Webasto Power Bridge scales battery testing to 1500V

Separate CAN connections for each paired 900 EX unit let the Power Bridge route control signals without altering either system’s native interface

(Image courtesy of Webasto)

Webasto has launched the 900 EX Power Bridge, a module that pairs two of its 900 EX power test systems to extend combined testing capacity to 1500V and 500kW. For test engineers already running 900 EX units, the announcement matters less for the headline figures than for how Webasto built the upgrade path on top of equipment customers already operate.

What the Power Bridge actually changes

The Power Bridge, part number 5914970, draws 100 to 240VAC at 1.2A while each connected 900 EX continues to take its own 480VAC three-phase 60Hz supply. Webasto states that each 900 EX keeps operating exactly as it does standalone, with no change to behavior, performance characteristics, or operating logic once the bridge is fitted. The company also says existing CAN control software operates automatically when the Power Bridge is configured, with no additional tools, processes, or training required beyond standard 900 EX calibration and maintenance procedures.

That combination separates this launch from a typical capacity upgrade.

What the 1500V ceiling actually requires

In the published specifications, the two-unit Series configuration is listed at up to 1500V, with current reaching ±1000A and power reaching ±500kW. That figure is the basis for Webasto’s 1500V and 500kW headline claim.

A standalone 900 EX, without the Power Bridge fitted, operates within a 900V ceiling and narrower current bands as voltage rises, stepping down from ±500A at up to 750V to ±300A above 825V in single-unit independent mode. The comparison is useful context for planning purposes, since it shows how far the Series configuration extends beyond a single unit’s own range. Engineers evaluating the Power Bridge for a 1500V test program should treat the published Series figures as the relevant spec for that use case.

Why 1500V testing capability matters now

The launch lands as battery architectures across automotive and adjacent electrification sectors continue shifting toward higher system voltages. A recent peer-reviewed review in Discover Applied Sciences notes that the move from 400V toward 800V architectures supports charging power above 350kW while reducing the current, and therefore the weight and volume, of cell, module, and high-voltage cabling. That broader shift toward higher-voltage architectures is the backdrop against which Webasto’s 1500V claim sits; the release itself does not reference this trend, and the connection here is editorial context rather than a Webasto statement. Webasto’s own positioning for the Power Bridge centers on heavier-duty and stationary energy storage applications, where higher-voltage testing demand is already concrete enough to be reflected in the Excel Engineering case below.

Excel Engineering, an independent test laboratory serving OEMs, Tier 1 suppliers, and electrification programs across automotive, off-road, rail, marine, and stationary markets, adopted the Power Bridge to meet rising demand from its own customers for 1500V platform testing. Matt Sobotka, the lab’s General Manager of Electrification Testing, said the setup delivered the high-frequency controls many of its projects require while preserving the controllability and straightforward installation the lab already valued in the standalone 900 EX. For labs facing similar demand, the case suggests scaling to 1500V doesn’t require replacing a qualified test platform.

What this means for procurement and lab planning

For OEMs, suppliers, and independent labs already running 900 EX systems, the Power Bridge offers a defined upgrade path rather than a forced platform change. Because Webasto says no new service or calibration regime applies, the procurement decision centers on the Power Bridge hardware and its published Series-mode rating rather than on retraining staff or requalifying existing equipment. Labs should confirm directly with Webasto whether configurations beyond the published Series specification are available before assuming the Power Bridge covers test programs that sit between standalone 900 EX capability and the full 1500V ceiling.

Webasto has not indicated whether further Power Bridge variants or higher-capacity configurations are planned beyond the current two-unit pairing.

Stay ahead in the electrification revolution. Explore more breakthroughs from leading innovators in electric commercial transport – visit our news page.