Marine Sunroof Catalog Webasto Product Range & Reference List
Ensuring mobility of the future Your solutions' partner in battery, thermal management and power test systems
Table of contents
Product portfolio
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eMobility products Standard Battery System Standard Battery Pro 40 Vehicle Interface Box (VIB) Vehicle Interface Gateway (VIG) Vehicle Interface Gateway Plus (VIG+)
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10 14 16 18 22 24 26
eBTM 2.0 (electric Battery Thermal Management 2.0) High Voltage Heaters (HVH 50/70, 100, 100 C, 100 C+, 120) eVTM (electrical Vehicle Thermal Management System)
360° Service
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eMobility case study
32
Power cycling & battery test systems
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History of innovation
37 38 41 42 43
900 EX ABC-600
ABC-170 / ABC-170 CE
ABC-150
Gustav Klein test systems
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Single-channel system I-TS-3870 / Single-channel system – overload I-TS-3870-ol Multi-channel system MI-TS-3871 / Multi-channel system – overload MI-TS-3871-ol
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52 56
Flex-channel system I-TS-3872 Case studies Battery Innovation Center (BIC)
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Ohio State University‘s Center for Automotive Research
3 63 62
Zero Motorcycles
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 250 kW High power advanced test system - fast, accurate & scalable
I-TS-3870 650 kW Single channel system for testing and simulation
ABC-170 125 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 systems. They maintain 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 With our scalable portfolio, we are able to accommodate your specific vehicle requirements and offer you the perfect configuration for your application.
Standardized & certified Our products are already in serial production and therefore thoroughly tested and certified. This way you can start directly with your electrification project.
Scalable system 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 Thanks to the standardization of our products, you bear no development costs. This enables you to easily integrate and quickly commission the vehicle.
Safety concept Our product portfolio has been certified in accordance with very high industry standards and therefore offers you a coordinated safety concept for maximum reliability.
360° service portfolio 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 CV Standard Battery System for commercial vehicles: the heart of every vehicle
The Webasto CV 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 CV Standard Battery System with a system configuration of 400 V and 800 V as well as up to 630 kWh Up to 18 CV Standard Battery Systems can be interconnected with the Vehicle Interface Gateway or up to 10 CV Standard Battery Systems with the Vehicle Interface Box
Future-proofing through further development of the battery system Vertical and horizo tal mounting positions allow flexible and easy integration
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 Isolation measurement, high voltage interlock and contactor monitoring included in every battery pack Temperature, voltage and current of different subcomponents are monitored Maintenance-free design
Norms & standards 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
Technical specifications
CV Standard Battery
Dimensions (L x W x H)
37.8 x 27 x 11.9 in (960 x 686 x 302 mm)
Weight
650 lbs. (295 kg) ** per pack
Installed energy Nominal capacity Depth of discharge
35 kWh
Company Standards: LV 123, LV 124 EMC: ISO 11452, ISO 7637, CISPR 25
99 Ah
80 / 90%
Voltage range Energy density
280 V – 400 V (~ 350 nominal) ~203 Wh / l, >118 Wh / kg
System requirements and the environment 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
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
113 / 112 kW
Up to 3.000 cycles*
Calendric lifetime
Up to 8 years
Volume flow Pressure loss
10 l/min. < 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 specifications
Norms & standards Homologation: ECE R100, ECE R10
Battery pack
Dimensions (L x W x H)
37.79 x 27 x 11.88 in (960 x 686 x 302 mm)
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 Voltage range Energy density
~40 kWh
99 Ah
Company standards: LV 123, LV 124 EMC: ISO 11452, ISO 7637, CISPR 25 Transport: UN T38.3
264 V – 418 V
~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
Safety features Physical separation between high voltage and cooling connectors Desiccant cartridges to avoid condensation over lifetime Integrated thermal runaway detection in each system State-of-the-art pressure equalization Isolation measurement, high voltage interlock and contactor monitoring included in every battery pack Temperature, voltage and current of different subcomponents are monitored
Under evaluation
Up to 3.000 cycles
Calendric lifetime
Up to 8 years
Volume flow per battery pack Pressure loss per battery pack
10 l/min. < 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. Production has been designed to meet the highest safety requirements and fulfills all quality demands far beyond automotive requirements. Our CO 2 -neutral battery production in in Schierling, Germany
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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 (350-400 kWh)
AUX connection: Continuous current: 20 A Peak current: - Integrated AC charging Continuous current: 67 A Peak current: -
DC Charging Continuous current: 200 A Peak current: -
Powertrain / Recuperation: Continuous current: 150 A Peak current: 250 A
Vehicle Interface Box (VIB)
To ensure the scalability of our Standard Battery Systems, we offer the Vehicle Interface Box (VIB). The VIB is not only a very efficient interface, but also combines the functions of power distribution, master BMS and fuses in one robust housing.
