Webasto PosiCharge ProCore User manual

PosiCharge ProCore
Service Manual

© Webasto Charging Systems, Inc., 2022. All rights reserved.
PosiChargeTM and ProCoreTM are products of Webasto Charging Systems, Inc.
(WCSI). Webasto Charging Systems and the Webasto Charging Systems logo
are trademarks of WCSI. Corporate names, trademarks, registered trademarks,
service marks, symbols, and logos stated herein are the property of the
respective companies.
Changes or modications to this product not completed by an authorized service
provider could void the product warranty.
Disclaimer: This manual includes the latest information available at the time of
printing. WCSI reserves the right to make changes to this manual and/or product
without further notice. Specications are subject to change without notice.
No portion of these materials may be duplicated, used, or disclosed without prior
written permission from WCSI.

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A NOTE ABOUT CUSTOMER SUPPORT
To ensure superior service, please write down the unit’s serial number in
the owner’s record above and have it available when contacting Webasto
customer support. The serial number can be found on the nameplate rating
label on the left side of the unit.
Customer Support:
1.866.767.4242
[e-mail]
Parts:
[e-mail]
OWNER’S RECORD
Model:
PosiCharge ProCore
Serial number (s/n):
Purchase date:
Output power:
24238-78 Rev 02

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Contents
1 SERVICE........................................................................................................................1
1.1 Symbol Usage....................................................................................................2
1.2 General Safety Precautions..........................................................................3
1.3 About This Manual ..........................................................................................4
1.4 Replace the Charging Module ....................................................................4
1.5 Replace the Output Cable ............................................................................4
1.6 Replace the System Controller/Display....................................................6
1.7 Replace the Backplane Fuses.......................................................................8
1.8 Replace Control Power Transformer.........................................................8
1.9 Replace Backplane Board..............................................................................9
1.10 Update Firmware............................................................................................9

CHAPTER 1
SERVICE

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1.1 SYMBOL USAGE
The PosiCharge ProCore is designed with safety as the highest priority.
Installation must comply with all local codes and the following safety
precautions must be read and observed.
Indicates information about safety practices which, if
not followed, may result in serious injury or death.
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.

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1.2 GENERAL SAFETY PRECAUTIONS
BEFORE YOU BEGIN
• Read the important safety instructions below.
• Only qualied personnel should install, use, or service
this unit.
• Read and understand these manufacturer’s
instructions and your employer’s safety practices
manual.
ELECTRIC SHOCK CAN KILL
• Touching live electrical parts can cause fatal shocks or
severe burns.
• The input power circuitry and internal circuits are live
whenever input power is on.
• An incorrectly installed or improperly grounded unit
is a hazard.
• Do not operate the unit if there is physical damage to
the unit, coupler, or cable.
• Do not subject the cable to damage or stress.
• Do not step on the DC output cable.
• Do not operate the unit if any access panels are open.

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1.3 ABOUT THIS MANUAL
This service manual provides instructions for replacing certain components
of PosiCharge ProCore battery chargers. The procedures should only be
performed by trained and qualied technicians to enhance safety and
protect equipment integrity. The following procedures are described:
• Replace the charging module
• Replace the output cable
• Replace the system controller
• Replace the fuses on the backplane
• Replace the control power transformer
• Replace the backplane board
• Update the rmware
1.4 REPLACE THE CHARGING MODULE
1. Unplug any vehicles connected to the charger.
2. Turn OFF AC power at the breaker and lock it out.
3. Wait ve minutes for capacitor voltages to bleed down.
4. On the right side of the charger, remove the side panel screws, then
remove the panel.
5. The charging module weighs 35 lbs. If you have diculty holding
that weight, get assistance before you attempt to remove the module
from the cabinet.
6. Grasp the charging module by the hand holes and pull rmly until
disengaged.
7. Slide the module out of the charger.
8. Carefully insert replacement module into the cabinet until module
face is ush with cabinet sill and has connected with the bus bar
connectors.
9. Replace right side panel and screws.
10. Remove lock out and turn on AC breaker.
1.5 REPLACE THE OUTPUT CABLE
1. Unplug any vehicles connected to the charger.
2. Turn o AC power at the breaker and lock it out.
3. Wait ve minutes for capacitor voltages to bleed down.
4. Remove right side panel.
5. The charging module weighs 35 lbs. If you have diculty holding
that weight, get assistance before you attempt to remove the
module(s) from the cabinet. Slide module(s) out of charger.
6. Grasp the charging module by the hand holes and pull rmly until
disengaged.
7. See Figure 1. Using a socket wrench, remove bolts from the output
cable connections.

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Figure 1: Output Connector Bolts
8. See Figure 2. Unplug the four-pin Molex Comm cable connector
from the bottom left corner of the backplane. You may need to
unbolt the cable on the bus bar above it to access the connector.
Figure 2: Comm Cable Connector
9. See Figures 1 and 3. Inside the cabinet, loosen the strain relief nut
for the Comm cable and pull the cable until you can access the
ferrite lter. Remove the snap-on ferrite lter from the Comm cable.
Figure 3: Snap-On Ferrite Filter
10. See Figures 1 and 4. The strain relief nuts are permanently
attached to their respective cables. To remove the cables, unscrew
the nuts holding them to the cabinet from inside the cabinet.

