910132_PTS_GK Brochure

Marine Sunroof Catalog Webasto Product Range & Reference List

Power Cycling & Test Systems The Standard for Advanced Testing

Table of contents

About us

Put your concepts to the test History of innovation

4 5

Power test systems product portfolio

900 EX

7 9

ABC-170 / ABC-170 CE

ABC-150 MT-30

10 11

Testing and simulation

Accessories for test and simulation systems

Gustav Klein test systems

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

20 24

Flex-channel system I-TS-3872

Power Test Systems accessories

Case studies

Battery Innovation Center (BIC) Ohio State University‘s Center for Automotive Research

30 33 34

Zero Motorcycles Spiers New Technology

Put Your Concepts To The Test Webasto Power Test Systems, located in Fenton, MI, is a pioneer of bi-directional and regenerative DC power test equipment. With a wide power range (5kW to 2.6MW), our Power Cyclers can handle virtually any DC supply or load requirement. This equipment enables manufacturers to develop, design, and test their batteries, fuel cells, ultra capacitors, hybrid energy systems, motors, generators, and powertrain components. 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.

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

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

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

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)

*Ask us about our power curves

evtestsystems.com

Power Cycling & Measurement Solutions

ABC-170 / ABC-170 CE

ABC-150

MT-30

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-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, 400 and 480 VAC

AC Voltage Tolerance

+10%/-15%

AC Current Frequency

220, 185 Amps

213 Amps respectively

60Hz ±2Hz (50Hz ±2Hz available)

50Hz ±2Hz

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)

evtestsystems.com

*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% 335 Amps

AC Current Frequency

60Hz ±2Hz (50Hz ±2Hz available)

Requires 150KVA external isolation transformer (240Vrms secondary)

Isolation Transformer

Power Factor

>0.99

Harmonic Distortion

< 3% THD; IEEE 519 Compliant

Power efficiency DC Voltage Max DC Current Max DC Power Max

95% 445V

±265A

±125kW 0-35 °C 0-60 °C

Operating environment - temperature Storage environment - temperature 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) Rise time voltage - step (0-265a)

5.98ms 1.375ms

Slew rate voltage Slew rate current Slew rate power

66.89V/ms 192.73A/ms 165.22kW/ms

Current ripple - independent & parallel mode

<0.058Arms / <0.38Arms

Operating Range Configuration

Voltage (Vdc)

Current (Adc)

Power (kW)

+8 to +420

-320 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)

*Ask us about our power curves

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

AC Voltage

3 Phase, 380, 440 and 480 VAC

AC Voltage Tolerance

+10%/-15%

AC Current Frequency

80, 73 and 67 Amps

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

94% 120V

ChA ±330A. ChB ±170A

±30kW 0-35 °C 0-60 °C

Operating environment - temperature Storage environment - temperature Operating environment - Humidity

0-90% Noncondensing

Weight

1,320 lbs (599 kg)

Dimensions

34.5” W x 55” H x 36” D (87.6cm W x 140cm H x 91.4cm 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 (0-330a)

21.08ms

Slew rate current

15.65A/ms

Operating Range Configuration

Voltage (Vdc) CH A +5 to +120 ‘CH B +5 to +120

Current (Adc)

Power (kW)

-330 to +330 -170 to +170 -500 to +500

-30 to +30 -20 to +20 -30 to +30

Independent

Parallel

+5 to +120

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 11

evtestsystems.com

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.

evtestsystems.com

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

Current range in A (per channel)

Number of DC channels

2 Systems max. 1300 kW max. ± 2400 A 4 Systems max. 2600 kW max. ± 4800 A

2 Systems max. 1000 kW max. ± 2400 A 4 Systems max. 2000 kW max. ± 4800 A

Parallel switching capability (flexible)

Parallel switching capability (rigid)

Available protection classes

IP20, IP21, IP23, IP54

Air cooling

Water cooling

Communication interfaces (standard) Communication interfaces (optional)

CAN, Modbus TCP, Ethernet, VNC Profibus, Profinet, EtherCAT, LabVIEW, Matlab/Simulink

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

Max. DC output voltage in V

1000, 1200

1000

2x 750, 1500

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

Current range in A (per channel)

2 oder 4

Number of DC channels

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.)

