910121_P3 Brochure

Power Cycling & Battery Test Systems

Power Cycling & Battery Test Systems The Standard for Advanced Testing

Contents

About Us

The Standard for Advanced Energy Testing

History of Innovation

Put Your Concepts to the Test

Application Guide

Test Systems Product Portfolio

900 EX

900

ABC-600

ABC-170 / ABC-170 CE

ABC-150

MT-30

Case Studies

Ohio State University‘s Center for Automotive Research

Zero Motorcycles

Spiers New Technology

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. The Standard For Advanced Energy Testing 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.

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.

Put Your Concepts To The Test With a full power range (+/-5kW to +/-1MW) of bi-directional DC equipment, our Power Cycling and Test Systems can handle virtually any DC supply or load requirement. In addition, Webasto systems can emulate any drivetrain component, enabling the testing of individual components or partial drivetrains accurately and realistically, allowing true hardware-in-the-loop testing. Our 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. View our Application Guide to find the right solution for you.

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

0-30kW

0-125kW

0-150kW

0-250kW

Category

Application

MT-30-

ABC-150

ABC-170 (CE)

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)

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 Resistence

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

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 ± 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.

Technical Specifications

Independent

Parallel

Multi-unit

900V 500A

900V

Voltage

1000A

4000A

Current

250kW

1000kW

Power

250μs (Ethernet)

Command latency

93%

Energy recovery efficiency

±0.05V or ±0.05% of reading

Measurement error-voltage

±160mA or ±0.05% of reading

Measurement error-current

3ms*

7ms*

Rise time voltage - step (0-500v)

0.5ms*

0.6ms*

0.9ms*

Rise time current - step (0-300a)

171V/ms

89V/ms

76V/ms

Slew rate voltage

769A/ms

1282A/ms

1935A/ms

Slew rate current

274kW/ms 50Hz (500V) 75Hz (250V) 175Hz (500A)

500kW/ms

833kW/ms

Slew rate power

50Hz (500V)

Tracking bandwidth voltage

150Hz (700A)

50Hz (700A)

Tracking bandwidth current

100Hz (150kW)

150Hz (250kW)

50Hz (250kW)

Tracking bandwidth power

10ms 10ms 50ms

Fiber to Ethernet CAN RS-232

Output data sampling

3 Phase, 380, 400 and 480 VAC

Input voltage options (+10%/-15%)

410, 389 and 324 Amps respectively

Current draw

6063 lb (2750 kg)

Weight

72” W x 76.5” H x 39” D (183cm W x 194cm H x 99cm D)

Dimensions

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 Amps respectively

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

< 65mArms and 130mArms, respectively

Current Ripple - Indepdendent & parallel mode

< 15Arms

Current Ripple - Max ripple from load

0-35°C

Operating Environment - Temperature

5-90% non-condensing

Operating Environment - Humidity

6063 lbs (2750 kg)

Weight

73” W x 76.5” H x 37” D (185cm W x 194cm H x 94cm D)

Dimensions

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)

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

3 Phase, 380, 440 and 480 VAC

Input Voltage Options

254, 218 and 200 Amps respectively

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

< 65mArms and 130mArms, respectively

Current Ripple - Indepdendent & parallel mode

< 15Arms

Current Ripple - Max ripple from load

0-35°C

Operating Environment - Temperature

5-90% non-condensing

Operating Environment - Humidity

2-power stages 4055 lbs (1839 kg)

Weight

73” W x 76.5” H x 37” D (185cm W x 194cm H x 94cm D)

Dimensions

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, 240VAC

3 Phase, 400, 415 and 480 VAC

Input Voltage Options

340Amps

203, 195, and 170 Amps respectively

Currency Draw

60Hz (50 Hz available)

50Hz (60 Hz optional)

Frequency

Requires external isolation transformer with 225KVA, 240Vrms secondary

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

0-35°C

Operating Environment - Temperature

5-90% non-condensing

Operating Environment - Humidity

1334 lbs (605 kg)

3925 lbs (1780 kg)

Weight

46” W x 55” H x 26” D (117cm W x 140cm H x 65cm D)

73”W x 71”H x 30”D (183cm W x 180cm H x 76cm D)

Dimensions

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)

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 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

325Amps

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

< 0.5Arms

Current Ripple - Indepdendent & parallel mode

< 15Arms

Current Ripple - Max ripple from load

0-35°C

Operating Environment - Temperature

5-90% non-condensing

Operating Environment - Humidity

1334 lbs (605 kg)

Weight

46” W x 55” H x 26” D (117cm W x 140cm H x 65cm D)

Dimensions

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 Amps

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

0-35°C

Operating Environment - Temperature

5-90% non-condensing

Operating Environment - Humidity

1320 lbs (599 kg)

Weight

34” W x 55” H x 40” D (87cm W x 140cm H x 102cm D)

Dimensions

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

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.

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.

“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

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.

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.

“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 experience.”

Raakesh Bhat, Production Engineer at Zero Motorcycles

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

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

in the automotive, aerospace, stationary power and defense industries.

Notes

You have questions regarding the Webasto products? We are here for you!

Toll Free: 800-860-7866 emobility@webasto.com

The Webasto Group is a global innovative systems partner to the mobility industry and one of the 100 largest suppliers to the automotive sector worldwide. The company's offering includes in-house developed roof, heating and cooling systems for various types of vehicles, batteries, battery testing and charging solutions for hybrid and electric vehicles, and additional services related to thermal management and electromobility. Among the customers of Webasto are manufacturers of passenger cars, commercial vehicles and boats, as well as dealers and end customers. In 2021, the Group generated sales of 3.7 billion euros and employed around 15,700 people at over 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-electrified.com

Webasto Thermo & Comfort North America, Inc. 15083 North Road Fenton, Michigan 48430 USA

Toll Free: 800-860-7866 Phone: 810-593-6000 webasto-electrified.com

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