Webasto ProCore Edge Installation and user guide

ProCoreTM Edge
North America
Installation, Operation, Service & Maintenance
Rev 04/27/23

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 2 of 112
© Webasto Charging Systems, Inc., 2023. All rights reserved.
ProCoreTM Edge 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.

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Part Number 5911110 A02Webasto Charging Systems, Inc. Page 3 of 112
Owner’s Record
Model: ProCore™ Edge
Serial Number (SN):
Purchase date:
Output power:
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]
Continued on next page.

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 4 of 112
In addition, please have the following information on hand before you call:
1. Failed charger SKU number and serial number
2. Failed module SKU number and serial number
3. Customer name (for our reference)
4. Problem description, including any fault codes
5. Data download from the charger, including charge logs and fault logs
6. Ship-to contact name
7. Ship-to phone number (if possible, include a cell phone number for text
messaging) and email address
8. Ship-to company address
We also recommend taking pictures using your cell phone in case you
need to send them to Webasto Customer Support via text message or email
– we can use the images to help diagnose any problems.

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Contents
Warnings and Cautions ............................................................................. 7
Installation and Operation ......................................................................... 9
Acronyms, Abbreviations and Symbols............................................... 10
Required Tools for 3-Bay and 5-Bay Cabinets .................................... 13
Technical Specications for 3-Bay and 5-Bay Cabinets ...................... 13
Required Tools for 10-Bay Cabinet ..................................................... 15
Technical Specications for 10-Bay Cabinet ....................................... 15
Positioning the Charger ...................................................................... 17
Choosing to Wall-Mount or Floor-Mount the Charger ......................... 18
AC Power Connection......................................................................... 29
DC Power Output ................................................................................ 35
Battery Connections for 3-Bay and 5-Bay Cabinets (Optional)........... 39
Battery Connections for 10-Bay Cabinet (Optional) ............................ 41
Connection and Description for 3-Bay and 5-Bay Cabinets................ 43
Charger Light Bar for 3-Bay, 5-Bay and 10-Bay Cabinets................... 46
Operating Instructions............................................................................. 48
Battery Display .................................................................................... 49
Alternate Battery Display..................................................................... 52
Faults and Warnings – Hardware Diagnostics .................................... 55
Initial Software Setup .......................................................................... 61
Required Equipment ........................................................................... 62
Procedure ........................................................................................... 62

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
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Service / Maintenance.............................................................................. 65
Preventative Maintenance Schedule ...................................................... 65
Replacing a Module............................................................................. 69
Replacing the Output Cable ............................................................... 81
Replacing the Controller PCBA........................................................... 85
Replacing the Door Panel ................................................................... 87
Removal .............................................................................................. 87
Installation .......................................................................................... 90
Interface Board Communication Connectors / Replacing the Fuse .... 91
Firmware Updates............................................................................... 95
Voltage Driven vs BMID Communications........................................... 99
Power Module Firmware Update........................................................... 101
Required Software ................................................................................. 101
Required Hardware................................................................................. 101
Denitions and Acronyms ..................................................................... 102
Procedure Log ....................................................................................... 102
Setup Instructions.................................................................................. 103
Setup Procedure ............................................................................... 103
Firmware Update .................................................................................... 109

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DANGER
Only qualied service personnel should remove the DC output power
cable panel and service the charger.
DANGER
RISK OF ELECTRIC SHOCK
DANGER
BATTERIES CAN BE DANGEROUS.
DANGER
DO NOT ATTEMPT TO CHARGE
NON-RECHARGEABLE BATTERIES.
Electric shock can cause death or serious injury.
• Do not touch the uninsulated portion of the output power cable, battery
connector or other live electrical parts, or uninsulated battery terminals.
• Disconnect the charger from the input power and battery before servicing.
Batteries generate explosive gases during normal charging and usage. Always
follow charging instructions and those of the battery manufacturer to reduce the
risk of battery explosion.
Fast chargers are designed to be used only for charging rechargeable batteries.
Attempting to charge non-rechargeable batteries could lead to death or injury
from exploding batteries.
Warnings and Cautions
WARNING
FLAMMABLE
• Keep batteries away from re.
• Do not smoke, use an open ame, or cause sparks near a battery.

