Webasto ProCore Edge 9 User manual

ProCoreTM Edge 9/15
North America
Installation, Operation and
Maintenance Manual
Rev 05/18/23

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© Webasto Charging Systems, Inc., 2023. 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 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.
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.
Customer Support: [email protected]
1-866-767-4242
Parts: [email protected]
Owner’s Record
Model: ProCore™ Edge
Serial Number (SN):
Installation date:
Output power:

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Contents
1. Installation, Operation and Maintenance Manual ............9
1.1. Scope.............................................................................9
1.2 Acronyms, Abbreviations and Symbols ........................10
2. Required Tools...................................................................12
3. Technical Specications for 48V and 80V
Modules Fitted with 3- or 5-Bay Cabinets ...........................12
4. Installation..........................................................................14
4.1. Multi-Charger Installation Schemes .............................14
4.2 Installation Precautions.................................................16
4.3 Positioning the Charger ...............................................17
4.4 Wall-Mount Installation..................................................18
4.5 Floor Stand Installation .................................................19
5. Remote Battery Connections (Option) ............................34
5.1. Ten-way Screw Terminal Connector.............................34
Table 1 Bare-Ended Signal Connections ............................36
5.2 Optional Features .........................................................37
6. Putting Back the DC-Panel and Top Covers ...................37
6.1. DC-panel Cover ...........................................................37
6.2. Top Cover.....................................................................37

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7. Charger Light Bar .............................................................38
8. Operating Instructions .....................................................40
8.1. Battery Display.............................................................42
8.2 Buttons..........................................................................47
9. Maintenance.......................................................................49
9.1 Power Module Replacement ........................................49
9.2. Air Filter Replacement (TBA – not yet available) .........60
9.3. Preventive Maintenance Activities ...............................60
Table 2 Preventative Maintenance Schedule .....................61
10. Faults and Warnings .......................................................63

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1. Installation, Operation and Maintenance Manual
1.1. Scope
This manual is intended for use by personnel trained to install and
use chargers for charging batteries in a safe and correct manner.
NOTE
NOTE
NOTE
Read and understand these manufacturer instructions and all safety
practices.
This manual covers the installation, operation, and maintenance of the
charger, and charger accessories.
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 e󰀨orts 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
Each ProCore Edge has been assembled and programmed for each
customer. Webasto recommends that you contact Webasto Technical
Support before making any modications and/or additions (such as
additional modules) to your ProCore Edge.

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1.2 Acronyms, Abbreviations and Symbols
Acronym,
Abbreviation or
Symbol
Meaning
°C Degrees Celsius
°F Degrees Fahrenheit
AAmp(s) / Ampere(s)
AC Alternating Current
AWG American Wire Gauge
BMID Battery Monitor and Identier
BMS Battery Management System
CAN Controller Area Network
CB Circuit Breaker
CSA Canadian Standards Association
D Depth
DC Direct Current
Di Delta Current
Dt Delta Temperature
EU European Union
ft Foot or Feet
GCAN (G-CAN) Ground Controller Area Network
h Height
Hz Hertz (frequency)
Icc Conditional Short Circuit Current
Icp Prospective Short Circuit Current
mr Minimum Required
IEC International Electromechanical Commission
in. Inch(es)
in-lbs Inch Pounds
IP Ingress Protection (Rating)

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Acronym,
Abbreviation or
Symbol
Meaning
kg Kilogram(s)
kW Kilowatt(s)
L Length
lb. Pound(s) by Weight
Max. Maximum
Min. Minimum
mm Millimeter(s)
mm2Square Millimeter(s)
NEMA National Electrical Manufacturers Association
Nm Newton-metre/meter
OK All Correct
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 “Thus it had been written”
SOC State of Charge
SOOW Cable type (Service), which features Oil-resistant insulation,
an Oil-resistant jacket, and is Water resistant
UL Underwriters Laboratories
VVolt(s)
VAC Volt(s) Alternating Current
VDC Volt(s) Direct Current
WWidth
WCSI Webasto Charging Systems, Inc.

