Ensuring mobility of the future Your system partner for battery and thermal management solutions
Your solutions' partner in battery, thermal management and power test systems Ensuring mobility of the future
Contents
Product Portfolio
4
eMobility Products
6
Standard Battery System
8
Standard Battery Pro 40
10
Vehicle Interface Box (VIB)
14
Vehicle Interface Gateway (VIG)
16
Vehicle Interface Gateway Plus (VIG+)
18
eBTM 2.0
22
High Voltage Heaters (HVH 50/70, 100, 100 C, 100 C+, 120)
24
360° Service
26
eMobility Case Studies
30
Power Cycling & Battery Test Systems
34
History of Innovation
37
Application Guide
39
900 EX
42
900
43
ABC-600
44
ABC-170 / ABC-170 CE
45
ABC-150
46
MT-30
47
IT-S
48
MI-TS
51
Power Cycling & Battery Test Systems Case Studies
56
3
Our product portfolio ensuring mobility of the future
High Voltage Heater (HVH 50/70, 100, 100 C, 100 C+, 120) 5.0 - 12 kW
Vehicle Interface Box (VIB)
Standard Battery System
Vehicle Interface Gateway (VIG)
eBTM 2.0 8.0 kW Cooling up to 10 kW Heating
Further Development of the Standard Battery System NextGen
900 EX up to 250 kW High Power Advanced Test System - Fast, Accurate & Scalable
MT-30 up to 30 kW
Dual Channel Cycling Station for Modules
ABC-170 up to 125 kW CE Certified, Dual Channel
Cycling Station with Extended Sink Power
Your system partner for the electrification of commercial vehicles and construction machinery
We at Webasto are your partner for future-proof and sustainable mobility. Our portfolio includes over 90 years of experience in the automotive industry.
We have developed a modular and scalable concept for the electrification of commercial vehicles and construction machinery. At the heart of this system is our Standard Battery system, which we are developing continuously. In addition, we offer a variety of interesting products, such as our thermal management system. It maintains the optimum operating temperature for your vehicle and its batteries at all times - no matter how hot or cold it is outside. Our 360° service portfolio rounds off the range. With us, you will always have the ideal, reliable partner by your side.
Plug & play solution
Standardized & certified
Scalable system
With our scalable portfolio, we are able to accommodate your specific vehicle requirements and offer you the perfect configuration for your application.
Our products are already in serial production and therefore thoroughly tested and certified. This way you can start directly with your electrification project.
We offer you a modular and scalable system in which you can interconnect up to 18 Standard Battery systems and three eBTM 2.0.
No development costs
Safety concept
360° service portfolio
Thanks to the standardization of our products, you bear no development costs. This enables you to easily integrate and quickly commission the vehicle.
Our product portfolio has been certified in accordance with very high industry standards and therefore offers you a coordinated safety concept for maximum reliability.
We are not only a product supplier, but are a partner and expert at your side - from the first system simulation to the extended warranty to the end of life of the product.
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Electrification of industrial vehicles
The electrification of industrial vehicles in particular is on the rise. Cities and municipalities also want to rely on CO 2 -neutral solutions, especially for construction vehicles, and have increasingly demanding requirements. What is rather good in theory poses some challenges for vehicle manufacturers in practice: the vehicles have long operating times and high energy requirements, must be vibration-resistant and have limited installation space. In addition, only small quantities are needed at first, as many manufacturers first build and test prototypes. This is where we come in with our standard portfolio for the electrification of industrial vehicles. We offer one-stop solutions and, thanks to our modular system, we can respond to your requirements in the best way possible.
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Our battery is suitable for a wide range of vehicle types
Standard Battery Pro 40
CV Standard Battery
Modular and scalable system
Developed according to the highest automotive standards
Flexible and easy integration into the vehicle
Robust housing and high safety and quality standards
The Standard Battery system is suitable for both commercial and industrial vehicles
Our Standard Battery System for commercial vehicles: The heart of every vehicle The Webasto Standard Battery system was developed according to the requirements in the commercial vehicle market and is therefore suitable as a traction battery for a wide range of vehicles. Scalable Standard Battery system with a system configuration of 400 V and 800 V as well as up to 630 kWh Up to 18 Standard Battery systems can be interconnected with the Vehicle Interface Gateway or up to 10 Standard Battery systems with the Vehicle Interface Box Future-proofing through further development of the battery system Flexible and easy integration into the vehicle due to vertical and horizontal installation position High-quality battery systems tested well beyond the standard ensure an exceptionally long service life thanks to integrated thermal management
Features:
Physical separation between high voltage and cooling connectors Desiccant cartridges to avoid condensation over the entire product life cycle
Integrated thermal runaway detection in each system Integrated, state-of-the-art pressure equalization Insulation measurement, high voltage interlock and contactor monitoring included in every battery pack Temperature, voltage and current of different sub-components are monitored Maintenance-free design
Technical specification of the Standard Battery system
Battery pack
Norms & standards
Dimensions (L x W x H)
37.8 x 27 x 11.9 in (960 x 686 x 302 mm) 650 lbs. (295 kg) ** per pack
Homologation: ECE R100, ECE R10 Transport: UN T38.3 (Transport of Dangerous Goods) Safety: ISO 6469, ISO 26262 (ASIL C) Environment: ISO 20653 (IP67/ IP6K9K) Vehicle Communication: CAN Bus conform to ISO 11898
Weight
Installed energy Nominal capacity Depth of discharge
35 kWh
99 Ah
Company Standards: LV 123, LV 124 EMC: ISO 11452, ISO 7637, CISPR 25
80 / 90%
Voltage range
280 V – 400 V (~350 nominal)
Energy density
~203 Wh / l, >118 Wh / kg
System requirements and the environment
Continuous use (CH / DCH) (@25 °C, SoC dependent) Peak power (CH / DCH) (10s, @25 °C, SoC dependent) Lifetime (DoD, temperature, and C-rate dependent)
50 / 56 kW
Optimized for vehicle classes M1, M2, M3, N1, N2 & N3 (EC Directive 2007/46) Designed for an ambient temperature of -30 °C to 60 °C, 3,500 meters above sea level and 0 – 100 % humidity
113 / 112 kW
Up to 3.000 cycles*
Calendric lifetime
Up to 8 years
Volume flow
10 l/min.