Specially designed for the Webasto Standard Battery Systems 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 Central communication interface to battery system Separate CAN communication for vehicle (vehicle and battery pack CAN)
Technical specifications
Norms & standards
VIB
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.)
Product dimensions (L x W x H)
21.6 x 27 x 6.1 in (548 x 686 x 155 mm)
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
Additional norms & standards*: ECE R100, UN GTR No. 20, ISO 16750, ISO 12405, ISO 19453
Continuous current CH OBC
67 A
* Tests & Requirements partially fulfilled.
Continuous current CH DC fast charging Peak current DCH (30 sec.) Peak current recuperation (30 sec.) Operational temperature
200 A
580 A 500 A
-40 to 185°F (-40 to +85°C)
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Small but powerful: Our master BMS solution
Vehicle Interface Gateway (VIG)
Compact interface between battery and vehicle
Small and flexible master BMS
Suitable for 400 V and 800 V connections
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 (630-720 kWh)
Vehicle Interface Gateway (VIG)
Vehicle Interface Gateway (VIG)
In addition to our powerful and intelligent VIB, 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 Systems and when used in a limited installation space.
Specially designed for the Webasto Standard Battery Systems 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
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 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 Features:
Technical specifications
Norms & standards 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
VIG
Product dimensions (L x W x H)
12.4 x 1.3 x 4.2 in (314 x 33 x 106 mm)
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
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
-40 to 185 °F (-40 to +85 °C)
*with 800 V configuration
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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 630-720 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 battery packs at a system voltage of 400 or 800 V. This creates a powerful multipack system with an energy content of up to 630-720 kWh.
High-performance master BMS enables the scalability of the battery system Configuration of up to 18 battery packs 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
Norms & standards CE-mark: CE certified for mobile machines* Safety: ISO 26262 (ASIL C) Vehicle communication: CAN and SAE J1939 Bus con- form to ISO 11898 IP protection class: IP 67 / EN 60529 Standards: LV 124 EMC: ISO 13766, ISO 14982, EN 12895, EN 61000-6
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)
Weight
~1 lb (~0.45 kg)
LV supply voltages HV compability Scalable energy
12 and 24 V 400 & 800 V
35 – 630 kWh 40 – 720 kW (max. 18 battery systems )
Additional norms & standards: ISO 16750, ISO 19453 * CE certified for various vehicle types (listing upon request) ** Tests & Requirements partially fulfilled
Scalable power
up to 1,109 kW
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
-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 standalone 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. 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 (1006 x 694 x 303 mm) Guarantees an optimal operating temperature of the battery and thus extends the service life of the entire system
>> Cooling Under stress or in warm weather conditions
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
>> Heating In extremely cold ambient conditions
>> Temperature control Dynamic temperature adjustment during driving phases
Low voltage power supply included on board Exceptionally high dimension/power ratio
>> Pre-conditioning During battery charging phases
Technical specifications
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
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
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)
Compressor
39.6 x 27.3 x 11.9 in (1006 x 694 x 303 mm) < 198 lbs. (< 90 kg)
Dimensions L x W x H
Weight
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Perfect climate for your electric vehicle
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:
High Voltage Heaters (HVH) High efficient heating system for your vehicle
Our 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.
