Webasto Hollandia 900 User manual

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Installation, Operation and Maintenance Manual
EV Test Systems
900
English

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© 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]
evtestsystems.com

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Warranty
Webasto 900 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 the date of
installation, but not more than 18 months from the 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 charges that 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 that vary
from jurisdiction to jurisdiction.

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WARNING
Before attempting to service the system:
1) Turn off the Input Circuit Breaker or Main Disconnect Switch .
2) Depress and latch the Emergency Off switch for at least 5 minutes to allow
the high voltage to discharge.
3) Do not open the covers; there are no user serviceable parts inside.
CONTACT WEBASTO’S CUSTOMER SERVICE DEPARTMENT
PRIOR TO PERFORMING ANY SERVICE ON THE UNIT.

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Table of Contents
WARRANTY 3
WARNING 4
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 Overview 10
1.2 Scope of Manual 10
1.2.1 Manual Organization 10
1.3 900 Applications 10
Constant Voltage Source 10
Constant Current Source 11
Battery Quick Charging 11
Battery Pack Cycling 11
Other Applications 12
2.0 SYSTEM DESCRIPTION 13
2.1 System Block Diagram 13
2.1.1 AC Inverter Functions & Controls 13
2.1.2 Isolation Fault Detection 15
2.1.3 DC Converter Functions & Controls 17
Independent Configuration 17
External Parallel Configuration 17
2.1.4 DC Side Connector Interface 19
Remote Operation Interface 20
900 Remote Operation System (ROS) 20
HV Interlock (Front Panel) 20
RVS (Remote Voltage Sense) 21
CAN Operation (Optional) 21
Analog Signal Control 21
2.1.5 Remote Emergency Stop (Optional) 22
2.2 Technical Specifications 23
2.2.1 Utility Requirements 23
AC Output 23
DC Output 23
Operating range 23
Accuracy 23
Operating Environment 24
Physical Specification 24
3.0 INSTALLATION 25

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4.0 OPERATION 27
4.1 Planning 28
4.1.1 Choosing a Load Configuration 28
4.1.2 Operating Below 750 Volts 28
Operating Above 750 Volts In Parallel Configuration 29
Operating Above 750 Volts In Independent Configuration 29
4.2 Independent Configuration 31
4.3 External Parallel Configuration 31
4.4 Choosing Operating Limits 32
General Limit Considerations 32
Operating Space 33
Second Boundary 33
Load 33
4.5 Operating the System 35
4.6 System Startup 37
4.7 Connecting the Load and Selecting the Configuration 37
4.8 Adjusting Operating Limits 38
4.9 Selecting Local or Remote Operation 39
4.10 Local Operation 39
4.10.1 Selecting Mode 39
4.10.2 Adjusting Setting 39
4.10.3 Changing Mode While Running a Test 40
4.10.4 Changing Operating Limits 40
4.10.5 Pausing a Test 41
4.10.6 Entering Remote Operation 41
4.10.7 Changing Load Configuration 42
4.11 Remote Operation 42
4.12 Turning Off Power 43
5.0 MAINTENANCE 44
5.1 Preventative Maintenance 44
5.2 Fault Indications 45
APPENDIX I: GLOSSARY OF TERMS 48
APPENDIX II: DC I/O CONNECTOR ASSEMBLY 50
II-1. STANDARD UNIT WITH CAMLOCKs 50
EQUIPMENT REQUIREMENTS: 50
General 50
Assembly Procedures 50
Disassembly Procedures 51
II-2. NO CAMLOCKs UNIT 52
EQUIPMENT REQUIREMENTS: 52

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General 52
Assembly Procedures 52
APPENDIX III: 900 REMOTE VOLTAGE SENSE OPERATION 53
APPENDIX IV: 900 ANALOG SIGNAL CONTROL 55
INDEPENDENT MODE 55
PARALLEL MODE 56
THE ANALOG VOLTAGE RESPONSE AND SCALING 56
APPENDIX V: HIGH VOLTAGE INTERLOCK WIRING 58

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Safety Precautions - Read Before Use
The 900 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.

