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

IOMM ProCore Edge North America
Webasto Charging Systems, Inc. Page iii of viii 31241-03-01
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.
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