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 HVH 50 Gen 1.5
HVH 120
HVH 70 Gen 1.5 HVH 100 Compact HVH 100 Compact+
Heating performance HV voltage range (DC)
5 / 7 kW
10 kW
12 kW
100 – 490 V
250 - 880 V
LV voltage Efficiency
12 V
12 / 24 V
> 95%
Controllability steps
50 W
100 W
Dimensions
11.2 x 7.9 x 2.1 in (284 x 200 x 54 mm)
11.2 x 7.9 x 2.8 in. (284 x 201 x 72 mm)
12.8 x 7.9 x 2.8 in. (326 x 201 x 72 mm)
Weight
4.4 lbs (2.0 kg)
5.0 lbs (2.3 g)
13.2 (2.6 g)
Temperature range for heating Temperature range for ambient
-40 to 194 °F (-40 to 90 °C) -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
Dielectric strength (DC) Coolant connection
2,500 V
VDA 19 mm
VDA 20 mm
IP protection class
IP 6K9K IP 6K7
HV connection NV connection
TYCO HVA280 Type A
TYCO HVA280 Typ E
LV FEP connector 8 PIN with integrated de-aerating membrane
Interlock
Passive
Electrical safety Functional safety
ISO 6469 Part 3
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
Isolation resistance
> 50 MΩ
> 30 MΩ
Service life
15 years or 12,000 heating hours
15 years or 15,000 heating hours
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electrical Vehicle Thermal Management System (eVTM)
For the electrical Vehicle Thermal Management (eVTM) from Webasto, various cooling and heating units work together in one system to ensure pleasant temperatures in the driver's cab and optimum conditions for batteries, powertrain and electronics. The heat is provided by a High Voltage Heater (HVH) with an efficiency of over 95 percent. The system also incorporates the waste heat generated in the vehicle. The ultra-flat air conditioning systems are installed between the roof and the ceiling panelling, which means they do not require any valuable interior space. eVTM and its components can be adapted for different vehicles and installation spaces. The thermal system is suitable for electrically powered buses, ambulances, trucks, motorhomes, agricultural vehicles and construction machinery.
Extended range Conditioning the battery cells increases the service life of the batteries, shortens charging cycles and reduces the total cost of ownership (TCO).
Energy efficiency through heat recovery eVTM uses the waste heat from electronic components to control the temperature of the battery, electronics and vehicle interior. This maximizes the efficiency of the heat pump.
Flexible and upgradeable system The components can also be easily integrated into existing series productions. Software updates are possible at any time.
Intelligent coolant utilization An innovative valve system distributes and mixes the coolant
optimally. It is only used in the electric heat pump system. The system itself is based on water.
Extend Battery Life & Boost Performance with Webasto‘s electrical Vehicle Thermal Management (eVTM) System
Waste Heat Recovery n Electrical drives n PEEM Systems
Passenger HVAC n Integrated n Rooftop
Heat Pump n Primary 1234yf loop n Secondary water/glycol loop
Driver HVAC n Air Conditioning n Heating
Traction Battery n Webasto Standard Battery n Any other water cooled battery
High Voltage Heater n Additional 7, 10 or 12 kW heating power
Floor Heaters n Additional heating in winter times
Radiator n Cold absorption n Heat rejection
Intelligent Valves System
Product specifications
The configuration of the eVTM depends on various factors such as the type and size of vehicle, the purpose and area of use, the size of the space to be temperature-controlled and the number of people in the vehicle. The thermal system and the choice of device components are individually adapted to customer requirements. For an initial assessment, please contact a Webasto sales representative.
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Single-Channel System 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 CO 2 -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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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, 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. In-house testing & prototyping in Hengersberg
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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 PowerBoxes from our products, each of which has 140 kWh of energy 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 12m 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.
Read the detailed case studies at webasto.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 predevelopment to the start of series production.
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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. Power Cycling & Battery Test Systems
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 and test systems – and for good reason. For more than three decades, Webasto’s breakthroughs in the testing, charging and development of batteries have been setting the standard for high power test equipment. 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, utilities, defense contractors, and government agencies. Our customers recognize the high current / high power capability, comprehensive operating envelope, and reliability of these Power Test Systems. The Webasto Power Test Systems product line is an industry leading family of grid tied DC power processing hardware and software solutions (excluding cell testing), that are used 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.
1901 Wilhelm Baier founds a company that goes by the name of: “Esslinger Draht und Eisenwarenfabrik Wilhelm Baier, Esslingen/Neckar“
1908 Wilhelm Baier Senior creates the new name Webasto out of his initials and the toponym Stockdorf
1987 Sunraycer wins 1,864-mile World Solar Challenge, with its small, but powerful electric motor
1990 GM Impact, electric concept car, debuts at the LA Auto Show
1996 EV1 becomes the first mass-produced modern electric car
2013 Launch of 900EX, a high power battery cycler
Today Webasto works with the world’s most innovative companies to test their electric-mobility solutions
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Advanced High Power Test System
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 ± 250kW, or combined, it can scale to ±1MW. 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.