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 8 of 112
WARNING
CAUTION
Use only copper wires.
CAUTION
Every ProCore Edge is assembled and programmed for each
customer’s specic needs. Webasto recommends that you contact
Webasto Technical Support before making any modications and/or
additions (such as modules) to your ProCore Edge.
Connecting a high-voltage battery (80 V or higher) to a low-range charger
(24 V – 48 V) may damage the charger.
Use voltage-keyed connectors on the chargers and batteries if your facility has
mixed battery voltages.
NOTE
Three- and ve-bay cabinets have eld wiring terminal blocks that can
accept a input wire gauge range from 10 to 14 AWG (6–2.5 mm2).
• The minimum and maximum screw-tightening is 22.2 in-lb
(2.5 Nm) and 26.4 in-lb (3 Nm) of torque, respectively.
• DC output power cables are provided with the charger.
• Anderson Euro, SB or SBX connectors are used.
• For more information, contact WCSI Customer Support at
1-866-767-4242.
The 10-bay cabinet has eld wiring terminal blocks that can accept
a input wire gauge range from #10 AWG to #4 AWG. Refer to the
Torque Specications Label on page 33 for the appropriate torque
value for the screws for each wire size.

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Installation and Operation
Read and understand these manufacturer instructions and all safety practices.
This manual provides important information for installing the charger and should
be carefully read.
This manual is based on information available at the time of publication. While
e󰀨orts have been made for the information to be accurate, it does not cover all
details of or variations in the hardware or software, nor provide for every possible
contingency in connection with installation.
The features described may not be included in all systems.
Always press the STOP button on the ProCore Edge battery display before
disconnecting SB cables from a battery. Pressing the STOP button will prevent
the possibility of electrical arcing.
NOTE
NOTE
NOTE
NOTE
This manual provides instructions for the installation and operation of the
ProCore Edge Charging System, as well the maintenance and service of select
components.
The procedures should only be performed by trained and qualied technicians
to enhance safety and protect equipment integrity.
Please refer to the Table of Contents on pages 5-6 for the list of procedures
included in this manual.

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 10 of 112
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
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)
IP Ingress Protection (Rating)
kg Kilogram(s)

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Acronym,
Abbreviation
or Symbol
Meaning
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
N-m 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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Required Tools for 3-Bay and 5-Bay Cabinets
Technical Specications for 3-Bay and 5-Bay Cabinets
• Hex key 4 mm – ller screws on the charger top panel
• TORX TX30 – charger top panel for units shipped during 2021-2022
• TORX TX25 – charger top panel for units shipped 2023 and later
• Flathead screwdriver – terminal screws
• TORX TX25 – DC output power cable panel
Model ProCoreTM
Edge 9
ProCoreTM
Edge 9
ProCoreTM
Edge 15
ProCoreTM
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 48 V 80 V 48 V 80 V
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 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 — —
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:
80-volt battery @ 2.4 V/cell — — 56 A 83 A — — 111 A 139 A
1The number of modules and module type determine the maximum output power rating.
2 The 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.

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 14 of 112
Model ProCoreTM
Edge 9
ProCoreTM
Edge 9
ProCoreTM
Edge 15
ProCoreTM
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. 50/60 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
4/031/0 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″ × 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 oor-stand mounting options
Environment Operating temperature: −4°F to 113°F (−20°C to +45°C)
Storage temperature: −13°F to 149°F (−25°C to +65°C)
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

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Required Tools for 10-Bay Cabinet
• Hex key 4 mm – ller screws on the charger top panel
• TORX TX25 – charger top panel
• Flathead screwdriver – terminal screws
• TORX TX25 – DC output power cable panel
Technical Specications for 10-Bay Cabinet
Number of tted
modules 6 7 8 9 10 6 7 8 9 10
Power Rating 18 kW 21 kW 24 kW 27 kW 30 kW 19.2 kW 22.4 kW 25.6 kW 28.8 kW 32 kW
Cabinet Size 10 Bay 10 Bay
Module Type 24V- 48V 48V - 96 V
Input voltage 480 VAC ±10% 3 ph 50/60 Hz
Input amps
(3-phase 480VAC) 25A 29A 33A 37A 41A 26A 30A 35A 39A 43A
Maximum
CB size[1] (A) 35A 40A 45A 50A 60A 35A 40A 45A 50A 60A
Minimum AC input
wire size (AWG) 10 8 6 6 4 10 8 6 6 4
Maximum output
amperage
24V @ 2.4V / cell
384 448 512 576 640 – – – – –
Maximum output
amperage
36V @ 2.4V / cell
384 448 512 576 640 – – – – –
Maximum output
amperage
48V @ 2.4V / cell
312 364 416 468 520 240 280 320 360 400
Maximum output
amperage
72V @ 2.4V / cell
– – – – – 222 259 296 333 370
Maximum output
amperage
80V @ 2.4V / cell
– – – – – 200 235 268 302 334
Maximum output
amperage
96 V @ 2.4 V/cell
(Only lithium)
– – – – – 167 195 222 250 278
Minimum DC
output wire size
(AWG)
4/0 or
350
mcm
2/0 x 2
or 350
mcm
3/0 x 2 4/0 x 2 4/0 x 2 2/0 2/0 4/0 4/0 4/0