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Figure 4: Strain Relief Nuts
11. Pull cables out of the cabinet.
12. Reverse above procedure to install new cable as follows.
13. Thread cables through cabinet openings and secure the strain relief
nuts to the cabinet.
14. Loop the Comm cable and reinstall snap-on ferrite lter onto
Comm cable as shown in Figure 3.
15. Connect Comm cable to backplane. Reconnect cable to bus bar.
16. Bolt output cables and two ring terminals to lter standos, red-to-
red and black-to-black. See Figure 1. Torque to 72 lb-in ± 7 lb-in.
17. Tighten strain relief nuts on all three cables.
18. Pull Comm cable from outside until ferrite lter is next to strain
relief. Tighten strain relief.
19. Pull output cable from outside to remove slack inside. Tighten
strain relief.
20. Replace modules, reinstall right side panel, remove lockout, turn
ON AC power.
1.6 REPLACE THE SYSTEM CONTROLLER/DISPLAY
1. Unplug any vehicles connected to the charger.
2. Turn OFF AC power at the breaker and lock it out.
3. Wait ve minutes for capacitor voltages to bleed down.
4. Remove right side panel.
5. The charging module weighs 35 lbs. If you have diculty holding
that weight, get assistance before you attempt to remove the
module from the cabinet.
6. Grasp module by hand holes and pull rmly until disengaged.
7. Slide the module out of the charger.
8. See Figure 5. Use a stubby Phillips screwdriver to remove four
screws securing the system controller/display as shown below:

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Figure 5: Removing the System Controller/Display Cover
9. Unplug the ribbon cable from the connector on the controller board.
10. See Figure 6. Remove controller board/display assembly from cabinet.
Figure 6: Removing the System Controller/Display
11. Reverse the above procedure to reinstall.

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1.7 REPLACE THE BACKPLANE FUSES
1. Unplug any vehicles connected to the charger.
2. Turn OFF AC power at the breaker and lock it out.
3. Wait ve minutes for capacitor voltages to bleed down.
4. Remove left side panel.
5. See Figure 7. Test each fuse with an ohmmeter.
Figure 7: Backplane Fuses
6. Replace all three fuses due to stress on the others with a correctly-
rated fuse (500V, 20A).
7. Replace left side panel.
8. Remove lock out and turn ON AC power.
1.8 REPLACE CONTROL POWER TRANSFORMER
1. Unplug any vehicles connected to the charger.
2. Turn OFF AC power at the breaker and lock it out.
3. Wait ve minutes for capacitor voltages to bleed down.
4. Remove right side panel.
5. The charging module weighs 35 lbs. If you have diculty holding
that weight, get assistance before you attempt to remove the
module from the cabinet. Slide the module out of the charger.
6. Unplug the ve-pin 24V control power cable from backplane.
7. Unscrew mounting nuts from transformer and remove transformer.
8. Install new transformer on mounting studs and replace nuts.
9. Plug control power cable into backplane.
10. Replace module(s), reinstall right side panel, remove lockout, turn
ON AC power.

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1.9 REPLACE BACKPLANE BOARD
1. Unplug any vehicles connected to the charger.
2. Turn OFF AC power at the breaker and lock it out.
3. Wait ve minutes for capacitor voltages to bleed down.
4. Remove right side panel.
5. The charging module weighs 35 lbs. If you have diculty holding
that weight, get assistance before you attempt to remove the module
from the cabinet. Slide the module out of the charger.
6. Remove left side panel.
7. Remove screws securing the backplane.
8. See Figure 8. Tilt backplane board to expose connectors on the
opposite side.
Figure 8: Backplane Cables and Connectors
9. Unplug all connectors and remove backplane board.
10. Reverse above procedure to install new backplane board.
1.10 UPDATE FIRMWARE
1. See Figure 9. Firmware is updated using the USB port on the left side
of the charger under the standby switch.
Figure 9: Standby Switch and USB Connector

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2. Contact WCSI Customer Support to download the PilotTerm utility.
Install PilotTerm on a Windows laptop with PilotTerm software.
3. Save the update .AVB le to the Desktop of the laptop.
4. Connect the laptop to the charger using an A-B (printer-type) USB
cable.
5. See Figure 10. Start the PilotTerm program and select Settings tab.
Figure 10: PilotTerm Settings Tab
6. Conrm that the correct comm port is selected and then click
“Connect COM port” button.
Figure 11: Update Parameter
7. See Figure 11. Select Update Firmware tab, click Browse to select the
.AVB update, then click the Update Now button.
8. Progress displays on the screen bottom. When update is completed
(about ve minutes), close PilotTerm and disconnect laptop from the
charger.

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Webasto Charging Systems, Inc.
1333 S. Mayower Ave., Ste 100
Monrovia, CA 91016
USA
Corporate headquarters:
Friedrichshafener Str. 9
82205 Gilching
Germany
Identication No. 24238-78_02 • 07/2022 • © Webasto Charging Systems, Inc., 2022