Pressure loss
< 50 mbar
Cell type
prismatic NMC
Operating temperature
-22 °F to 140 °F 3,500 meters above sea level 0 - 100% humidity
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Our Standard Battery Pro 40 for commercial vehicles and mobile machines The Webasto Standard Battery Pro 40 was designed according to the high requirements of the commercial vehicle market and is therefore suitable as a traction battery for a wide range of vehicles.
Features:
Scalable system with up to 18 Standard Battery Pro 40, a voltage of 400 or 800 V and with up to 720 kWh Robust housing enables use in rough terrain
Intensively tested and certified to the highest safety and quality standards Vertical and horizontal mounting positions allow flexible and easy integration Convincing total cost of ownership thanks to standardized product
Technical specification of the Standard Battery Pro 40
Battery pack
Norms & standards
Dimensions (L x W x H)
37.79 x 27 x 11.88 in (960 x 686 x 302 mm)
Homologation: ECE R100, ECE R10 CE-mark: CE certified for mobile machines* Safety: ISO 6469, ISO 19014, ISO 26262 (ASIL C) Environment: ISO 20653 (IP67/ IP6K9K) Vehicle communication: CAN-Bus conform to ISO 11898
Weight
655 lbs. (297 kg)
Installed energy Nominal capacity
~40 kWh
99 Ah
Voltage range
264 V – 418 V
Company standards: LV 123, LV 124 EMC: ISO 11452, ISO 7637, CISPR 25 Transport: UN T38.3
Energy density
~237 Wh / l, >137 Wh / kg
Continuous use (CH / DCH) (@25 °C, SoC dependent) Maximum performance (CH / DCH) (10s, @25 °C, SoC dependent) Lifetime (DoD temperature and C-rate dependent)
Under evaluation
Under evaluation
Safety features
Physical separation between high voltage and cooling connectors
Up to 3.000 cycles
Calendric lifetime
Up to 8 years
Desiccant cartridges to avoid condensation over lifetime Integrated thermal runaway detection in each system State-of-the-art pressure equalization Insulation measurement, high voltage interlock and contactor monitoring included in every battery pack Temperature, voltage and current of different sub-components are monitored
Volume flow per battery pack
10 l/min.
Pressure loss per battery pack
< 50 mbar
Cell type
prismatic NMC
Operating temperature
-22 °F to 140 °F ( -30 °C to +60 °C) 3,500 meters above sea level 0 - 100% humidity
* Standard Battery Pro 40 still under development. Subject to change without notice.
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Made in Schierling for customers all over the world. Our state- of-the-art multi-production line in Bavaria is one of the most modern production facilities worldwide for battery systems. Up to 40,000 units can be manufactured annually. Our CO 2 -neutral battery production in in Schierling, Germany
Production has been designed to meet the highest safety requirements and fulfills all quality demands far beyond automotive requirements.
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Efficient interface between battery system and vehicle
Vehicle Interface Box (VIB)
Efficient interface between battery system and vehicle
Main control unit of the entire battery system
Suitable for 400V and 800V connections
Configuration of up to 10 battery systems possible
The VIB can be used for different vehicles
Municipal vehicle with two Standard Battery systems
Light commercial vehicle with three Standard Battery systems
Scalable to up to 10 batteries (350 kWh)
Per AUX connection: Continuous current: 20 A Peak current: -
DC Charging Continuous current: 200 A Peak current: -
Powertrain / Recuperation: Continuous current: 150 A Peak current: 250 A
Integrated AC charging Continuous current: 67 A Peak current: -
Vehicle Interface Box (VIB) To ensure the scalability of our Standard Battery system, we offer two different interfaces: the Vehicle Interface Box (VIB) and the Vehicle Interface Gateway (VIG). The VIB is not only a very efficient interface, but also combines the functions of power distributor, master BMS and fuses in one robust housing.
Vehicle Interface Box - Benefits at a glance:
Specially designed for the Webasto CV Standard Battery system Configuration of up to 10 battery packs possible (2s5p, 1s5p) Cost-efficient solution for an intelligent gateway power distribution unit
Enables high level of scalability of the battery system Designed and developed to highest safety standards
Features:
Designed to enable DC charging Connection for onboard charger available (AC charging)
Intelligent switching concept and central battery pack balancing Central coordination and monitoring of isolation measurement Evaluation of the high voltage interlock Cable protection for power trains and auxiliary components Central communication interface to battery system Separate CAN communication for vehicle (vehicle and battery pack CAN)
Technical specifications of the Vehicle Interface Box (VIB)
Norms & standards
VIB
Product dimensions (L x W x H)
21.6 x 27 x 6.1 in (548 x 686 x 155 mm)
Homologation: ECE R10 Safety: ISO 6469, ISO 26262 (ASIL C), ISO 17409 Environment: ISO 20653 (IP67/ IP6K9K) Vehicle Communication: CAN Bus conform to ISO 11898. Signal mapping to SAE J1939 upon request. (Signal security requires alignment with Webasto.)
