Webasto Hollandia 900 User manual

11816-03-D Page 1 of 58 Webasto Charging Systems, Inc.
Installation, Operation and Maintenance Manual
EV Test Systems
900
English

11816-03-D Page 2 of 58 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]
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