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2. Required Tools
• Hex key, 4 mm, for the ller 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 Specications for 48V and 80V Modules Fitted
with 3- or 5-Bay Cabinets
Technical Specications
Model ProCore Edge 9 ProCore Edge 9 ProCore Edge 15 ProCore Edge 15
Number of tted modules 23234545
Max. output power rating16 kW 9 kW 6.4 kW 9.6 kW 12 kW 15 kW 12.8 kW 16 kW
Module type 48V 80V 48V 80V
Nominal input voltage 480 VAC + 10% 3 ph. 50/60Hz
Cabinet size 3-bay 5-bay
Max. input amps (3-phase
480VAC) 9 A 14 A 9 A 14 A 19 A 24 A 19 A 24 A
Max. CB size215 A 20 A 15 A 20 A 25 A 30 A 25 A 30 A
Min. tted AC input
wire size (AWG) 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 ― ―
1The 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 tted 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 tted modules 23234545
Max. output power rating16 kW 9 kW 6.4 kW 9.6 kW 12 kW 15 kW 12.8 kW 16 kW
Module type 48V 80V 48V 80V
Nominal input voltage 480 VAC + 10% 3 ph. 50/60Hz
Cabinet size 3-bay 5-bay
Max. output amperage:
48V battery @ 2.4 V/cell 104 A 156 A 80 A 120 A 208 A 260 A 160 A 200 A
Max. output amperage:
72V battery @ 2.4 V/cell ― ― 76 A 114 A ― ― 151 A 189 A
Max. output amperage:
80V battery @ 2.4 V/cell ― ― 69 A 104 A ― ― 139 A 173 A
Max. output amperage:
96V lithium-ion battery @
full charge
― ― 56 A 83 A ― ― 111 A 139 A
Min. DC output wire size
(AWG) 1/0 1/0 1/0 1/0 3/0 3/0 or 4/031/0 1/0
Protective class I
PSCCR max. (Icc) 3.6 kA
PSCCR min. (Icp, mr) 320 A
OCV II
Pollution degree 2
Efciency and power factor Efciency = 94% maximum
Power factor = 0.95 maximum
Output protection Short circuit protection
Reverse polarity protection
Dimensions (H×W×D) 18.6 in. × 21 in. × 14.7 in.
(473 mm × 534 mm × 374 mm)
24.8 in. × 21 in. × 14.7 in.
(631 mm × 534 mm × 374 mm)
Weight 51.8. (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, stand, or oor 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%, non-condensing
Enclosure IP20, NEMA 1–only indoor use
Operating altitude Up to 3000 m (9843 ft)
Certications
CSA certied to UL1564, C22.2 107.2-01, and CEC
NOM-208-SCFI-2016
Technical Dictum for exemption of NOM-001-SCFI-2018.
3Stated output currents require connectors and electrical cables of adequate capacity.

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

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4.1.2. 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 3 Side-to-Side Charger Spacing with Dividers
 
4 in
(10 cm)
4.1.3 O󰀨set (45-degree–Angle) Charger Installation
Chargers may be installed also at an o󰀨set 45-degree angle for
higher density installations (Figure 4).
Figure 4 O󰀨set 45-Degree Angle Charger Installation

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4.2 Installation Precautions
DANGER
DANGER
Only authorized, trained, and qualied personnel should install
and service this charger.
NEVER PLACE THE CHARGER DIRECTLY ABOVE
OR BELOW THE BATTERY BEING CHARGED.
Gases or uids from the battery will corrode and damage the
charger.
• Locate the charger as far away from the battery as DC
cables permit.
Installation must be carried out only by suitably qualied personnel
and in accordance with the NEC, ANSI/NFPA 70, or equivalent,
and comply with current local and national wiring regulations.
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-ventilat-
ed location away from corrosive fumes and humid atmo-
spheres. 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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4.3 Positioning the Charger
CAUTION
The battery charger, when tted 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 ller screws with a 4-mm hex key before attaching
the lifting eyebolts
Figure 5 Attaching Points for M8 Lifting Eyebolts, Top Panel View

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4.4 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 6 Charger, Wall, Wall-Mount Hanger,
Bottom Bracket and Screw with an M5 thread
Figure 7 Charger on
the Wall-Mount Hanger
Figure 8 Bottom Bracket
Mounted to the Charger

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4.5 Floor Stand Installation
Figure 9 Floor Stand
Bottom bracket for
a 3-bay charger
Bottom bracket for
a 5-bay charger
Hole for a pogo stick

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Figure 10 Pre-Drilled Holes for Bolting the Bast to the Floor
Figure 11 Optional Pogo Stick Attached to the Pogo Bracket

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Figure 12 Charger Hung on the Floor Stand

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Figure 13 Bottom Bracket Mounted to the Charger and Floor
Stand with a Tightening Torque of 52.22 in-lbs (5.9 Nm)
M5 Screw

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DANGER
CONNECTION TO MAIN POWER
Only qualied service personnel should remove the cover.
Only a qualied electrician is to make electrical connections!
• Make sure that the service AC input voltage is powered o󰀨
before wiring the charger.
This device does not contain any user serviceable parts.
DANGER
• Ensure that the AC power cables to be used are disconnected
from the AC power supply before continuing!
• Verify that there is no connection to the AC before opening
the cabinet, which exposes AC wiring, and making terminal
connections!
• Disconnect all power before servicing!