Weight
92.6 lbs. (42kg)
Supply voltages System voltages
12 & 24 V
400 & 800 V
Scalable energy with CV Standard Batteries
35 – 350 kWh (max. 10 batteries)
Company standards: LV 123, LV 124 EMC: ISO 11452, ISO 7637 & CISPR 25
Scalable power
Up to 460 kW
Continuous current DCH
380 A
Continuous current CH OBC
67 A
Additional norms & standards*: ECE R100, UN GTR No. 20, ISO 16750, ISO 12405, ISO 19453
Continuous current CH DC fast charging Peak current DCH (30 sec.) Peak current recuperation (30 sec.) Operational temperature
200 A
* Tests & Requirements partially fulfilled.
580 A 500 A
-40 to 185°F (-40 to +85°C)
15
Small but powerful: Our master BMS solution
Vehicle Interface Gateway (VIG)
Compact interface between battery and vehicle
Suitable for 400 V and 800 V connections
Small and flexible master BMS
Configuration of up to 18 battery packs possible
The VIG can be used flexible for different vehicles
Municipal vehicle with two Standard Battery systems
Light commercial vehicle with three Standard Battery systems
Scalable to up to 18 batteries (630 kWh)
Vehicle Interface Gateway (VIG)
Vehicle Interface Gateway (VIG)
In addition to our powerful and intelligent Vehicle Interface Box, we also offer our Vehicle Interface Gateway (VIG). This gives you even more power for your vehicle - and with more compact dimensions. This offers greater flexibility when combined with our Standard Battery system and when used in a limited installation space.
Vehicle Interface Gateway - Benefits at a glance:
Specially designed for the Webasto CV Standard Battery system Master BMS function (one central control unit for vehicle implementation) Up to 18 battery packs possible (individual configuration to be aligned with Webasto) Small and flexible system design Offers a high level of battery system scalability and outstanding battery system power Designed and developed to the highest safety standards
Features:
Enables high power outputs with maximum number of battery packs thanks to no HV limitations AC and DC charging possible with additional vehicle-side HV architecture Intelligent switching concept and central battery pack balancing
Installation and housing specifications according to quick manual requirements Central coordination and monitoring of isolation measurement on 400V system High voltage interlock monitoring on vehicle level possible Central CAN communication interface between vehicle and battery system Supports 12 and 24 V power supplies in one solution
Technical specifications of the Vehicle Interface Gateway (VIG)
Norms & standards
VIG
Product dimensions (L x W x H)
12.4 x 1.3 x 4.2 in (314 x 33 x 106 mm)
Homologation: ECE R10 Safety: ISO 26262 (ASIL C) Vehicle communication: CAN and SAE J1939 Bus conform to ISO 11898 Company standards: LV 124 EMC: UN ECE R10
Weight
~1 lb (~0.45 kg)
LV supply voltages
12 & 24 V
HV compability
400 & 800 V
Scalable energy with CV Standard Batteries
35 – 630 kWh (max. 18 packs)* Up to 1,109 kW
Scalable power
Continuous current DCH Continuous current CH Peak current DCH (30 sec.) Peak current CH (30 sec.) Operational temperature
1,215 A 1,102 A 1,400 A 1,400 A
Additional norms & standards: ISO 16750, ISO 19453
-40 to 185 °F (-40 to +85 °C)
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*with 800 V configuration
Flexible and powerful: Multi-pack solution for mobile machines
Vehicle Interface Gateway Plus (VIG+)
Enables communication between vehicle and battery
Powerful multipack system up to 630 kWh
Robust housing suitable for off-road use
Configuration of up to 18 battery packs possible
Vehicle Interface Gateway Plus (VIG+)
The Vehicle Interface Gateway Plus (VIG+) enables communication between the vehicle and up to 18 Webasto CV Standard Battery systems at a system voltage of 400 or 800 V. This creates a powerful multipack system with an energy content of up to 630 kWh.
High-performance master BMS enables the scalability of the battery system Configuration of up to 18 CV Standard Batery systems possible Robust housing for us in mobile machines Central CAN communication interface between vehicle and battery system Designed and developed to the highest safety standards Features:
Technical specifications of the Vehicle Interface Gateway Plus (VIG+)
Norms & standards
VIG+
Product dimensions (L x W x H) with connector Product dimensions (L x W x H) without connector
16.5 x 7.8 x 4.7 in (420 x 200 x 120 mm) 15.6 x 17.8 x 4.7 in (397 x 200 x 120 mm)
CE-mark: CE certified for mobile machines* Safety: ISO 26262 (ASIL C) Vehicle communication: CAN and SAE J1939 Bus conform to ISO 11898 IP protection class: IP 67 / EN 60529 Standards: LV 124 EMC: ISO 13766, ISO 14982, EN 12895, EN 61000-6
Weight
~1 lb (~0.45 kg)
LV supply voltages HV compability Scalable energy
12 and 24 V 400 & 800 V
35 – 630 kWh (max. 18 battery systems )
Scalable power
up to 1,109 kW
Additional norms & standards: ISO 16750, ISO 19453
Continuous current DCH Continuous current CH Peak current DCH (30 sec.) Peak current CH (30 sec.) Operational temperature
1,215 A 1,102 A 1,400 A 1,400 A
* CE certified for various vehicle types (listing upon request) ** Tests & Requirements partially fulfilled
-40 to 185 °F (-40 to +85 °C)
*with 800 V configuration
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Electrification of buses, trucks and municipal vehicles
According to the Paris climate protection agreement, more and more vehicles in the city shall be electrified. However, the topic of electrification still poses major challenges for many companies. Above all, the high costs for battery production, the long development times for batteries and the lack of know-how play a significant role. With our standard portfolio, you can start with electrification right away, even with small quantities. Our products originate directly from series production and all important certifications have already been carried out. Moreover, you can rely on us as a partner by your side - we support you on the way to electrification with all important questions.