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
900 EX
900 EX
Technical Specifications
900EX
Independent
Parallel
Multi-unit
AC Voltage
3 Phase, 380, 400, 415, 440 and 480 VAC
AC Voltage Tolerance
+10%/-15%
AC Current Frequency
435, 413, 398, 375, and 344 Amps respectively
50/60 Hz ±2Hz, 480V only 60Hz ±2Hz
Power Factor
≥ 0.95
Harmonic Distortion
3.7% THD; IEEE 519 Compliant
Power efficiency DC Voltage Max DC Current Max DC Power Max
92% 900V
±500A
±1000A ±250kW
±4000A
±250kW
±1000kW
Operating environment - temperature Storage environment - temperature Operating environment - Humidity
0-35 °C 0-60 °C
0-90% Noncondensing
Weight
7,610 lb (3,461 kg)
Dimensions
72” W x 76.5” H x 39” D (183cm W x 194cm H x 99cm D)
Performance Data Control Interface / Output data sampling
Local Control / Fiber to Ethernet 10ms / CAN 10ms / RS-232 50ms LabView; C++ and visual basic, Remote operation system (ROS)
Control Software Options
Rise time voltage - step (0-500v) Rise time voltage - step (0-300a)
3ms
7ms
7ms
0.5ms
0.6ms
0.9ms
Slew rate voltage Slew rate current Slew rate power
171V/ms 769A/ms 274kW/ms
89V/ms
76V/ms
1282A/ms 500kW/ms
1935A/ms 833kW/ms
Current ripple - independent & parallel mode
0.61A
0.82A
1.06A @1000A 50Hz (500V) 50Hz (700A) 50Hz (250kW)
50Hz (500V) 75Hz (250V) 175Hz (500A) 100Hz (150kW)
Tracking bandwidth voltage Tracking bandwidth current Tracking bandwidth power
50Hz (500V) 150Hz (700A) 150Hz (250kW)
Operating Range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +750
-500 to +500 -400 to +400 -300 to +300 -1000 to +1000 -800 to +800 -600 to +600
-250 to +250 -225 to +225 -200 to +200 -250 to +250 -225 to +225 -200 to +200
Independent
+751 to +825 +826 to +900
+8 to +750
Parallel
+751 to +825 +826 to +900
Accuracy & Resolution Measurement
Accuracy (±) 0.05% full scale 0.05% full scale
Resolution
Voltage
16mV 16mA
Current Independent (2 channels)
39
*Ask us about our power curves
Power Cycling & Measurement Solutions
ABC-150
ABC-600
ABC-170 / ABC-170 CE
ABC-600
Dual independently controlled channels Multiple control interfaces/options Automatic shutdown on loss of power (anti-islanding) Energy returned to the grid at 92+% efficiency Features:
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 600VDC and a current range of ±600ADC.
