 17
Analog Signal Control 17
Optional Data Acquisition Interfaces 18
Optional RS-232 CAN Interface 18
2.1.4 Remote Emergency Stop 18
NOTE: The base unit does not come with this feature. 18
2.2 Technical Specifications 19
2.2.1 Utility Requirements 19
AC Output 19
DC Output 19
Accuracy 19
Communication 20
Operating Environment 20
Cabinets 20
3.0 INSTALLATION 21

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4.0 O ERATION 23
4.1 lanning 24
4.1.1 Choosing a Load Configuration 24
4.2 Independent Configuration 25
4.3 External arallel Configuration 27
4.4 Choosing Operating Limits 27
General Limits Considerations 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 34
4.10 Local Operation 34
4.10.1 Selecting 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 36
4.10.6 Entering Remote Operation 36
4.10.7 Changing Load Configuration 37
4.11 Remote Operation 37
4.12 Turning Off ower 37
5.0 MAINTENANCE 39
5.1 reventative Maintenance 39
5.2 Fault Indications 41
A ENDIX I: GLOSSARY OF TERMS 44
A ENDIX II: DC I/O CONNECTOR ASSEMBLY 46
EQUI MENT REQUIREMENTS: 46
General 46
Assembly rocedures 46
Disassembly rocedures 47
A ENDIX III: ABC-600NS REMOTE VOLTAGE SENSE O ERATION 48
A ENDIX IV: ABC-600NS ANALOG SIGNAL CONTROL 50

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Safety recautions - Read Before Use
The ABC-600NS 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 RECAUTIONS
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 (H 2 )
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-600NS 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 APU’s, flywheels, motors, inverters, batteries, fuel cells,
capacitors, and more.
The ABC-600NS is an ideal test system for a wide range of DC loads in addition to
batteries; offering more capability than a traditional power supply system. The ABC-
600NS 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-600NS 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-600NS 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-600NS and instructions for the
installation, operation and maintenance of the ABC-600NS.
1.2.1 Manual Organization
This manual is divided into six sections with several support appendices as follows.
Section
Description
2.0
Outlines some typical ABC-600NS
applications and describes the system
architecture and function
3.0
Provides step-by-step instructions for
installing the ABC-600NS
4.0
Discusses operation of the ABC-600NS,
using typical ABC-600NS applications as
examples
5.0
Provides preventative maintenance
Appendices
ABC-600NS terms and details of
application procedures
1.3 ABC-600NS Applications
The ABC-600NS 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-600NS.
Constant Voltage Source
In Voltage Mode, the ABC-600NS regulates the voltage of a given DC
output channel. The load may draw current from the ABC-600NS at the

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regulated voltage and the voltage level may be varied on demand, as with
a conventional DC power supply. In addition, the ABC-600NS allows the
user to define voltage, current and power limits to protect the load and
maintain safe operating conditions. The ABC-600NS 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, when the utility
voltage is lost, the ABC-600NS will cease operation.
Constant Current Source
In Current Mode, the ABC-600NS 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.
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-600NS.
By setting the correct upper voltage limit and operating the system in
constant Current Mode, the user can assure that the ABC-600NS 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-600NS Remote Operation System.
Battery ack 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-600NS was designed specifically to handle the demands of EV
battery pack cycling. Using the ABC-600NS Remote Operating 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.

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Battery Emulation
With its computer control capabilities, the ABC-600NS can be programmed
to emulate a battery. The ABC-600NS would first be put into constant
Voltage Mode at the desired state of harge. As current is drawn from the
ABC-600NS, the voltage would be lowered; as if the “battery” was 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.
Other Applications
As the above examples illustrate, the ABC-600NS is very flexible and
versatile and it can be used for many other applications. Testing or
emulation of most DC power system can be achieved with the powerful
computer controlled testing capabilities.
The ABC-600NS may be valuable even for very simple applications 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-
600NS in a virtually limitless set of applications.
The ABC-600NS base unit can be customized for particular applications
with ROS scripts or/and 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-600NS architecture is shown in the following system block diagram
(Figure 2.1). The AC Inverter connects to the utility via an 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 via an RS-232 data
link. The DC Converter provides the DC interface to a load (or possibly two
separate loads) in one of two operating modes.
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-600NS 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. The maximum for the Intermediate
DC Bus is 600 Volts DC with 150KW source and 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.
Optional Data Collection Systems:

Contact Webasto for Additional
Information

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Figure 2.2. AC Inverter Front anel
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 Pressed to apply and remove power to the system. The
switch
OWER 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 Pressed it to remove input control power to the system.
The
OFF switch has a locking mechanism and must be rotated
counterclockwise to enable the control power to power
the system.

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DANGER
The main circuit breaker must be switched off and
locked out by authorized personnel 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.
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. All DC converter configurations can be set either via the ROS
computer or manually through the front panel (shown in Figure 2.3).
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.
External arallel Configuration
This configuration is called Parallel because internally the two converter
circuits function in parallel to provide higher current capability. When
operating in this mode, user must use the output on both channel terminals.
The DC Converter incorporates safety features minimize the possibility of
an improperly connected load, or hazardous voltage exposure. The DC
Converter monitors internal switches, which indicate where 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, the
output terminals will automatically be disconnected, using internal
contactors, if one of the connectors is pulled from the unit.
The internal contactors remain disconnected during load configuration or
reconfiguration, and will also be disconnected in the event of a load fault

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condition (e.g., a short circuit) or an unsafe operating condition (e.g., a
voltage higher than the user-defined limit).
Figure 2.3. DC Converter Front anel
The following displays and controls are operable in manual mode or
through the ROS. The ABC-600NS starts up with both Channel A and
Channel B in manual mode. Both the Remote A and the Remote B buttons
are unlit in this mode. To toggle to remote operation, press the button for
the corresponding channel. Ensure that you have the ROS computer
operational and connected to the ABC-600NS and that the remote button
lights up (yellow).
CONFIGURATION
The ABC-600NS starts up in Independent mode as its
default. To change this configuration, press either the
External Parallel buttons (yellow) to enable external parallel
operation or the RVS button (yellow) to enable RVS
(Remote Voltage Sensing) in either mode. If both buttons
are unlit, the unit is in default independent.