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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.
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 900 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 include APU’s, flywheels,
motors, inverters, batteries, fuel cells, capacitors, and more.
The 900 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
900 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 900
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 900 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 900 and instructions for the
installation, operation and maintenance of the system.
1.2.1 Manual Organization
This manual is divided into five sections with several support appendices as
follows.
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 900
4.0
Discusses operation of the 900, using
typical 900 applications as examples
5.0
Provides preventative maintenance
guidelines
Appendices
Defines 900 terms and details of
application procedures
1.3 900 Applications
The 900 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 900.
Constant Voltage Source
In Voltage Mode, the 900 regulates the voltage of a given DC output
channel. The load may draw current from the 900 at the regulated

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voltage and the voltage level may be varied on demand, as with a
conventional DC power supply. In addition, the 900 allows the user to
define voltage, current and power limits to protect the load and maintain
safe operating conditions. The 900 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 900 will cease operation.
Constant Current Source
In Current Mode, the 900 regulates the current of a given DC output
channel. As in constant Voltage Mode, the load may draw or provide
current bi-directionally based on 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 900. By setting the correct upper voltage limit and
operating the system in constant Current Mode, the user can assure that
the 900 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 900 Remote Operation
System or other scripting tool.
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 900 was designed specifically to handle the demands of EV battery
pack cycling. Using the 900 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 900 can be programmed to
emulate a battery. To do so, the 900 would first be put into constant
Voltage Mode at the desired state of charge. As current is drawn from the
900, 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 900 Remote
Operation System or other scripting tool.
Other Applications
As the above examples illustrate, the 900 is very flexible and versatile
and can be used for many other applications. Testing or emulation of
almost any DC power system can be achieved with the powerful
computer-controlled testing capabilities.
The 900 can also be valuable 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 900 in a
numerous set of applications.
The 900 can be customized for particular applications with ROS scripts or
other optional 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 900 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 900 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
PC
High Voltage Interlock A
High Voltage Interlock B
Figure 2.1 – 900 System Block Diagram
2.1.1 AC Inverter Functions & Controls
The AC Inverter interfaces the utility to an internal Intermediate DC Bus.
The Intermediate DC Bus voltage is regulated by the AC Inverter based
on the maximum voltage expected by the DC Converter connected. The
range for the Intermediate DC Bus is 750 - 910 Volts DC.
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 found below.
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.
•
Contact Webasto for
Additional Information

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Figure 2.2 – AC Inverter Front Panel
Figure 2.2 shows the 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 pressed to remove all power to the system except input
power.
OFF The switch has a locking mechanism and must be
rotated counterclockwise to power the control 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.
Ready Light (green) when the system power is on and the system is
functioning normally.

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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 Tables 5.1 and 5.2 in
Section 5 of this manual to determine the definition of any
faults indicated.)
2.1.2 Isolation Fault Detection
Internal Isolation is monitored with a separate circuit (See Figure 2.3).
Prior to contactor closure, this circuit monitors the impedance between
the positive and negative busses and the chassis. Once the contactors
have been closed and the Unit Under Test (UUT) is connected to the 900,
the isolation monitor is disabled to prevent nuisance trips with low
impedance loads.
Figure 2.3 – Isolation Fault Detection Panel
The isolation monitor has four indicator lights for displaying the state of the system to the
users. The lights indicate the following states:
State
Ready Light
(green)
Reset light
(yellow)
-Bus Fault
(red)
+ bus fault
(red)
Standby
1 Hz Flash
-
-
-
Standby fault
-
-
On steady
On steady
Monitor
On steady
-
-
-
+ bus fault
-
-
-
On steady
- bus fault
-
-
On steady
-
Operate
On steady
-
-
-
Reset
-
1 Hz flash
-
-
Reset complete
-
On steady
-
-