2 oder 4 Channels max. 500 kW

Parallel switching capability (flexible)

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.)

max. ± 2000 A (1500 V) max. ± 4000 A (750 V)

2 Systems max. 1200 kW max. ± 4000 A

Parallel switching capability (rigid)

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

Communication interfaces (standard) Communication interfaces (optional)

Profibus, Profinet, EtherCAT

Not available

Standard

Optional

Single-Channel System I-TS-3870 / I-TS-3870-ol (overload)

fuel cell

Fuel cell test

Electrolyzer test

Battery test

Battery emulation

Power- train test

Circuit diagram

DC Our high-performance test system I-TS-overload (Infeed test system – overload) is a high dynamic, bidirectional DC power supply with continuous and seamless transition from source to sink operation. The outstanding performance is the basis for a wide range of applications in the automotive, hydrogen and laboratory sectors. AC The I-TS-3870 overload version of our Infeed test system enables a short-term overload at the DC output. This means that certain operating points outside the nominal range can be approached and thus requirements in the test sequence can be fulfilled by the I-TS. DC DC DC The technical data of the DC converter in terms of output voltage and output current remain unchanged. However, up to 50 % higher rated output load is available for a maximum of 60 s. The subsequent regeneration time ( ≤ nominal load) is 5 times the overload time. DC AC DC

General technical data I-TS-3870 / I-TS-3870-ol AC mains voltage / AC mains frequency

380 / 400 / 440 / 480 / 690 V ± 10 %, 3-phase, PE, 50 / 60 Hz ± 5 %

Measurement accuracy

Voltage: 16 Bit ADC // Current: 16 Bit ADC Voltage: 0.1 % fs // Current: 0.1 % fs

Control accuracy

Ripple voltage / current Voltage tolerance dynamic (0-100 % INom in 3 ms) Short circuit performance

≤ 0.1 % eff. fs Battery tester < 3 % fs Battery emulator < 1 % fs

Short circuit proof: Systems up to 600 A: Icw: 3 kA Systems with 1000 A: Icw: 8 kA Systems with 1200 A: Icw: 15 kA

Permissible environmental conditions: Storage as per EN 60721-3-1 Transport as per EN 60721-3-2 Operation as per EN 60721-3-3

1K21 / 1M11, +5 to +40 °C 2K12 / 2M4, -45 to +70 °C 3K22 / 3M11, +5 to +40 °C

Cooling method

Enforced air cooling (IP20, IP21, IP23) // enforced water cooling (IP54)

Safety of machinery - Safety-related parts of control systems

EN ISO 13849-1 EN ISO 13849-2

Safety of machinery

EN 60204-1 Exception: • Sec. 11.3 Protection type see Techn. Data • Sec. 13.2 Identification of conductors EN 61000-2-4 Class 3 EN 61000-6-2 EN 61000-6-4 respectively EN 55011 (Tab. 2) EN 61800-3 Cat.C2 (A1)

EMC Standards

Performance hyperbole

U max.

I min.

I max.

evtestsystems.com

Type

Power in kW Current in A Dimensions (W x D x H in mm)

Voltage range 5 – 1000 V I-TS-3870-1000-60-200 I-TS-3870-1000-100-200 I-TS-3870-1000-100-600 I-TS-3870-1000-100-1000 I-TS-3870-1000-100-1200 I-TS-3870-1000-160-200 I-TS-3870-1000-160-600 I-TS-3870-1000-160-1000 I-TS-3870-1000-160-1200 I-TS-3870-1000-250-600 I-TS-3870-1000-250-1000 I-TS-3870-1000-250-1200 I-TS-3870-1000-320-600 I-TS-3870-1000-320-1000 I-TS-3870-1000-320-1200 I-TS-3870-1000-400-600 I-TS-3870-1000-400-1000 I-TS-3870-1000-400-1200 I-TS-3870-1000-500-600 I-TS-3870-1000-500-1000 I-TS-3870-1000-500-1200 I-TS-3870-1000-650-1000 I-TS-3870-1000-650-1200 Voltage range 10 - 1200 V I-TS-3870-1200-320-600 I-TS-3870-1200-320-1200 I-TS-3870-1200-650-1200