Technical Specifications
ABC-600
AC Voltage
3 Phase, 400, 440 and 480 VAC
AC Voltage Tolerance
+10%/-15%
AC Current Frequency
240, 218 and 200 Amps respectively 60Hz ±2Hz (50Hz ±2Hz available)
Power Factor
>0.99
Harmonic Distortion
< 3% THD; IEEE 519 Compliant
Power efficiency DC Voltage Max DC Current Max DC Power Max
>90% 600V ±300A
±150kW 0-35 °C 0-60 °C
Operating environment - temperature Storage environment - temperature Operating environment - Humidity
0-90% Noncondensing
Weight
5,900 lb (2,676 kg)
Dimensions
73” W x 76.5” H x 37” D (185cm W x 194cm H x 94cm D)
Performance Data Control Interface / Output data sampling
Local Control / CAN 33ms / RS-232 50ms
Control Software Options
LabView; C++ and visual basic, Remote operation system (ROS)
Rise time voltage - step (0-300a)
2.4ms
Slew rate current
125A/ms
Operating Range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
Independent
+8 to +600 +8 to +600
-300 to +300 -600 to +600
-150 to +150 -150 to +150
Parallel
Accuracy & Resolution Measurement
Accuracy (±)
Resolution
Voltage
0.1% full scale 0.1% full scale
50mV 20mA
Current Independent (2 channels)
41
*Ask us about our power curves
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, 415 VAC
AC Voltage
3 Phase, 480 VAC
AC Voltage Tolerance
+10%/-15%
AC Current Frequency
185 Amps 60Hz ±2Hz
213 Amps
50Hz ±2Hz (60Hz ±2Hz available)
Power Factor
>0.99
Harmonic Distortion
< 3% THD; IEEE 519 Compliant
Power efficiency DC Voltage Max DC Current Max DC Power Max
96% 445V
+265A,-320A
+125kW, -170kW
Operating environment - temperature Storage environment - temperature Operating environment - Humidity
0-35 °C 0-60 °C
0-90% Noncondensing
Weight
3,925 lbs (1,780 kg)
Dimensions
73” W x 71” H x 30” D (183cm W x 180cm H x 76cm D)
Performance Data Control Interface / Output data sampling
Local Control / CAN 33ms / RS-232 100ms
Control Software Options
LabView; C++ and visual basic, Remote operation system (ROS)
Rise time voltage - step (0-400v) Rise time voltage - step (0-265a)
8.18ms 1.395ms
Slew rate voltage Slew rate current Slew rate power
48.90V/ms 189.96A/ms 166.67kW/ms
Current ripple - independent & parallel mode
<0.077Arms / <0.057Arms
Operating Range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +420
-320 to +265 -160 to +160
-170 to +125
Independent
+420 to +435 +435 to +445
-70 to +70 -40 to +40
-90 to +90
+8 to +420
-640 to +530 -160 to +160
-170 to +125
Parallel
+420 to +435 +435 to +445
-70 to +70 -40 to +40
-90 to +90
Accuracy & Resolution Measurement
Accuracy (±)
Resolution
Voltage
0.1% full scale 0.1% full scale
20mV 20mA
Current Independent (2 channels)
*Ask us about our power curves
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 125kW, with a voltage range of 8 to 445VDC and a current range of ±530ADC. The ABC-150 is used worldwide 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 AC Voltage 3 Phase, 240VAC AC Voltage Tolerance +10%/-15% AC Current 335 Amps Frequency 60Hz ±2Hz (50Hz ±2Hz available) Isolation Transformer Requires 150KVA external isolation transformer (240Vrms secondary) Power Factor >0.99 Harmonic Distortion < 3% THD; IEEE 519 Compliant Power efficiency 95% DC Voltage Max 445V DC Current Max ±265A DC Power Max ±125kW Operating environment - temperature 0-35 °C Storage environment - temperature 0-60 °C Operating environment - Humidity 0-90% Noncondensing Weight 1,400 lbs (635 kg) Dimensions 46” W x 55” H x 26” D (117cm W x 140cm H x 65cm D) Performance Data Control Interface / Output data sampling Local Control / CAN 33ms / RS-232 100ms Control Software Options LabView; C++ and visual basic, Remote operation system (ROS) Rise time voltage - step (0-400v) 5.98ms Rise time voltage - step (0-265a) 1.375ms Slew rate voltage 66.89V/ms Slew rate current 192.73A/ms Slew rate power 165.22kW/ms Current ripple - independent & parallel mode <0.058Arms / <0.38Arms
Operating Range Configuration
Voltage (Vdc)
Current (Adc)
Power (kW)
+8 to +420
-265 to +265 -160 to +160
-125 to +125
Independent
+420 to +435 +435 to +445
-70 to +70 -40 to +40
-90 to +90
+8 to +420
-530 to +530 -160 to +160
-125 to +125
Parallel
+420 to +435 +435 to +445
-70 to +70 -40 to +40
-90 to +90
Accuracy & Resolution Measurement
Accuracy (±)
Resolution
Voltage
0.1% full scale 0.1% full scale
20mV 20mA
Current Independent (2 channels)
43
*Ask us about our power curves
Testing and simulation
Bidirectional power supplies for testing and simulating batteries, fuel cells, drives and further components.
Single-Channel System DC source / sink: I-TS-3870 Single-channel system for testing and simulating batteries, fuel cells and powertrains. One output with up to 1200 V and 1200 A. Maximum power in single operation 650 kW, up to 2.6 MW in parallel operation.