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Standby When the 900 is first powered up, the isolation monitoring
circuit monitors the DC bus voltage to ensure that it has
risen to a sufficient level to prevent nuisance isolation
monitor trips. While this is happening, the Ready light
(green) is flashing. The 900 will stay in this state until the
voltage threshold is reached, or for a maximum of nine (9)
seconds, after which the unit declares a Standby Fault.
Standby Fault When the Isolation monitoring circuit times out
during Standby (the DC bus failed to reach the threshold
voltage within nine seconds), the circuit disables the 900
and illuminates both fault lights (red).
Monitor After the bus voltage has risen to its set point, the
isolation monitoring circuit evaluates the isolation level of
the high voltage power system. If no faults are detected,
the system displays the Ready light (green) with steady
illumination. The system is now ready to be used.
+Bus Fault/ If loss of internal isolation is detected, the isolation fault
-Bus Fault detection circuit will prevent the 900 from operating. The
+ or – bus fault indicators (red) will be illuminated to aid in
determining the cause of the fault. The system will
remain in this state until manually reset or reset by a
power-down of the system.
Operate If no faults have been detected, following connection to a
UUT, the system disconnects the isolation monitoring,
allows the output contactors to close, and continues to
display the ready light (green).
Reset After a fault has been detected and the cause of the fault
corrected, the unit must be reset. This can be done either
by a power-down and re-start of the unit (as would have
to be done to perform any work inside the unit) or by
manually pressing the RESET button (yellow). To clear
the fault manually, hold the reset button down for eight (8)
seconds. The light will flash while you are holding down
the button. Once the fault is cleared, the light will return
to a steady yellow indicating the circuit is ready to resume
monitoring and the 900 lockout has been released.

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2.1.3 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 2.4).
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 Parallel 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, the user must use the output on both channel
terminals.
The DC Converter incorporates safety features to 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
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 2.4 – DC Converter Front Panel
The following displays and controls are operable in manual mode or
through a scripting tool, like the ROS. The 900 starts up with both
Channel A and Channel B in manual mode. Both the Remote A and the
Remote B LEDs are unlit in this mode. To toggle to remote operation,
press the button for the corresponding channel. Ensure that the user has
the ROS (or other scripting tool) computer operational and connected to
the 900 and that the remote button lights up (yellow).
CONFIGURATION The 900 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 mode.
.
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

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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 900 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
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
Section 4.3.1 for a special configuration option.)
PROTECTED While operating in Remote mode, the operator can
REMOTE change the status of 900 to Standby by
OPERATION pressing the Standby button;
Pressing the 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.
2.1.4 DC Side Connector Interface
All of the manual functions of the 900 are controllable with the Remote
Operation System or other scripting tool. In addition, there are serial data
output and monitoring connectors that are accessible on the DC
Connector Panel (Figure 2.5). Details of the connector pin outs and the
function of each are described below.

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CAN
PORT
Figure 2.5. Connector Panel with Jumper Connectors
Remote Operation Interface
The Remote Operation Interface is an isolated input based on the RS-232
communication standard, and allows communication between the DC
Converter and the 900 Remote Operation System (ROS). The purpose of
this interface is to provide status information and DC output
measurements from the 900 to the ROS and to accept commands from
the ROS. For more information on the Remote Operation Interface,
please refer to the 900 Remote Operation System Manual and CAN
Interface document.
900 Remote Operation System (ROS)
The 900 Remote Operation System (ROS) is a personal computer-based
system for controlling the 900. The system consists of the computer itself
and any peripherals, and the 900 Remote Operation System application.
This software provides a graphical user interface for controlling and
monitoring the operation of the 900, a command language interpreter that
allows for simple implementation of complex test programs and
communication with the system.
HV Interlock (Front Panel)
Each channel of the 900 has a High Voltage Interlock Switch (HVIS) for
added protection (Figure 2.6). The HVIS can put one channel of the 900
into Standby Mode without affecting the other channel. It is designed to
be used as part of an automated test setup.
Figure 2.6. 900 Connector Pinouts.