200 200 600

1400 x 1000 x 2000

100 100 100 100 160 160 160 160 250 250 250 320 320 320 400 400 400 500 500 500 650 650

(1000 + 1000) x 800 x 2000 (1000 + 1200) x 800 x 2000 (1000 + 1200) x 800 x 2000 (1000 + 1200) x 800 x 2000 (1200 + 1000) x 800 x 2000 (1200 + 1200) x 800 x 2000 (1200 + 1200) x 800 x 2000 (1200 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000

1000 1200

200 600

1000 1200

600

1000 1200

600

1000 1200

600

(1200 + 1200 + 1200) x 800 x 2000 (1200 + 1200 + 1200) x 800 x 2000 (1200 + 1200 + 1200) x 800 x 2000 (1400 + 1200 + 1200) x 800 x 2000 (1400 + 1200 + 1200) x 800 x 2000 (1400 + 1200 + 1200) x 800 x 2000 (1600 + 1200 + 1200) x 800 x 2200 (1600 + 1200 + 1200) x 800 x 2200

1000 1200

600

1000 1200 1000 1200

320 320 650

600

(1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000

1200 1200

(1600 + 1200 + 1200) x 800 x 2200

These types are particularly popular by our customers.

Type

Power in kW

Current in A

Dimensions (W x D x H in mm)

Overload in % for 60 s then 3 min cooling time at nominal load

Voltage range 5 - 1000 V

I-TS-3870-1000-60-200-ol I-TS-3870-1000-100-200-ol I-TS-3870-1000-100-600-ol I-TS-3870-1000-100-1000-ol I-TS-3870-1000-100-1200-ol I-TS-3870-1000-160-600-ol I-TS-3870-1000-160-1000-ol I-TS-3870-1000-160-1200-ol I-TS-3870-1000-250-600-ol I-TS-3870-1000-250-1000-ol I-TS-3870-1000-250-1200-ol I-TS-3870-1000-320-600-ol I-TS-3870-1000-320-1000-ol I-TS-3870-1000-320-1200-ol I-TS-3870-1000-400-600-ol I-TS-3870-1000-400-1000-ol I-TS-3870-1000-400-1200-ol I-TS-3870-1000-500-1000-ol I-TS-3870-1000-500-1200-ol

200 200 600

50% 50% 50% 50% 50% 50% 50% 50% 25% 25% 25% 25% 25% 25% 25% 25% 25% 25% 25%

(1000 + 1000) x 800 x 2000 (1200 + 1000) x 800 x 2000 (1200 + 1200) x 800 x 2000 (1200 + 1200) x 800 x 2000 (1200 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000 (1400 + 1200) x 800 x 2000

100 100 100 100 160 160 160 250 250 250 320 320 320 400 400 400 500 500

1000 1200

600

1000 1200

600

1000 1200

600

1000 1200

600

1000 1200 1000 1200

These types are particularly popular by our customers.

evtestsystems.com

Multi-Channel System MI-TS-3871 / MI-TS-3871-ol (overload)

Our high-performance test system MI-TS (Multichannel Infeed test system) is a multi-channel, highly dynamic, bidirectional DC power supply with continuous and seamless transition from source to sink mode. Thanks to its multi-channel capability and outstanding performance, the MI-TS is the ideal test system for a wide range of applications in the automotive, hydrogen and laboratory sectors. At the same time, it offers the possibility of increasing performance thanks to parallel output channels.

fuel cell

Fuel cell test

Electrolyzer test

Battery test

Battery emulation

Power- train test

Our high-performance test system MI-TS (Multichannel Infeed test system – overload) is a multi-channel, highly dynamic, bidirectional DC power supply with continuous and seamless transition from source to sink mode. Thanks to its multi-channel capability and outstanding performance, the MI-TS is the ideal test system for a wide range of applications in the automotive, hydrogen and laboratory sectors. The MI-TS-3871-overload version of our multichannel Infeed test system enables a short-term overload at the DC output and also offers the option of parallel output channels. This means that certain operating points outside the nominal range can be approached and thus requirements in the test sequence can be fulfilled by the MI-TS. The technical data of the DC converter in terms of output voltage and output current remain unchanged. However, a nominal output load up to 50 % higher is available for a maximum of 60 s. The subsequent regeneration time ( ≤ nominal load) is 5 times the overload time.