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LIMITS Upper and lower limit buttons are included for each
converter (A and B). 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.
When these buttons are flashing, the DC Converter is
prompting the user to check the operating limits and adjust
them if necessary.
MODE Determines what control algorithm (mode) 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.
During operation (after the mode has been selected), a
flashing mode button indicates that a user limit has been
reached and that the ABC-600NS is now regulating to the
set limit rather than to the command in the selected mode.
STATUS Each channel will display (local or remote) status channel
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. (See Se tion 4.3.1 for a special configuration
option.)
ROTECTED While operating in Remote mode, the operator can change
the
REMOTE status of ABC-600NS to standby by pressed the Standby
button.
O ERATION Pressing this button will open the output contactor and
isolate the output of the respective 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 DC Side Connector Interface
All of the manual functions of the ABC-600NS are controllable with the
Remote Operation System. In addition, there are serial data output and
monitoring connectors, which are accessible on the DC Connector Panel
(Figure 2.4). Details of the connector pinouts and the function of each are
described below.

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ANALOG
INPUT
ANALOG
INPUT
HV
INTLK
HV
INTLK
Figure 2.4. Connector anel with Jumper Connectors.
Remote Operation Interface
The Remote Operation Interface is an isolated input based on the RS-232
communication standard, allows communication between the DC
Converter and the ABC-600 Remote Operation System (ROS). The
purpose of this interface is to provide status information and DC output
measurements from the ABC-600NS to the ROS and to accept commands
from the ROS. For more information about the Remote Operation Interface,
please refer to the ABC-600 Remote Operation System Manual and CAN
Interfa e do ument.
ROS Isolated RS-232 ort
The ABC-600NS has serial ROS data out via the Isolated RS-232 Port.
The pinouts for this feature are detailed in Figure 2.5:
Figure 2.5. ROS ISOLATED ORT
ABC-600 Remote Operation System
The ABC-600 Remote Operation System is a personal computer-based
system for controlling the ABC-600NS. The system consists of the
computer itself and any peripherals, and the ABC-600 Remote Operation
System application.
This software provides a graphical user interface for controlling and
monitoring the operation of the ABC-600NS, a command language

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interpreter that allows for simple implementation of complex test programs
and communication with the system.
HV Interlock (Front anel)
Each channel of the ABC-600NS has a High Voltage Interlock Switch
(HVIS) for added protection (Figure 2.6). The HVIS can put one channel
of the ABC-600NS into the standby mode without affecting the other
channel and is designed to be used as part of an automated test setup.
Figure 2.6. ABC-600NS Connector inouts.
Pin 1 (+V) is a system-supplied +5V isolated voltage source that must be
connected to Pin 2 (+sense). The Pin 3 (-sense) must be connected to
Pin 4 (the GND signal), which is the ground of the (+V) isolated supply. A
break in either one of these links will put that channel into the standby mode
(opening the output contactor and isolating the output of the ABC-600NS
from the load).
RVS (Remote Voltage Sense)
To increase voltage accuracy at the Load, the ABC-600NS can feed back
on a remote voltage measurement. The RVS mode is activated by pressed
the front panel button. The RVS feature can be used in voltage mode as
well as power mode. (See Appendix III for proper wiring and use of this
feature.) In current mode, the remotely measured voltage will be displayed
once the RVS mode is enabled.
Analog Signal Control
The ABC-600NS 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).
NOTE: The Analog Signal must be isolated.

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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
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
2.1.4 Remote Emergency Stop
Within the ABC-600NS, there is a provision to allow installation of an
external switch to control the emergency stop function of the system. To
enable a system provided with this option, an electrical connection must be
made between pins 1 and 4 of this interface (Figure 2.7). Opening this
connection will induce a complete power-down of the ABC-600NS.
NOTE: The base unit does not come with this feature.
*
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 2.7. Remote Emergency Stop

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2.2 Technical Specifications
2.2.1 Utility Requirements
Voltage 3-phase, 380 Volts RMS, + 10% / - 15%, < 5% imbalance
Other voltages optional
Current 250 Amps RMS for 380VAC
Frequency 60 ± 2 Hz (50 + 1Hz Optional)
Ground Connected to chassis
AC Output
Power factor > 99%
DC Output
Operating range
Configuration
Voltage
Current
ower
Independent Channel A
Channel B
8 to 600 V
8 to 600 V
±400 ADC
±200 ADC
±150 KW
±150 kW
External Parallel 8 to 600 V ±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.
Accuracy
Configuration
Voltage
Current
Current Ripple
Independent ± 250
mV or
.15%
± 250 mA or .25% of
reading
<65 mA RMS
Parallel ± 250
mV or
.15%
± 300 mA or .35% of
reading
<130 mA RMS
The power accuracy at each point is a simple multiple of the voltage and
current accuracy for that point (with offsets).

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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 temperatures can be
sustained at a lower continuous power rating)
Humidity 0-90% non-condensing
Cabinets
Dimensions, each cabinet: ~ 36” (92 cm) x 72” (182 cm) x 72” (182 cm)
Weight ~ 3500 lbs (1588 Kg)