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The perfect climate control for your battery system
Electric Battery Thermal Management (eBTM 2.0)
Plug & play thermal management solution for batteries
8 kW Cooling capacity 7/10 kW Heating capacity
Pre- conditioning during battery charging
Ensures optimum temperature for the battery system
Universal plug & play thermal management solution for battery packs: eBTM 2.0
The Webasto eBTM 2.0 is a stand-alone Battery Thermal Management Unit which ensures optimal functioning of water-cooled battery packs used in electrical commercial vehicles and ensures ideal battery cell performance over the long term. eBTM 2.0 - Benefits at a glance: Designed for use in buses, trucks, construction vehicles and light commercial vehicles All necessary components for heating and cooling the battery combined in one unit with compact dimensions 39.6 x 27.3 x 11.9 in (1,006 x 694 x 303 mm) Flexible installation due to compact design and multiple mounting points Guarantees an optimal operating temperature of the battery and thus extends the service life of the entire system
Features:
Cooling capacity: 8 kW Heating capacity: 7 /10 kW Plug & play installation Maximum 3,600 l/h coolant flow 400 / 800 V DC R1234yf with low GWP Rooftop and chassis installation
Low voltage power supply included on board Exceptionally high dimension/power ratio
Technical specifications of the eBTM 2.0
>> Cooling Under stress or in warm weather conditions
eBTM 2.0
Nominal Voltage (DC)
400 V
800 V
Cooling capacity
8 kW
Heating (electrical heater HVH) Max power consumption @HV
7 kW
10 kW
>> Heating In extremely cold ambient conditions
10.5 kW 6 kW/h
Max battery packs @35
Refrigerant
R-1234yf with low GWP 60 l/min @ dP 2.1 barA
Nominal coolant volume flow
>> Temperature control Dynamic temperature adjustment during driving phases >> Pre-conditioning During battery charging phases
Communication
CAN BUS
Low voltage supply for ECUs and coolant valves signals Operational temperature range Storage temperature range
12/24V (< 5A)
- 31 to 122 °F (- 35 to +50 °C) - 40 to 158 °F (- 40 to +70 °C ) Scroll (High voltage electric) 39.6 x 27.3 x 11.9 in (1,006 x 694 x 303 mm)
Compressor
Dimensions L x W x H
Weight
< 198 lbs. (< 90 kg)
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Perfect climate for your electric vehicle
Electric High Voltage Heater (HVH)
Efficient and certified
heating system for your electric vehicle
Choice of 5, 7, 10, 12 kW heat output
Precise and seamless controllability
Broad voltage range up to 880V
Powerful and reliable heat output: all-time comfort for the driver Efficient and quick performance: longer driving experience without energy waste Precise and stepless controllability: better performance and highest driving range Reliable and certified safety: three mechanisms to handle faults and guarantee safety Features:
Highly efficient heating system for your vehicle Electric High Voltage Heaters HVH 50/70, 100, 100 C, 100 C+, 120 Our electric High Voltage Heater (HVH) is the ideal heating system for plugin hybrids and electric vehicles. It converts DC electric power into heat with practically no losses. Depending on the application and requirements, the 5, 7, 10 or 12 kW variant can be selected, which provide different heating outputs. High Voltage Heater (HVH) - Benefits at a glance: Powerful 5/7/10/12 kW heating performance and wide voltage range up to 880 V independent of coolant temperature Better ranges with the same battery capacity and optimum climate comfort
Innovative Layer technology for extremely fast heat-up Highest efficiency through quick and direct heat transfer Seamless and exact controllability with no inrush currents Reliable safety concept with redundant controls Certified for automotive requirements with ECE R10 and ECE R122 type approval
Technical specifications of the High Voltage Heater (HVH)
New
New
New
HVH 50 Gen 1.5 HVH 70 Gen 1.5
HVH 100
HVH 100 C
HVH 100 C+
HVH 120
Heating performance
5 / 7 kW
10 kW
12 kW
HV voltage range (DC)
100 – 490 V
250 – 870 V
250 - 880 V
LV voltage
12 V
12 / 24 V
Efficiency
> 95%
Controllability steps
50 W
100 W
Dimensions
11.2 x 7.9 x 2.1 in (284 x 200 x 54 mm)
12.8 x 7.9 x 2.8 in. (326 x 201 x 72 mm)
11.2 x 7.9 x 2.8 in. (284 x 200 x 72 mm)
12.8 x 7.9 x 2.8 in. (326 x 201 x 72 mm)
Weight
2.0 g
2.6 g
2.3 g
2.6 g
Temperature range for heating
-40 to 194 °F (-40 to 90 °C)
Temperature range for ambient
-40 to 257 °F (-40 to 125 °C)
Communication
LIN 2.1
LIN 2.2
LIN 2.2, CAN, Main Switch
Passive discharge (V) according to ISO 6469-3.3.
