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