General technical data MI-TS-3871 AC mains voltage / AC mains frequency

380 / 400 / 440 / 480 / 690 V ± 10 %, 3-phase, PE, 50 / 60 Hz ± 5 %

Measurement accuracy

Voltage: 16 Bit ADC // Current: 16 Bit ADC Voltage: 0.1 % fs // Current: 0.1 % fs

Control accuracy

Ripple voltage / current Voltage tolerance dynamic (0-100 % INom in 3 ms) Short circuit performance

≤ 0.1 % eff. fs Battery tester < 3 % fs Battery emulator < 1 % fs

Short circuit proof: Systems up to 600 A: Icw: 3 kA Systems with 1000 A: Icw: 8 kA Systems with 1200 A: Icw: 15 kA

Permissible environmental conditions: Storage as per EN 60721-3-1 Transport as per EN 60721-3-2 Operation as per EN 60721-3-3

1K21 / 1M11, +5 to +40 °C 2K12 / 2M4, -45 to +70 °C 3K22 / 3M11, +5 to +40 °C

Cooling method

Enforced air cooling (IP20, IP21, IP23) // enforced water cooling (IP54)

Safety of machinery - Safety-related parts of control systems

EN ISO 13849-1 EN ISO 13849-2

Safety of machinery

EMC standards

Circuit diagram

evtestsystems.com

Type

Channels Power in kW Current in A Dimensions (W x D x H in mm)

Voltage range 5 – 1000 V

MI-TS-3871-1000-250-1000-2 2 MI-TS-3871-1000-320-1200-2 2 MI-TS-3871-1000-400-600-4 4 MI-TS-3871-1000-400-1000-2 2 MI-TS-3871-1000-500-1000-2 2 MI-TS-3871-1000-650-1000-4 4

250 320 400 400 500 650

1000 1200

(1400 + 1200 + 1200) x 800 x 2000 (1400 + 1200 + 1200) x 800 x 2000

600

(1200 + 1200 + 1200 +1200 + 1200 + 1200) x 800 x 2000

1000 1000 1000

(1200 + 1200 + 1200 + 1200) x 800 x 2000 (1400 + 1200 + 1200 + 1200) x 800 x 2000

(1600 + 1200 + 1200 + 1200 + 1200 + 1200) x 800 x 2200

Voltage range 10 – 1200 V

MI-TS-3871-1200-320-1200-2 2 MI-TS-3871-1200-320-600-4 4 MI-TS-3871-1200-650-1200-2 2

320 320 650

1200

(1400 + 1200 + 1200) x 800 x 2000

600

(1400 + 1200 + 1200 + 1200 + 1200) x 800 x 2000 (1600 + 1200 + 1200 + 1200) x 800 x 2200

1200

These types are particularly popular by our customers. Excerpt from the product range, over 400 types available.

Type

Channels Power in kW Current in A Dimensions (W x D x H in mm)

Voltage range 5 – 1000 V MI-TS-3871-1000-250-1000-2-ol MI-TS-3871-1000-320-1200-2-ol MI-TS-3871-1000-400-600-4-ol

2 2 4

250 320 400 400 500

1000 1200

(1400 + 1200 + 1200) x 800 x 2000

(1200 + 1200 + 1200 + 1200) x 800 x 2000

600

(1400 + 1200 + 1200 +1200 + 1200 + 1200) x 800 x 2000

MI-TS-3871-1000-400-1000-2-ol 2

1000 1000

(1400 + 1200 + 1200 + 1200) x 800 x 2000 (1600 + 1200 + 1200 + 1200) x 800 x 2200

MI-TS-3871-1000-500-1000-2-ol

These types are particularly popular by our customers. Excerpt from the product range, over 100 types available.