< 60 in 4 Sec
< 60 in 40 Sec*
Dielectric strength (DC)
2,500 V
Coolant connection
VDA 19 mm
VDA 20 mm
IP protection class
IP 6K9K IP 6K7
HV connection
TYCO HVA280 Type A
TYCO HVA280 Type E
NV connection
LV FEP connector 8 PIN with integrated de-aerating membrane
Interlock
Passive
Electrical safety
ISO 6469 Part 3
Functional safety
According to ISO 26262 ASIL B for overheat
According to ISO 26262 ASIL D for overheat
Cyber security
UN-ECE WP.29 / ISO 21434
EMC
ECE R10 Rev. 5
> 50 M Ω
> 30 M Ω
Insulation resistance
Service life
15 years or 12,000 heating hours
15 years or 15,000 heating hours
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* with the active discharge support function, the discharge time can be reduced to milliseconds.
Service in every aspect Your trusted partner on the way to electrification
We are more than just a product supplier: we accompany you on the journey to electrification at every step of the vehicle development process. Our experts support you and are always there for you if you have any questions.
Planning phase With our system simulation, we provide you with advice and support even before the implementation of your project. We take a close look at your application and analyse your required system under all parameters - such as desired range, climate conditions and vehicle installation space. This system is perfectly adapted to your specific application and includes heating and cooling solutions for battery and vehicle.
Project phase We are also available to you at any time with our technical expertise during the implementation of your project. We support you with integration of the system, with commissioning and with all questions that arise, both remotely and on site. In addition, we can train your employees on our products and offer you comprehensive customer support. End of product life We take responsibility for the environment and are actively involved in various initiatives. Our battery systems are manufactured in a CO2-neutral process in Schierling, Germany. Furthermore, battery recycling is also close to our hearts. Therefore, we also use batteries as storage systems at the end of their life.
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In-house testing & prototyping in Hengersberg
Thanks to our unique testing and validation processes, Webasto battery systems meet the highest quality and safety standards far beyond automotive requirements. At our test and prototype center in Hengersberg, Germany, we continuously test both Cells and Battery Systems and can build up to 1,200 prototypes a year. Our competencies include in-house mechanical system development and integration, our leading thermal management, in-house software and algorithm development, and design and production of all E/E components. In this way, even the highest performance demands are met.
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100% Webasto power Our customers around the world
We are a long-term and experienced partner for our customers and are happy about our increasing customer base. We would like to show you some of our partnerships and projects in the field of electrification.
Successful electrification of Doosan excavators with E.C.E
Electromobility is gradually reaching the construction industry and our customer Electric Construction Equipment (E.C.E) is a pioneer in the conversion of fuel-powered Doosan excavators. For this, they rely on batteries, the Vehicle Interface Box and the appropriate thermal management system from Webasto.
They build so-called PowerBoxes from the products, each of which has 140 kWh and can be easily exchanged during operation. E.C.E also wants to electrify more construction site vehicles in the future and focus on sustainable mobility.
Together for emission-free airports with Goldhofer AG
Goldhofer is, among other things, a manufacturer of aircraft tractors and now also offers these as electrified variants. Webasto batteries are used for the "SHERPA" E and the "BISON" E, as they convinced Goldhofer with their high quality, modularity and durability. In addition, Goldhofer was looking for a
reliable partner, which they found in Webasto - thus the two companies are moving together into an electric future.
Fully electric city bus e-Kent C from the Turkish bus manufacturer Otokar
The Turkish bus manufacturer Otokar is the pioneer among electric bus manufacturers in Turkey and has taken another step towards a zero-emission future with its twelve-meter-long passenger bus. To power the bus, the company relies on the Webasto Standard Battery system for commercial vehicles.
Otokar is very satisfied with its choice of Webasto as a battery partner. The batteries are not only very reliable, but also have a very high quality.
The e-Kent is already being used in various cities - we are very happy about the project and about the success of our customer.
Read the detailed case studies on our website: webasto-electrified.com
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Our competencies for your Individualized Battery System at a glance
Component design
Procurement
Manufacturing technology
System development
Installation
Individualized Battery Systems tailored to your needs
In addition to our Standard Battery system, we can also use our skills to develop customized battery systems for you. This gives you a high degree of flexibility and allows us to respond to all of your requirements. With our modular Webasto design approach, we successfully develop customized or "build-to-print" battery solutions for passenger and commercial vehicles according to customer specifications. Our product and process development, the additional production capabilities of in-house prototyping, electronics development and manufacturing, and our test center ensure a shortened time-to- market from pre-development to the start of series production.
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Power Cycling & Battery Test Systems
Webasto Power Test Systems located in Fenton, MI is a pioneer of electric vehicle charging technology and battery test systems. Our power processing and battery testing equipment is a vital part of our product lineup and enables OEM vehicle manufacturers to develop, design, and test their advanced batteries and vehicles of tomorrow. At Webasto, we are committed to developing advanced power, transportation, and energy storage solutions for a brighter, more sustainable tomorrow. Webasto can enable your success as a clean technology provider.
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History of Innovation Webasto has a tradition of progress that spans more than 100 years. Today, Webasto is one of the 100 leading suppliers to the automotive industry worldwide. From developing the first modern electric car to the energy systems of tomorrow, Webasto sets the standard.
