Webasto ProCore Edge 9 User manual

ProCore™ Edge
North America
Installation, Operation, and
Maintenance Manual

ProCore Edge North America IOMM
31241-03-01 Page ii of viii Webasto Charging Systems, Inc.
© Webasto Charging Systems, Inc., 2021. All rights reserved
PosiCharge™ systems is a product line 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 modifications 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.
Specifications are subject to change without notice.
No portion of these materials may be duplicated, used,
or disclosed without prior written permission from WCSI.
posicharge.com | posichargeprocore.com

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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.
Owner’s Record
Model:
ProCore™ Edge
Serial Number (SN):
Installation Date:
Customer Support:
[email protected]
1–866–767–4242
Parts:
[email protected]

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Contents
1. Installation, Operation, and Maintenance Manual... 1
Scope ..............................................................1
Acronyms, Abbreviations, and Symbols...........2
2. Required Tools ..........................................................5
3. Technical Specifications for 48- and 80-Volt
Modules Fitted with Three- or Five-Bay Cabinets ... 5
4. Installation .................................................................7
Multicharger Installation Schemes ................... 7
Installation Precautions.................................... 9
Positioning the Charger ................................. 10
Wall-Mount Installation .................................. 11
Floor-Stand Installation.................................. 12
AC Power Connection ................................... 16
DC Battery Connection ..................................21
5. Remote Battery Connections (Option)................... 27
Ten-way Screw Terminal Connector.............. 27
Optional Features .......................................... 30

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6. Putting Back the DC-Panel and Top Covers.......... 30
DC-panel Cover.............................................30
Top Cover...................................................... 30
7. Charger Light Bar.................................................... 31
8. Operating Instructions........................................ 3333
Battery Display .............................................. 35
Buttons .......................................................... 41
9. Maintenance ............................................................43
Power Module Replacement.......................... 43
Air Filter Replacement ................................... 53
Preventive Maintenance Activities ................. 53
10. Faults and Warnings ............................................... 56

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Figures
Figure 1 Side-to-Side Airflow Design, Top View...........................7
Figure 2 Standard Side-to-Side Charger Spacing........................7
Figure 3 Side-to-Side Charger Spacing with Dividers ..................8
Figure 4 Offset 45-degree Angle Charger Installation .................. 8
Figure 5 Attaching Points for M8 Lifting Eye-bolts,
Top-panel View........................................................... 10
Figure 6 Charger, Wall, Wall-Mount Hanger, Bottom Bracket,
and Screw with an M6 Thread ....................................11
Figure 7 Charger on the Wall-Mount Hanger ............................ 11
Figure 8 Bottom Bracket Mounted to the Charger with a
Tightening Torque of 52.22 in.-lb. (5.9 N-m) ............... 11
Figure 9 Floor Stand..................................................................12
Figure 10 Predrilled Holes for Bolting the Base to the Floor....... 13
Figure 11 Pogo Stick (Optional) Attached to the Pogo Bracket .. 13
Figure 12 Charger Hung on the Floor Stand .............................. 14
Figure 13 Bottom Bracket Mounted to the Charger and
Floor Stand with a Tightening Torque of
52.22 in.-lb. (5.9 N-m) ...............................................15

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Figure 14 Six M6 Panel crews, Top-panel View......................... 17
Figure 15 AC Service Entrance ................................................. 18
Figure 16 AC Service Entrance for the Three-bay Cabinet ........ 19
Figure 17 AC Service Entrance for the Five-bay Cabinet........... 20
Figure 18 Two TORX TX25 Screws Securing
the DC Output Power Cable Panel ............................ 24
Figure 19 Three- and Five-bay Bus Bar Arrangement................ 25
Figure 20 Ten-way Screw Terminal Connector.......................... 27
Figure 21 Battery Communication Wires Connected to
the Screw Terminal ................................................... 28
Figure 22 Charger Display......................................................... 33
Figure 23 Graphical Battery Display .......................................... 35
Figure 24 Alternate Tabular Battery Display .............................. 40
Figure 25 Latch on the Side of the Charger ............................... 43
Figure 26 Disconnected Power Cables...................................... 44
Figure 27 Ground Cable Disconnection ..................................... 45
Figure 28 Single-Cable Connection ...........................................46
Figure 29 Multicable Connection ............................................... 47

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Figure 30 Power Module Removal............................................. 48
Figure 31 Replacement Power Module Insertion ....................... 49
Figure 32 Power Module Position Selector ................................ 50
Figure 33 Power Module Positions ............................................ 50
Figure 34 Flat Cable Reconnection to the Power Module .......... 51
Figure 35 Flat Cable Connection to the Termination Block ........ 52
Figure 36 Reconnected DC Output Power Cable...................... 53
Figure 37 Reconnected Ground Cable and
AC Input Power Cable...............................................53
Tables
Table 1 Bare-ended Signal Connections ................................... 29
Table 2 Preventive Maintenance Schedule................................ 54

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1. Installation, Operation, and Maintenance Manual
NOTE
Read and understand these manufacturer instructions and all
safety practices.
NOTE
This manual provides important information on how to install
the charger and should be carefully read.
This manual is based on information available at the time of
publication. The information herein, while efforts have been
made to be accurate, does not cover all details of,
or variations in, the hardware or software; or provide for
every possible contingency in connection with installation.
Features described herein may not be present in all systems.
NOTE
This manual covers the installation, operation, and
maintenance of the charger, and charger accessories.
Scope
This manual is intended for use by personnel trained to install and
use chargers for charging batteries in a safe and
correct manner.