Multi-Channel System DC source / sink: MI-TS-3871
Multi-channel system for energy-saving tests and simulations. Two or four outputs, up to 1200 V and 1200 A per output (without galvanic isolation between the DC outputs).
Flex-Channel System DC source / sink: I-TS-3872
NEW
State-of-the-art, water-cooled DC source / sink. Depending on requirements, the system can be used in single, serial or parallel mode. Voltages of up to 1500 V are possible in serial mode.
Accessories for test and simulation systems
Additional accessories are available to compliment and round off our power supplies.
PDSB (Power distribution switching box)
Capacitor box Touch-proof housing with capacitors to stabilize the control loop.
Control cabinet for parallelizing several DC outputs or for swit- ching a DC output to different test benches. Over 50 different variants are available.
PDU (Power distribution unit)
DCU (Discharge Unit)
Control cabinet for local connection of the test object in the test bench. Additional capacitors and isolating devices can also be integrated here.
If the possibility of AC mains recovery is not sufficient, the Discharge Unit offers the possibility of using discharge resistors to reduce the energy of the device under test in the battery emulation.
45
Gustav Klein test systems
I-TS-3870 Standard
I-TS-3870-ol overload
60, 100, 120, 160 250, 320, 400, 500, 650
60, 100, 160, 250, 320, 400, 500
Power rating in kW
Power overload capability performance
Max. DC output voltage in V
1000, 1200
1000
Voltage with center point
± 200 ± 600 ± 1000 ± 1200
± 200 ± 600 ± 1000 ± 1200
Current range in A (per channel)
1
1
Number of DC channels
2 Systems max. 1000 kW max. ± 2400 A 4 Systems max. 2000 kW max. ± 4800 A
2 Systems max. 1300 kW max. ± 2400 A 4 Systems max. 2600 kW max. ± 4800 A
Parallel switching capability (flexible)
Parallel switching capability (rigid)
IP20, IP21, IP23, IP54
Available protection classes
IP20, IP21, IP23, IP54
Air cooling
Water cooling
CAN, Modbus TCP, Ethernet, VNC Profibus, Profinet, EtherCAT, LabVIEW, Matlab/Simulink
CAN, Modbus TCP, Ethernet, VNC Profibus, Profinet, EtherCAT, LabVIEW, Matlab/Simulink
Communication interfaces (standard) Communication interfaces (optional)
Not available
Standard
Optional
Gustav Klein test systems
MI-TS-3871 Standard
MI-TS-3871-ol overload
I-TS-3872 Standard
Power rating in kW
250, 320, 400, 500, 650
250, 320, 400, 500
300, 600
Power overload capability performance
1000, 1200
1000
2x 750, 1500
Max. DC output voltage in V
Voltage with center point
± 1000 (750 V) ± 1000 (1500 V) ± 2000 (750 V) 1 (1500 V) 2 (750 V) 2 Systems max. 1200 kW
± 1000 ± 1200
± 1000 ± 1200
Current range in A (per channel)
2 oder 4
2 oder 4
Number of DC channels
2 oder 4 Channels max. 500 kW
2 oder 4 Channels max. 650 kW max. ± 2400 A (2 Chan.) max. ± 4800 A (4 Chan.) 2 oder 4 Channels max. 650 kW max. ± 2400 A (2 Chan.) max. ± 4800 A (4 Chan.)
Parallel switching capability (flexible)
max. ± 2000 A (1500 V) max. ± 4000 A (750 V)
max. ± 2400 A (2 Chan.) max. ± 4800 A (4 Chan.) 2 oder 4 Channels max. 500 kW max. ± 2400 A (2 Chan.) max. ± 4800 A (4 Chan.)
2 Systems max. 1200 kW max. ± 4000 A
Parallel switching capability (rigid)
IP20, IP21, IP23, IP54
IP20, IP21, IP23, IP54
IP54
Available protection classes
Air cooling
Water cooling
CAN, Modbus TCP, Ethernet, VNC Profibus, Profinet, EtherCAT, LabVIEW, Matlab/Simulink
CAN, Modbus TCP, Ethernet, VNC Profibus, Profinet, EtherCAT, LabVIEW, Matlab/Simulink
CAN, Modbus TCP, Ethernet, VNC
Communication interfaces (standard) Communication interfaces (optional)
Profibus, Profinet, EtherCAT
Not available
Standard
Optional
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