The world’s leading automotive, battery and fuel cell companies
rely on Webasto’s bidirectional, programmable power cycling
1901 Wilhelm Baier founds a company that goes by the name of: “Esslinger Draht und Eisen- warenfabrik Wilhelm Baier, Esslingen/ Neckar“.
and test systems – and for good reason. For more than three
1908 Wilhelm Baier Senior creates the new name Webasto out of his initials and the toponym Stockdorf
decades, Webasto’s breakthroughs in the testing, charging and
development of batteries have been setting the standard for
high-power test equipment.
1987 Sunraycer wins 1,864-mile World Solar Challenge, with its small, but powerful electric motor
The Power Cycling and Test Systems were initially created
in 1989 to support the development and testing of the GM
Impact. These systems have supported the world’s leading
automotive OEMs, battery and fuel cell manufactures,
1990 GM Impact, electric concept car, debuts at the LA Auto Show
utilities, defense contractors, and government agencies. Our
customers recognize the high-current / high power capability,
1996 EV1 becomes the first mass-produced modern electric car
comprehensive operating envelope, and reliability of these
Power Test Systems.
The Webasto Power Test Systems product line is an industry-
1999 Launch of 900, a high power battery cycler for Allison Transmission’s E-Axle development team
leading family of grid-tied DC power processing hardware
and software solutions (excluding cell testing), that are used
Today Webasto works with the world’s most innovative companies to test their electric-mobility solutions
to examine advanced power cycling and alternative energy
storage systems. Our products have received a reputation for
dependability, adaptability and convenience, and are therefore
the choice of many top automotive OEMs and organizations.
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Application Guide Webasto Power Cycling and Test Systems are used for a wide range of testing, charging and development activities associated with advanced batteries, fuel cells, ultra capacitors, hybrid energy systems, motors, generators, uninterruptible power systems, and powertrain components.
Low
Medium
High
0-30 kW
0-125 kW
0-150 kW
0-250 kW
ABC-170 (CE)
Category
Application
MT-30-
ABC-150
ABC-600
900
900EX
• • • • • • • • • • • • • • • • • • •
Battery Testing & Cycling Battery Cell
Battery Module
• • • • • • • • • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • • •
Battery Management Systems (BMS)
• • • • • • • • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • •
Battery Pack
Production Testing
Simulation
Battery
Powertrain
Fuel Cell
Hardware in the Loop
Energy Storage Charging
Fuel Cell
& Testing
Super & Ultra Capacitors
Flywheels
Power Generation
Electric Components
Equipment Testing
Power Supplies
Generators
Stationary Power
Inverters
Military & Aerospace
Life, Run-in, Burn-in
Uninterruptable Power Supplies
• •
Hybrid & Electric Vehicle
Powertrain
Testing
Production Testing
Medium & Heavy-duty EVs
•
•
(buses, trucks, military, locomotives)
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Advanced high power test system
900 EX
Fast response times
More accurately represent real world conditions
Enhanced error detection & fault correction
Control modes: voltage, current, power, resistance
Features:
Industry standard for high performance testing Flexibly test virtually any DC source, load, or battery storage system
Test faster and more efficiently > Save time & money Regenerative to the grid > Save energy and money More predictive results Two channels for flexibility in testing/simulating multiple devices with a single machine Open communication protocol allowing easy integration into any test set-up Self-contained cooling system requiring no external cooling system Voltage with Internal Resistance
Power Cycling and Measurement Solutions
900
ABC-150
Energy returned to the grid at 92+% efficiency
Dual independently controlled channels
Automatic shutdown on loss of power (anti islanding)
Multiple control interfaces/options
MT-30
ABC-170
ABC-170 CE
ABC-600
41
900 EX The 900 EX is ideal for testing and emulating energy storage and drive train components. The increased performance (rise time/slew rate) and increased accuracy make the 900 EX ideal for applications like Heavy Industrial (ships, trains, trucks, and aircraft), Military (hybrid drives and aircraft launch systems), Power Electronics (solar panels, inverters), and Hardware in the loop testing. Digital controls protect critical systems and components, and the system can self-adjust to external environmental events like unstable power sources. The bi-directional system can operate at ± 250 kW, or combined, it can scale to ±1 MW.
The 900 EX, with new LCD touchscreen display, is an intelligent system that will give you the accuracy, speed, and control to add value to your tests.