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Acronyms, Abbreviations, and Symbols
Acronym,
Abbreviation,
or Symbol
Meaning
°C Degrees Celsius
°F Degrees Fahrenheit
A Amp(s)/Ampere(s)
AC Alternating Current
AWG American Wire Gauge
BMID Battery Monitor and Identifier
BMS Battery Management System
CB Circuit Breaker
CSA Canadian Standards Association
D Depth
DC Direct Current
EU European Union
ft Foot or Feet
H Height
Hz Hertz

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Acronym,
Abbreviation,
or Symbol
Meaning
Icc and Icp, mr Conditional Short-Circuit Current and
Minimum Required Prospective Short-Circuit
Current (the Symbol for Current is I:
Intensité du Courant [Current Intensity])
IEC International Electrotechnical Commission
in. Inch(es)
IP Ingress Protection (Rating)
kg Kilogram(s)
kW Kilowatt(s)
L Length
lb. Pound(s)
(Latin) (Libra Pondo: [a] Pound [by] Weight)
Max. Maximum
Min. Minimum
mm Millimeter(s)
mm2 Square Millimeter(s)
NEMA National Electrical Manufacturers Association
N-m Newton-metre/meter
OK Oll Korrect [sic]: Facetious Alteration of
All Correct

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Acronym,
Abbreviation,
or Symbol
Meaning
OCV Open-Circuit Voltage
ph. Phase(s)
PSCCR Prospective Short-Circuit Current Rating
SB® Storage Battery Connector
SBX® Storage Battery Connector with
Auxiliary Contacts
sic Sic (Erat Scriptum) (Latin)
(“Thus [It Had Been Written]”)
SOC [sic] State of Charge
SOOW Cable Type (Service) and the Agents against
Which It Protects (Oil-resistant Insulation,
Oil-resistant Jacket, and Water resistant)
TBA To Be Announced
UL Underwriters Laboratories
V Volt(s)
VAC Volt(s) Alternating Current
VDC Volt(s) Direct Current
W Width
WCSI Webasto Charging Systems, Inc.

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2. Required Tools
•Hex key, 4 mm, for the filler screws on the charger top panel
•TORX TX30 for the charger top panel
•Flathead screwdriver for the terminal screws
•TORX TX25 for the DC output power cable panel
3. Technical Specifications for 48- and 80-Volt
Modules Fitted with Three- or Five-Bay Cabinets
Model
ProCore™
Edge 9
ProCore™
Edge 9
ProCore™
Edge 15
ProCore™
Edge 15
Number of fitted modules 2 3 2 3 4 5 4 5
Max. output power rating16 kW 9 kW 6.4 kW 9.6 kW 12 kW 15 kW 12.8 kW 16 kW
Module type
48-volt
80-volt
48-volt
80-volt
Nominal input voltage
480 VAC ±10% 3 ph. 50/60 Hz
Cabinet size
3-bay
5-bay
Max. input amps
(3-phase 480-volt AC)
9 A 14 A 9 A 14 A 19 A 24 A 19 A 24 A
Max. CB size
2
15 A
20 A
15 A
20 A
25 A
30 A
25 A
30 A
Min. fitted AC input
wire size (mm
2
) per NEC
14 12 14 12 10 10 10 10
Max. output amperage:
24-volt battery @ 2.4 V/cell
128 A 192 A ――256 A 320 A ――
Max. output amperage:
36-volt battery @ 2.4 V/cell
128 A 192 A ――256 A 320 A ――
Max. output amperage:
48-volt battery @ 2.4 V/cell
104 A 156 A 80 A 120 A 208 A 260 A 160 A 200 A
Max. output amperage:
72-volt battery @ 2.4 V/cell
――76 A 114 A ――151 A 189 A
Max. output amperage:
80-volt battery @ 2.4 V/cell
――69 A 104 A ――139 A 173 A
Max. output amperage:
96-volt lithium-ion battery
@ full charge
――56 A 83 A ――111 A 139 A
1 The number of modules and module type determine the maximum output power rating.
2The circuit breaker ratings (maximum CB size) should be based on the charger maximum input ratings
(input amps), for the number of fitted modules, as stated in this section.