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Flex-Channel System I-TS-3872

Our high-performance test system I-TS (Infeed test system) is a high dynamic, bidirectional DC power supply with continuous and seamless transition from source to sink operation. Thanks to the 3-level technology, it offers an adjustable voltage range of 10 – 1500 V with a center point. The DC channels can also be operated individually or in parallel. The outstanding performance is the basis for a wide range of applications in the automotive, hydrogen and laboratory sectors.

fuel cell

Fuel cell test

Electrolyzer test

Battery test

Battery emulation

Power- train test

Performance hyperbole

U max.

I min.

I max.

Circuit diagram

Single Mode: DCC1, DCC2 DCC1 and DCC2 are operated separately. The DC converters are controlled individually. Performance values (nominal data): UDC = 2x 5 – 750 V IDC = 2x -1000 A to 1000 A

750 V

AC AC

750 V 750 V

AC AC

750 V 750 V

Seriell Mode: DCC1 – DCC2 DCC1 and DCC2 are connected in serie. Performance values (nominal data): UDC = 10 – 1500 V IDC = -1000 A to 1000 A

1500 V 750 V

AC AC

1500 V

AC AC

1500 V

750 V

Parallel Mode: DCC1 II DCC2 DCC1 and DCC2 are connected in parallel Goal power values (nominal data): UDC = 5 – 750 V IDC = -2000 A to 2000 A AC AC

750 V

AC AC

750 V

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Standard features

 2x fieldbus interfaces EtherCAT or Profinet IO or Profibus DP (one per channel)  Door lock  Fail-safe feedback: Emergency stop, stop, DC output contactors open (no individual selection possible) Options (extract)

The I-TS-3872 impresses even in the standard system configuration with its extensive equipment and is therefore ready for immediate use by customers from all over the world. The following is a small excerpt: Allgemeine Daten  Input voltage 380 / 400 V, 50 / 60 Hz  Sense connections for voltage measurement / regulation  DC current and voltage measurement with 0.1 % full scale accuracy  Switchable battery tester / battery emulator version  Protection class IP54  Water cooling  Integrated water/water heat exchanger  Plug and Play parallelization of two I-TS 3872 with the same technical data Safety features  Lockale main switch as load-break switch  Safety control for Performance Level d in accordance with EN 60204-1 / ISO 13849-1.  Voltmeter and indicator light in cabinet door  Redundant DC output contactors  Connection terminals for external „emergency stop“  2x connection terminals for external „Stop“  1x connection terminals for external „operating mode selection“  DC output electrically isolated  2x insulation monitoring devices (separately switchable) Interfaces  10 inch display with touch operation  Modbus / TCP interface

 CAN interface  VNC interface

General technical dataI-TS-3872 AC mains voltage / AC mains frequency

380 / 400 V ± 10 %, 3-phase, PE, 50 / 60 Hz ±5 %

Measurement accuracy Ripple voltage / current Voltage tolerance dynamic (0-100 % INom in 3 ms) Short circuit performance

Voltage: 16 Bit ADC // Current: 16 Bit ADC

≤ 0,1 % eff. fs Battery tester < 3 % fs Battery emulator < 1 % fs

Short circuit proof: Icw: 4,5 kA

Permissible environmental conditions: Storage as per EN 60721-3-1 Transport as per EN 60721-3-2 Operation as per EN 60721-3-3

1K21 / 1M11, +5 to +40 °C 2K12 / 2M4, -25 to +70 °C 3K22 / 3M11, +5 to +40 °C Enforced water cooling (IP54)

Cooling method

Safety of machinery - Safety-related parts of control systems

EN ISO 13849-1 EN ISO 13849-2

Safety of machinery

EN 60204-1 Exception: • Sec. 11.3 Protection type see Techn. Data • Sec. 13.2 Identification of conductor

EMC standards

EN 61000-2-4 Class 3 EN 61000-6-2 EN 61000-6-4

Type

Power in kW Current in A Dimensions (W x D x H in mm)

Voltage range 2x 5 – 750 V / 1x 10 - 1500 V I-TS-3872-1500-300-1000

300 600

1000 1000

2400 x 800 x 2200 4800 x 800 x 2200

I-TS-3872-1500-600-1000

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Power Test Systems accessories

900EX calibration box Description

Part Number

For calibrating your 900EX. Comes with ISO 17025 calibration.