Technical specifications
Independent
Parallel
Multi-unit
900 V 500 A
900 V
900 V
Voltage
1,000 A 250 kW
4,000 A
Current
250 kW
1,000 kW
Power
250 μs (Ethernet)
Command latency
93%
Energy recovery efficiency
±0.05 V or ±0.05% of reading
Measurement error-voltage
±160m A or ±0.05% of reading
Measurement error-current
3 ms*
7 ms*
7 ms*
Rise time voltage - step (0-500v)
0.5 ms*
0.6 ms*
0.9 ms*
Rise time current - step (0-300a)
171 V/ms
89 V/ms
76 V/ms
Slew rate voltage
769 A/ms
1,282 A/ms
1,935 A/ms
Slew rate current
274 kW/ms
500 kW/ms
833 kW/ms
Slew rate power
50 Hz (500 V) 75 Hz (250 V) 175 Hz (500 A)
50 Hz (500 V)
50Hz (500 V)
Tracking bandwidth voltage
150 Hz (700 A)
50Hz (700 A)
Tracking bandwidth current
100 Hz (150 kW)
150 Hz (250 kW)
50Hz (250 kW)
Tracking bandwidth power
Fiber to Ethernet CAN RS-232
10 ms 10 ms 50 ms
Output data sampling
3 Phase, 380, 400 and 480 VAC
Input voltage options (+10%/-15%)
410, 389 and 324 A respectively
Current draw
6,063 lbs. (2,750 kg)
Weight
72 x 39 x 76.5 in. (183 x 99 x 194 cm)
Dimensions (L x W x H)
Operating range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +750
-500 to +500
-250 to +250
+751 to +825
-400 to +400
-225 to +225
Independent
+826 to +900
-300 to +300
-200 to +200
+8 to +750
-1000 to +1000
-250 to +250
+751 to +825
-800 to +800
-225 to +225
Parallel
+826 to +900
-600 to +600
-200 to +200
900 The 900 is Webasto’s heavy duty test solution. With greater voltage, current and power capability, this system is ideal for testing and emulating energy storage and drivetrain components of large electric and hybrid electric vehicles (HEV), such as buses, trucks and military vehicles. The 900 is used worldwide to support the development of fuel cell buses, hybrid locomotives and other HEVs.
All Webasto power cycling systems are equipped with a real-time clock on the system’s control board that enables accurate measurement of Ah and kWh during cycling.
Technical specifications
900
3 Phase, 380, 440 and 480 VAC
Input voltage options
410, 354, and 324 A respectively
Currency draw
60 Hz (50 Hz available)
Frequency
Internal transformer
Isolation transformer
> 99%
Power factor
< 3% THD; IEEE 519 Compliant
Harmonic distortion
Manual; Remote Operation System (ROS); DCOM Driver for LabVIEW; C++ and Visual Basic; CAN
Multiple user interfaces
< 65mArms and 130mArms, respectively
Current ripple - indepdendent & parallel mode
< 15 Arms
Current ripple - max ripple from load
32 - 95°F (0 - 35°C)
Operating environment - temperature
5-90% non-condensing
Operating environment - humidity
6,063 lbs. (2,750 kg)
Weight
73 x 37 x 76.54 in. (185 x 94 x 194 cm)
Dimensions (L x W x H)
Operating range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +750
-500 to +500
-250 to +250
Independent
+751 to +825
-400 to +400
-225 to +225
Optional range
+826 to +900
-300 to +300
-200 to +200
+8 to +750
-1000 to +1000
-250 to +250
Parallel
+751 to +825
-800 to +800
-225 to +225
Optional range
+826 to +900
-600 to +600
-200 to +200
Accuracy & resolution Measurement
Accuracy (±)
Resolution
250mV or 0.15% of the output voltage
50mV
Voltage
250mA or 0.25% of the reading
40mA
Current independent (2 channels)
350mA or 0.35% of the reading
80mA
Current external parallel (1 channels)
43
ABC-600 Webasto's ABC-600 is a high voltage cycling station that was originally developed to meet specific customer requirements. This system is ideal for testing hybrid vehicles and high voltage drivetrains, motors and energy storage devices.
The ABC-600 offers power up to 150kW, with a voltage range of 8 to 600 VDC and a current range of ±600 ADC.
Technical specifications
ABC-600
3 Phase, 380, 440 and 480 VAC
Input voltage options
254, 218 and 200 A respectively
Currencydraw
60 Hz (50 Hz available)
Frequency
Internal transformer
Isolation transformer
> 99%
Power factor
< 3% THD; IEEE 519 Compliant
Harmonic distortion
Manual; Remote Operation System (ROS); DCOM Driver for LabVIEW; C++ and Visual Basic; CAN
Multiple user interfaces
< 65mArms and 130mArms, respectively
Current ripple - indepdendent & parallel mode
< 15Arms
Current ripple - max ripple from load
32 - 95°F (0 - 35°C)
Operating environment - temperature
5-90% non-condensing
Operating environment - humidity
2-power stages 4,055 lbs. (1,839 kg)
Weight
73 x 37 x 76.5 in. (185 x 94 x 194 cm)
Dimensions (L x W x H)
Operating range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +600
-300 to +300
-150 to +150
Independent
+8 to +600
-600 to +600
-150 to +150
Parallel
Accuracy & resolution Measurement
Accuracy (±)
Resolution
250mV or 0.15% of the output voltage
50mV
Voltage
250mA or 0.25% of the reading
20mA
Current independent (2 channels)
450mA or 0.35% of the reading
40mA
Current external parallel (1 channels)
ABC-170 / ABC-170 CE The ABC-170/170CE power processing system is used to meet fuel cell testing and sinking power needs. Originally developed for fuel cell testing applications and for systems that require additional sinking power, Webasto customers have also used this versatile machine to cycle hybrids and batteries.
The ABC-170 offers power from +125kW to - 170kW, with a voltage range of 8 to 445 VDC and a current range of +530ADC to - 640ADC.
