Webasto PosiCharge ProCore Installation guide

PosiCharge ProCore™
Operations and Maintenance

Page ii of iv Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
© Webasto Charging Systems, Inc. All rights reserved
PosiCharge™ systems is a product line of Webasto Charging
Systems, Inc. Webasto Charging Systems, Inc., and the Webasto
Charging Systems logo are trademarks of Webasto Charging
Systems, Inc. Corporate names, trademarks, registered
trademarks, service marks, symbols, and logos stated herein are
the property of the respective companies. Specications are
subject to change without notice. Images are representative;
production models may vary. No portion of these materials may
be duplicated, used, or disclosed without prior written permission
from Webasto Charging Systems, Inc.
Disclaimer: this manual includes the latest information available
at the time of printing. Webasto Charging Systems, Inc., reserves
the right to make changes to this manual and/or product without
further notice. Changes or modications to this product not
completed by an authorized service provider could void the
product warranty.
posicharge.com | posichargeprocore.com | webasto-charging.com

Page iii of iv Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
A NOTE ABOUT CUSTOMER SUPPORT
Please write down the unit serial number in the Owner’s Record
(below) to ensure superior service, and have it available when
contacting Webasto Customer Service. The serial number can be
found on the nameplate rating label on the left side of the unit.
Customer Support
[email protected]
1–866–767–4242
Parts
[email protected]
Owner’s Record
Model:
PosiCharge ProCore™
Serial Number (SN):
Installation Date:
MAC Address ID:

Page iv of iv Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Contents
1. Symbol Usage ........................................................ 1
2. Performance Ratings ............................................. 2
3. Operation ............................................................... 3
3.1. Charger Display ....................................................................3
3.2. Battery Display......................................................................4
3.3. Buttons..................................................................................7
3.4. Standby Switch and USB Port ..............................................8
3.5. Power Module Redundancy..................................................9
3.6. Power Module Replacement.................................................9
3.7. User-Level Troubleshooting................................................10
3.8. Maintenance .......................................................................12
Figures
Figure 1 Charger Display...............................................................3
Figure 2 Battery Display ................................................................4
Figure 3 Alternate Battery Display .................................................6
Figure 4 Standby Switch and USB Port.........................................8
Tables
Table 1 ProCore™ Physical and Performance Parameters ..........2

Page 1 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Indicates information about safety practices
which, if not followed, could result in personal
injury, re, or equipment overheating
Indicates helpful information for installation
or usage, but does not contain personnel or
equipment safety-related information
1. Symbol Usage
The PosiCharge ProCore™is designed with safety as the
highest priority. The following safety precautions must be read
and observed.
WARNING
NOTE

Page 2 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Power Rating 10 kW 15 kW 20 kW
30 kW w
a single
cable
30 kW w
a single
cable
30 kW w
a dual
cable
30 kW w
a dual
cable
Max. output current
at 24/36/48V
(A)
200/200/
200
320/320/
320
400/400/
400
400/400/
400
500/500/
500
500/500/
500
600/600/
600
Max. output
current at 60V
(A)
167 250 320 320 500 500 500
Max. output current
at 48/72/80V
(A)
200/139/
125
300/208/
187
400/278/
250
400/400/
375 NA NA NA
Max. output
current at 100V
(A)
100 150 200 300 NA NA NA
Min. input
conductor size
(AWG)
12 10 8 6 6 6 6
Min. grounding
conductor size
(AWG)
12 10 8 8 8 8 8
Min. input wire
terminal torque
(in-lb)
30–33 30–33 30–33 30–33 30–33 30–33 30–33
Min. ground wire
terminal torque
(in-lb)
35–44 35–44 35–44 35–44 35–44 35–44 35–44
Circuit breaker
rating 480 VAC 20A 25A 40A 50A 50A 50A 50A
Connector option Euro Euro Euro Euro Rema Euro Euro
SBX
Dimensions
H×W×D (in)
28.5×20
×7
28.5×20
×11.5
28.5×20
×11.5
28.5×20
×16.5
28.5×20
×16.5
28.5×20
×16.5
28.5×20
×16.5
Weight
(with cables) 81 lbs 129 lbs 129 lbs 173 lbs 184 lbs 197 lbs 197 lbs
Table 1 ProCore™ Physical and Performance Parameters
Table 1 provides the physical and performance parameters for
each ProCore™model.
2. Performance Ratings
• Operating temperature range: −25 °C to 45 °C
• Storage temperature range: −30 °C to 65 °C