5913176

Configuration Kits 2 unit configuration kit Description

Part Number

For paralleling two 900EXs together. Includes (1) Multi-Unit interlock Cable and (2) Fiber Cables. 20 ft.

24800-2020 24800-2040 24800-2060

40 ft. 60 ft.

3 unit configuration kit Description

Part Number

For paralleling three 900EXs together. Includes (2) Multi-Unit interlock Cable and (3) Fiber Cables. 20 ft.

24800-3020 24800-3040 24800-3060

40 ft. 60 ft.

4 unit configuration kit Description

Part Number

For paralleling four 900EXs together. Includes (3) Multi-Unit interlock Cable and (4) Fiber Cables. 20 ft.

24800-4020 24800-4040 24800-4060

40 ft. 60 ft.

Male Camlock Connectors For use with the 900EX, 900 and ABC-600 Description

Part Number

Kit includes (2)black and (2) red

5914393

For use with the ABC-150, ABC-170/170CE and MT-30 Kit includes (2) black, (2) red and (4) cover cap black

30316-01

Extended Warranties and Startup + Commissioning Options available on All Models Ask us about our Extended Warranty and Startup + Commissioning Options Remote Operating Software (ROS) Provided free with the equipment for editing test parameters, running test remotely, and extracting data.

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Enhancing Battery Innovation with Webasto Equipment The Battery Innovation Center (BIC) stands at the forefront of advancing battery technology, driving progress in electric vehicles, energy storage grids, and commercial applications. Established 11 years ago, to support the Department of Defense, BIC has expanded its focus to the commercial sector. To continue leading in battery innovation, BIC needed reliable, high-performance equipment for testing and development. For this, they turned to Webasto. Partnering with Webasto Seth McCoy, the Testing Evaluation Manager at BIC, emphasizes the critical role Webasto’s equipment has played in their operations. Around the facility, BIC utilizes various Webasto test systems, including the 900EX, 900, ABC-170, and MT-30. These systems are integral for module and pack-level cycling, as well as for conducting environmental and tests. The 900EX, in particular, has become integral for high-precision testing, providing accuracy and flexibility in evaluating battery performance. Simplifying Complex Testing with Versatile Equipment One of the main reasons BIC chose Webasto’s equipment is due to its simplicity and versatility. The equipment interfaces easily with CAN communication, allowing for dynamic cycling profiles and various operational modes, such as constant current, constant voltage, resistance, and power modes. This flexibility is crucial for implementing drive profiles related to different applications, such as electric vehicle packs or industrial mining packs. The intuitive manual controls also provide a straightforward way to charge or discharge batteries as needed.

Supporting Advanced Research and Development Throughout the research and development process, BIC relies on Webasto’s equipment to collect critical data at every stage—from cells to modules and from modules to packs. The high fidelity of Webasto’s equipment ensures accurate data acquisition and analysis, which is essential for determining the performance and reliability of battery systems in real-world conditions. This capability is particularly important as the industry trends towards higher voltages and power systems, necessitating equipment that can handle extremely high currents. Real-World Application and Feedback BIC’s collaboration with Webasto extends beyond just equipment usage. Manufacturers bring their batteries to BIC for real-world evaluation, gaining invaluable feedback to improve their offerings. This collaborative approach allows BIC to work side-by-side with customers, offering a comprehensive prototype and research center that supports new materials, equipment, and software development. Training and Workforce Development In addition to testing, BIC is dedicated to workforce development. They offer training classes, including Battery 101 and Battery Technician courses. This educational initiative addresses the growing demand for skilled workers in the expanding battery industry in the United States. The Battery Innovation Center’s partnership with Webasto has been instrumental in their success, providing the tools and support needed to advance battery technology. Webasto’s equipment enables BIC to conduct thorough and precise testing, driving innovation and ensuring that battery systems are reliable and market ready. This collaboration exemplifies how strong partnerships can propel the battery industry forward, meeting the challenges of today and anticipating the needs of tomorrow.