Technical specifications
ABC-170
ABC-170 CE
3 Phase, 240 VAC
3 Phase, 400, 415 and 480 VAC
Input voltage options
340 A
203, 195, and 170 A respectively
Currency draw
60 Hz (50 Hz available)
50 Hz (60 Hz optional)
Frequency
Requires external isolation transformer with 225KVA, 240Vrms secondary
Internal transformer
Isolation transformer
> 99%
> 99%
Power factor
< 3% THD; IEEE 519 Compliant
< 3% THD; IEEE 519 Compliant
Harmonic distortion
Manual; Remote Operation System (ROS); DCOM Driver for LabVIEW; C++ and Visual Basic; CAN
Manual; Remote Operation System (ROS); DCOM Driver for LabVIEW; C++ and Visual Basic; CAN
Multiple user interfaces
< 0.5Arms
< 0.5Arms
Current ripple - indepdendent & parallel mode
< 15Arms
< 15Arms
Current ripple - max ripple from load
32 - 95°F (0 - 35°C)
32 - 95°F (0 - 35°C)
Operating environment - temperature
5-90% non-condensing
5-90% non-condensing 3,925 lbs. (1,780 kg) 73 x 30 x 71 in. (183 x 76 x 180 cm)
Operating environment - humidity
1,334 lbs. (605 kg)
Weight
46 x 26 x 55 in. (117 x 65 x 140 cm)
Dimensions (L x W x H)
Operating range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +420
-320 to +265
-170 to +125
Independent
+420 to +435
-160 to +160
-70 to +70
Optional range
+435 to +445
-90 to +90
-40 to +40
+8 to +420
-640 to +530
-170 to +125
Parallel
+420 to +435
-160 to +160
-70 to +70
Optional range
+435 to +445
-90 to +90
-40 to +40
Accuracy & resolution Measurement
Accuracy (±)
Resolution
250mV or 0.15% of the output voltage
20mV
Voltage
100mA or 0.25% of the reading
20mA
Current independent (2 channels)
200mA or 0.35% of the reading
40mA
Current external parallel (1 channels)
45
ABC-150 The ABC-150 was originally developed to support the design and development of the drivetrain and subsystems of the GM Impact, the first modern electric car. All Webasto power cycling systems are equipped with a real-time clock on the system’s control board that enables measurement of Ah and kWh during cycling. The ABC-150 offers power up to 125 kW, with a voltage range of 8 to 445 VDC and a current range of ±530 ADC. The ABC-150 is now the worldwide standard for the testing of advanced batteries, fuel cells, capacitors and other alternative energy technologies in the automotive, aerospace, stationary power and defense industries.
Technical specifications
ABC-150
3 Phase, 240Vrms, +10%/-15%, <5% imbalance
Input voltage options
325 A
Currency draw
60Hz (50 Hz available)
Frequency
Requires 150KVA external isolation transformer
Isolation transformer
> 99%
Power factor
< 3% THD; IEEE 519 Compliant
Harmonic distortion
Manual; Remote Operation System (ROS); DCOM Driv er for LabVIEW; C++ and Visual Basic; CAN
Multiple user interfaces
< 0.5 Arms
Current ripple - indepdendent & parallel mode
< 15 Arms
Current ripple - max ripple from load
32 - 95°F (0 - 35°C)
Operating environment - temperature
5-90% non-condensing
Operating environment - humidity
1,334 lbs (605 kg)
Weight
46 x 26 x 55 in. (117 x 65 x 140 cm)
Dimensions (L x W x H)
Operating range Configuration
Voltage (Vdc)
Current (Amps)
Power (kW)
+8 to +420
-265 to +265
-125 to +125
Independent
+420 to +435
-160 to +160
-70 to +70
Optional range
+435 to +445
-90 to +90
-40 to +40
+8 to +420
-530 to +530
-125 to +125
Parallel
+420 to +435
-160 to +160
-70 to +70
Optional range
+435 to +445
-90 to +90
-40 to +40
Accuracy & resolution Measurement
Accuracy (±)
Resolution
250mV or 0.15% of the output voltage
20mV
Voltage
100mA or 0.25% of the reading
20mA
Current independent (2 channels)
200mA or 0.35% of the reading
40mA
Current external parallel (1 channels)
MT-30 Webasto’s MT-30 is ideal for testing smaller applications such as battery modules, fuel stacks, partial modules and smaller components. This system provides an economical solution for a variety of testing needs while occupying a small footprint in the laboratory.
All Webasto power cycling systems are equipped with a real-time clock on the system’s control board that enables measurement of Ah and kWh during cycling.
Technical specifications
MT-30
3 Phase, 240, 380, 440 and 480 VAC
Input voltage options
130, 83, 71 and 66 A
Currency draw
60Hz (50 Hz available)
Frequency
Internal transformer
Isolation transformer
> 99%
Power factor
< 3% THD; IEEE 519 Compliant
Harmonic distortion
Manual; Remote Operation System (ROS); DCOM Driver for LabVIEW; C++ and Visual Basic; CAN
Multiple user interfaces
< 0.5Arms
Current ripple - indepdendent & parallel mode
< 15Arms
Current ripple - max ripple from load
32 - 95°F (0 - 35°C)
Operating environment - temperature
5-90% non-condensing
Operating environment - humidity
1,320 lbs (599 kg)
Weight
34 x 40 x 55 in. (87 x 102 x 140 cm)
Dimensions (L x W x H)
Operating range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+5 to +120
-330 to +330
-30 to +30
Channel A
+5 to +120
-170 to +170
-20 to +20
Channel B
+5 to +120
-500 to +500
-30 to +30
Parallel
Accuracy & resolution Measurement
Accuracy (±)
Resolution
125mV or 0.15% of the reading
20mV
Voltage
125mA or 0.25% of the reading
20mA
Current channel A
50mA or 0.25% of the reading
20mA
Current channel B
135mA or 0.25% of the reading
40mA
Current parallel
47
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