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 16 of 112
Number of tted
modules 6 7 8 9 10 6 7 8 9 10
Power Rating 18 kW 21 kW 24 kW 27 kW 30 kW 19.2 kW 22.4 kW 25.6 kW 28.8 kW 32 kW
Cabinet Size 10 Bay 10 Bay
Module Type 24V- 48V 48V - 96 V
AC Power System TN, TT : Star (no Neutral connection)
Protective Class 1
PSCCR 640A min, 4KA max
OCV II
Pollution Degree 2
Dimensions
H x W x D
40.47 in x 21.18 in x 14.76
(1028 mm x 538 mm x 375 mm)
Weight 94.8 lb (43 Kg) Without module
9.2 lb (4.2 Kg) Per module
Installation Wall, stand, or oor mounting options
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
Field Repair Module replacement

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Positioning the Charger
The battery charger can be very heavy when tted with modules. 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 use a lifting hoist with straps or chains wherever
possible, especially when the charger is raised above ground level.
M8 thread lifting eyebolts can be attached to four locations on the top panel of
the charger to aid the process. Use a 4 mm hex key to remove the ller screws
before attaching the lifting eyebolts.
The battery charger can be very heavy when tted with modules. 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 use a lifting hoist with straps or chains wherever
possible, especially when the charger is raised above ground level.
M8 thread lifting eyebolts can be attached to four locations on the top panel of
the charger to aid the process. Use a 4 mm hex key to remove the ller screws
before attaching the lifting eyebolts.
CAUTION
Fig. 1 – Attaching points for M8
lifting eyebolts, top panel view

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 18 of 112
Wall Mount Installation for 3-Bay and 5-Bay Cabinets
Check with a professional installation professional to determine the proper
mounting technique for your facility.
Fig. 2 – Charger, wall, wall mount hanger, bottom bracket and
screw with an M6 Thread for units shipped during 2021-2022.
For units shipped in 2023 and later, use an M5 Thread.
Choosing to Wall-Mount or Floor-Mount the Charger
Before you set up the ProCore Edge to be operational, you will want to choose
whether to install the charger as a wall-mounted unit or a oor-mounted unit.
This will help you to decide your spacing needs and length of cables, etc.

Installation, Operations, Service & MaintenanceProCore Edge
Part Number 5911110 A02Webasto Charging Systems, Inc. Page 19 of 112
1. Using the bolt hole locations
for reference, secure the
top bracket to the wall.
NOTE:
Wall anchor bolts are
not included in the wall
mounting kit.
2. There are two slots on
the back of the charger
for mounting it to the wall
mount bracket – mount
the charger onto that top
bracket.
3. After mounting the charger
on the wall bracket,
secure the underside of
the charger with the L
bracket and torque the
bolts.
M6: 52.22 in-lbs (5.9 Nm)
M5: 35.4 in-lbs (4.0 Nm)
Then secure the L bracket
to the wall.
Bracket Slots
Fig. 3 – Bolt Hole Locations
Fig. 4 – Bracket Slots
Fig. 5 – L Bracket

Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 20 of 112
Floor Mount Installation for 3-Bay and 5-Bay Cabinets
Charger
Hanging
Bracket
Underside Securing
Brackets
Two available positions:
One for 3-Bay
One for 5-Bay
Arm for Cable
Management
Accessories
(Cable Tidy / Pogo)
Stand Base
Central Beam
Fig. 6 – Floor Mount Stand