Page 3 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Figure 1 Charger Display
Indicator Description
Status • Indicates whether a vehicle is connected to the
charger (Figure 1)
"Connect Vehicle" indicates that there is no
vehicle connected to the charger (and that in
order to be connected, it must be connected).
The charger is idle.
Charger
name
• Displays the name broadcast to the
ProCore™Mobile Application (App)
You can change the charger name, using the
mobile app, in the Charger Data window.
Charger
maximum
output
power
• Displays the power rating for the charger
The value changes as modules are added
or removed.
Day and
time
• The ProCore™Mobile App automatically sets
this indicator.
NOTE If the status bar displays
“Connect Vehicle,” then the buttons
have no function.
3. Operation
3.1. Charger Display

Page 4 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Figure 2 Battery Display
The graphical battery display (Figure 2) changes, showing
parameters relating to the battery state of charge (SOC), when the
charger connects to a battery.
3.2. Battery Display
Indicator Description
SOC wheel The charger estimates the battery charge
percentage (or SOC) at the connection.
The SOC wheel adds segments as the
battery charges. The SOC displayed in
the center of the wheel increases in value.
The color of the wheel also indicates the
SOC, as indicated below, allowing the
battery charging status to be monitored at
a distance.
Color Charge Percentage
Yellow Less than 80%
Blue 80% or greater
Green 100% fully charged battery

Page 5 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Indicator Description
Equalization (EQ)
schedule indicator Color Meaning
Light gray No EQ scheduled
Black EQ scheduled
Flashing green EQ charge in progress
Solid green EQ charge completed
for the current week
Battery temperature The temperature reading comes from
a temperature sensor installed in the
battery. If there is no sensor, then the
display grays out.
The display can be set to °F or °C, using
the ProCore™Mobile App Charger Setup/
Display Options window.
If the battery is over-temperature, then
the charger faults and displays the battery
temperature window as red.
Status bar Indicates the charging status with the
following displays:
• Charging
• Charge Stopped
• Charge Completed
• EQ Charging
• Full Charging
• O󰀪ine-charging stopped to use the
ProCore™Mobile App to change
the conguration
• Fault-additional information displays
about the fault or warnings

Page 6 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Water level
indicator
Charge current
and voltage
The charger controls the charging current
via Webasto proprietary
charging algorithms.
Color Indication
Grayed out There is no battery
monitor and
identier (BMID)
with a water level
sensor present.
Red background LOW: the battery
water level is low.
White background OK: the battery
water level is OK.
Indicator Description
3.2.1. Alternate Battery Display
You can switch the battery graphical display to an alternate tabular
battery display that shows additional parameters for the
charging battery.
3.2.1.1. Press and hold the Start button for three seconds to
change the graphical battery display to the alternate
tabular battery display (Figure 3). Repeat this step to
return the display to the graphical battery display.
Figure 3 Alternate Battery Display

Page 7 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Button Function
Start If the charger is in the Charge Stopped state, then
press the Start button (Figure 2) momentarily to
restart the charge.
Press and hold the Start button for three
seconds to switch from the battery display
(Figure 2) to the alternate battery display
(Figure 3). Press and hold the Start button again to
switch back to the battery display.
Stop Press the Stop button (Figure 2) to stop the charge.
The charger displays, on the status bar,
“Charge Stopped.”
EQ
Schedule
Equalization (EQ) is an extended low-current
charge performed once per week to maintain
battery health. EQ normally is scheduled
automatically by settings in the charger or BMID,
and it is performed if scheduled after a regular
charge to 100% SOC.
The alternate battery display shows the
EQ Scheduled status (Figure 3).
If, at the top, the alternate battery display shows
• “Charging,” then press the EQ Schedule
button (Figure 2) to schedule or unschedule an
EQ charge.
• “Charge Stopped,” then press the
EQ Schedule button to start an EQ charge.
• “Battery Undervoltage," then press and hold the
EQ Schedule button to start a recovery charge,
which is a low-current charge designed to raise
safely the battery voltage. The battery should
be able to accept a normal charge after the
recovery charge is complete.
ProCore™starts charging automatically when you
connect a vehicle. You can disconnect a vehicle
safely from ProCore™even while charging. You
do not need to start or stop the charge with the
following buttons.
3.3. Buttons
NOTE

Page 8 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Turning the Standby switch to the OFF
position ONLY turns o󰀨 the display and
prevents charger operation. High-voltage
alternate current (AC) is still present in the
cabinet. AC voltage can be turned o󰀨 only
at the breaker.
3.4. Standby Switch and USB Port
The standby switch and universal serial bus (USB) port
(Figure 4) are located on the left side of the charger. The Standby
switch must be turned to the ON position (indicated) before the
display turns on and charger operates.
The USB port is used only by qualied service personnel to
update software and run diagnostics.
Figure 4 Standby Switch and USB Port
WARNING