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Model
ProCore™
Edge 9
ProCore™
Edge 9
ProCore™
Edge 15
ProCore™
Edge 15
Number of fitted modules 2 3 2 3 4 5 4 5
Max. output power rating16 kW 9 kW 6.4 kW 9.6 kW 12 kW 15 kW 12.8 kW 16 kW
Module type
48-volt
80-volt
48-volt
80-volt
Nominal input voltage
480 VAC ±10% 3 ph. 50/60 Hz
Cabinet size
3-bay
5-bay
Min. DC output
wire size (AWG)
1/0 1/0 1/0 1/0 3/0 3/0 or 4/03 1/0 1/0
Protective class I
PSCCR max. (Icc) 3.6 kA
PSCCR min. (Icp, mr) 320 A
OCV II
Pollution degree 2
Efficiency and power factor
Efficiency = 94% maximum
Power factor = 0.95 maximum
Output protection
Short circuit protection
Reverse polarity protection
Dimensions (H×W×D)
18.6″ × 21″ × 14.7″
(473 mm × 534 mm × 374 mm)
24.8″ × 21″ × 14.7″
(631 mm × 534 mm × 374 mm)
Weight
51.8 lb. (23.5 kg) without module
9.2 lb. (+4.2 kg) per module
64.8 lb. (29.4 kg) without module
9.2 lb. (+4.2 kg) per module
Installation Wall and floor-stand mounting options
Environment
Operating temperature: −20°C to +45°C (−4°F to 113°F)
Storage temperature: −25°C to +65°C (−13°F to 149°F)
Relative humidity 90%, noncondensing
Enclosure
IP20, NEMA 1–only indoor use
Operating altitude
Up to 3000 m (9843 ft)
Certifications
CSA certified to UL1564, C22.2 107.2-01, and CEC
3Stated output currents require connectors and electrical cables of adequate capacity.

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4. Installation
Multicharger Installation Schemes
The side-to-side airflow design (Figure 1) requires adequate
spacing between chargers, or other arrangements,
for proper operation.
Figure 1Side-to-Side Airflow Design, Top View
Standard Side-to-Side Charger Spacing
The minimum side-to-side charger spacing,
for standard installations, is 18 in. (46 cm) (Figure 2).
Figure 2Standard Side-to-Side Charger Spacing
Hot air
exhaust
Cool air
intake
18 in.
(46 cm)

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Side-to-Side Charger Spacing with Dividers
Place metal panels between chargers for closer spacing
(Figure 3). The minimum charger-to-divider spacing,
for standard installations, is 4 in. (10 cm). The divider dimensions
should be, at a minimum, 24″H × 20″W and 30″H × 20″ W
(609.6 mm H × 508 mm W and 762 mm H × 508 mm W)
for 3- and 5-bay cabinets, respectively.
Figure 3Side-to-Side Charger Spacing with Dividers
Offset (45-degree–Angle) Charger Installation
Chargers may be installed also at an offset 45-degree angle for
higher density installations (Figure 4).
Figure 4Offset 45-degree Angle Charger Installation
4 in. (10 cm)

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Installation Precautions
DANGER
Only authorized, trained, and qualified personnel
should install and service this charger.
Installation must be carried out only by suitably qualified personnel
and in accordance with the NEC, ANSI/NFPA 70, or equivalent,
and comply with current local and national wiring regulations.
DANGER
NEVER PLACE THE CHARGER DIRECTLY ABOVE
OR BELOW THE BATTERY BEING CHARGED.
Gases or fluids from the battery will corrode and damage
the charger.
•Locate the charger as far away from the battery as
DC cables permit.
WARNING
The charger is only for indoor use.
•Do not expose the charger to rain.
The charger should be sited in a cool, dry, and well-ventilated
location away from corrosive fumes and humid atmospheres.
An ambient temperature range of between −4°F and 113°F must
be maintained.
•Ensure that ventilation is not obstructed at the left air-intake
and right exhaust vents.
Check, before installation, that the charger has not sustained any
damage in transit. Make sure that the electrical ratings are
suitable for both the intended AC input supply and the DC output
current and voltage for the batteries to be charged. Also, ensure
that the screw terminal connector polarity is correct and matches
the battery connector polarity.

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Positioning the Charger
CAUTION
The battery charger, when fitted with modules,
can be very heavy. Take precautions to avoid injury
when moving the charger.
Use appropriate material handling aids
(e.g., a pallet truck) to move the charger into position.
It is recommended to make use of a lifting hoist
(with straps or chains) wherever possible, especially
when the charger is raised above ground level.
Lifting eyebolts (M8 thread) can be attached to four
locations on the top panel of the charger to aid the
process (Figure 5). Remove the filler screws with
a 4-mm hex key before attaching the lifting eyebolts.
Figure 5Attaching Points for M8 Lifting Eyebolts,
Top-panel View

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Wall-Mount Installation
Check with professional installation personnel to determine proper
mounting techniques for all wall types. (Figure 6, Figure 7, and
Figure 8).
Figure 6Charger, Wall, Wall-Mount Hanger, Bottom Bracket,
and Screw with an M6 Thread
Figure 7
Charger on the
Wall-Mount Hanger
Figure 8
Bottom Bracket Mounted
to the Charger with a Tightening
Torque of 52.22 in.-lb. (5.9 N-m)

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Floor-Stand Installation
Figure 9Floor Stand
Bottom bracket for
a three-bay charger
Bottom bracket for
a five-bay charger
Hole for a pogo stick