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Setting a World Land Speed Record The Ohio State University’s Center for Automotive Research (CAR), in conjunction with Venturi Automobiles, were able to set this record in 2010 – and then again in 2016. The third generation of the student-built Venturi Buckeye Bullet (VBB3) held the record of being the world’s fastest electric car, with an average speed of 341.4 mph and a top speed of 358 mph. A 38-foot long, 8,000 pound vehicle with 1.5 megawatts of power divided into two traction axles and a primary braking system consisting of a parachute, the VBB3 represents a truly unique electric automotive project.Built to be rugged and resilient, the 900 was able to handle the long trip, rough terrain and salty environment it encounters at the Bonneville Salt Flats for the team to go seamlessly from lab to speedway. “The 900 enables us to push EV technology to its limit – and beyond – without risking the Venturi Buckeye Bullet’s systems. With help from Webasto...we are able to accomplish things that we never even dreamed possible, and are empowering the movement for EV adoption.” Matile D’arpino, Research Associate Center for Automotive Research, Ohio State University 32

Webasto 900 Heavy Duty Dual Channel Cycling Station

The Webasto 900 is a 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 deployed worldwide to support the development of fuel cell buses, hybrid locomotives and other HEVs.

Eco-Minded Zero Motorcycles Reaps Design Engineering, Manufacturing Benefits from MT-30 Electric-powered vehicles live and die by their batteries. Electric motorcycle manufacturer Zero Motorcycles represents the next step in the evolution of the motorcycle. By combining the best aspects of a traditional motorcycle with today’s most advanced technology, Zero makes high-performance electric motorcycles that are lightweight, efficient, fast, and fun to ride. Zero Motorcycles turned to the MT-30 for managing their battery and battery management system, enabling them to conduct battery lifecycle testing. Their investment in the MT-30 allowed them to make a lower cost, better performing e-motorcycle. “The better we can test our bikes before they get on the road, the better they will perform once they’re there. The MT-30 ensures that our batteries can and will do what they are supposed to do for a superior riding expe- rience.” Raakesh Bhat, Production Engineer at Zero Motorcycles evtestsystems.com

Webasto MT-30 Dual Channel Cycling Station for Modules

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.

Spiers New Technology Maximizes The Value Of Used Advanced Batteries Dirk Spiers, a problem solver with a passion for renewable energy, saw the popularity of EVs rise, but noticed a problem that wasn‘t getting a lot of attention. Used EV batteries were being cast aside, their useful lives cut short because they weren‘t being repaired or refurbished. Tossing aside used batteries can cause numerous negative effects, including the lost value that could have been drawn from the discarded units and environmental harm. The ABC-150 became an essential component to the Spiers New Technology 4R system of repairing, remanufacturing, refurbishing and repurposing advanced batteries. Compatible with different battery chemistries, SNT was able to reliably test approximately 10,000 battery modules on a weekly basis, making the ABC-150 ideal for their unique operations.

Webasto ABC-150 Dual Channel Cycling Station

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. 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 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.

Working with a versatile and reliable test system is key for Spiers New Technology’s 4R operations.

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

ABC-170 CE up to 125 kW CE Certified, Dual Channel

NEW

Cycling Station with Extended Sink Power

I-TS-3872 up to 1500 V Flex-Channel System Water-Cooled DC Source / Sink

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Contacts

Josh Jyawook Sales Manager 810.347.5123 Mobile Josh.Jyawook@webasto.com

Dimitri Liambotis Senior Sales Manager 847.921.3736 Mobile Dimitri.Liambotis@webasto.com

Webasto locations

As a global innovative systems partner to the mobility industry, Webasto is one of the 100 largest suppliers to the automotive sector worldwide. In development, manufacturing and sales, the company focuses on roof systems on the one hand and on vehicle electrification on the other hand. The product range includes, openable and fixed panoramic roofs, electric high-voltage heaters and batteries, as well as thermo management solutions. Among the customers of Webasto are manufacturers of passenger cars, commercial vehicles, and boats, as well as dealers and end customers. In 2022, the Group generated sales of over 4 billion euros and employed about 16,800 people at more than 50 locations. The headquarters of the company, which was founded in 1901, is located in Stockdorf near Munich (Germany). For more information, please visit www.webasto.com

PTS_GK Brochure

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Contact

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www.webasto-comfort.com

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