Page 9 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
3.5. Power Module Redundancy
ProCore™models rated 15kW or more have multiple power
modules. If any power module faults, then it becomes disabled;
charging continues at reduced power using the remaining
module(s). The display shows a warning stating that the
charger has a faulting module. Replace the faulty module as soon
as practical.
Use the ProCore™Mobile App, to speed service, to send the
charger fault log to Webasto Customer Support.
3.6. Power Module Replacement
Follow these simple steps to replace a faulting power module.
3.6.1. Turn o󰀨 the utility power breaker to the charger, and lock
out the breaker.
3.6.2. Disconnect the vehicle, if there is one.
3.6.3. Wait ve minutes to allow capacitor voltages in the
charger to bleed down.
3.6.4. Remove the right side panel of the charger.
3.6.5. Grasp the hand holds on the power module, and pull them
rmly to unseat the module.
3.6.6. Slide the power module out of the cabinet. Be careful:
a module weighs 35 lbs.
3.6.7. Slide the replacement power module into the cabinet.
3.6.8. Seat the module by making sure that it is ush with the
cabinet sill.
3.6.9. Replace the right panel.
3.6.10. Restore the utility power.

Page 10 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
3.7. User-Level Troubleshooting
Fault
Message
Possible Cause(s) Solution(s)
CURRENT
CONTROL
The charging
current
cannot
be produced.
The module failed. Replace the
power module.
OVP FAULT
There is
a module
overvoltage.
The battery became
disconnected without
opening the pilot.
Wait for the fault
to clear.
OCP FAULT
There is
a module
overcurrent.
The module failed. Replace the
power module.
GATE DRIVE
UV
There is a
gated drive
undervoltage.
The module failed. Replace the
power module.
POWER
SUPPLY FLT
The module failed. Replace the
power module.
MODULE
OVER TEMP
The air intake is
blocked.
The module failed.
Remove the blockage.
Replace the
power module.

Page 11 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Fault
Message
Possible Cause(s) Solution(s)
BATT
UNDER VOLT
The battery is
drained to a voltage
below a safe level
for charging.
The BMID number of
battery cells setting
is incorrect.
Press and hold the
EQ Schedule button
to initiate a recovery
charge and safely raise
the battery voltage.
Use the ProCore™App
BMID setup to set the
correct number of
battery cells.
BAT OVER
VOLTAGE
The BMID number of
battery cells setting
is incorrect.
Use the ProCore™App
BMID setup to set the
correct number of
battery cells.
BATTERY
TEMP
The battery
temperature is
too high.
The faulty battery
cannot accept a
high-charge current.
An incorrect BMID
setting is
resulting in an
improper charging.
Service the battery.
Use the ProCore™App
to correct the
BMID settings.
BMID LOST
COMM
BMID
communication
is lost.
There are
damaged BMID
communication
(comm) wires in the
charger output cable
or in the vehicle.
Repair the wiring.
CABLE TEMP
There is
a connector
over
temperature.
Damage to the
charging connector
is causing an unsafe
temperature.
Repair the
charging connector.
AC POWER
HIGH
The utility AC
voltage is too high
for safe charger
operation.
Check the AC
input voltage.

Page 12 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Fault
Message
Possible Cause(s) Solution(s)
AC POWER
LOW
The utility AC
voltage is too low
for safe
charger operation.
Check the AC
input voltage.
AC POWER
PHASE
The charger is not
receiving AC power
in all three phases.
The module has
failed and blown a
backplane fuse.
Conrm that the utility
breaker has not tripped
on one of the phases.
Replace the power
module that caused the
fuse to blow,
and replace the
backplane fuses.
MODULE TYPE
ERR
The power module
and cabinet
voltage settings do
not match.
Install the correct
power module.
3.8. Maintenance
3.8.1. Brush dust from the intake grill, on the bottom, every
six months.
3.8.2. Check the condition of the output cable and connectors
every month.

Page 13 of 13 Webasto Charging Systems, Inc.
PosiCharge ProCore™Operations and Maintenance Manual
24407-W-03 Rev-01
Webasto Charging Systems, Inc.
1960 Walker Avenue
Monrovia, CA 91016-4847
Corporate headquarters:
Friedrichshafener Str. 9
82205 Gilching
Germany
Identification No. • 24407-W-03 • 06/20 • © Webasto Charging Systems, Inc., 2020