Webasto ProCore User manual
Installation ManualProCore
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Installation Manual
ProCoreTM Auto-Watering Kit,
24VDC Valve & Mount-On Pedestal
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© Webasto Charging Systems, Inc., 2022. All rights reserved.
ProCoreTM 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 trade-
marks, service marks, symbols, and logos stated herein are the property of the respective companies.
Changes or modications 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. Specications 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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Owner’s Record
Model:
ProCore™
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.
1-866-767-4242
Parts: [email protected]
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Table of Contents
Overview......................................................................................................................................7
Safety Precautions – Read Before Using....................................................................................7
Installation Note...........................................................................................................................9
Preparation .................................................................................................................................9
Hardware.....................................................................................................................................9
Installation ...................................................................................................................................9
Connecting a Second Port to an Existing Tank .........................................................................16
Fill Water Considerations ..........................................................................................................16
Operation...................................................................................................................................16
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Overview
Flooded batteries lose water as they are charged and discharged. A forklift battery can lose up to 1.5 gallons of
water in a week of heavy use. Automatic battery watering assures that the electrolyte level is maintained properly
for battery health and safety.
Electrolyte levels rise as a battery is charged; adding water when a battery is not fully charged can result in
overows later. Auto watering prevents overlling by adding water during the weekly equalization charge cycle.
This assures that the battery is fully charged before water is added and also allows the bubbling action to mix
the water with the electrolyte.
Safety Precautions – Read Before Using
Symbol Usage
WARNING Contains information about safety practices necessary to prevent re or
equipment overheating.
DANGER Contains information about safety practices necessary to prevent personal
injury or death.
• Disconnect charger unit from utility power and any vehicles or battery packs while assembling and mounting
the auto watering kit.
• Wear safety glasses while using drill.
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Installation Note
The installation kit is only used with PosiCharge chargers.
Preparation
This manual is to be used for installation of the following kits:
Part Number Description
25046 Kit, 5 Gal. Tank Auto Watering, 24VDC Valve, ProCore
25047 Spec, Kit, Auto Watering Expansion, 24VDC Valve, Hoses, Couplings, No Tank, Instructions
Hardware
Items Tools – Standard Hardware Qty
1 Hardware kit from P/N # 25046 Auto Watering Kit See installation steps below
2 7/16-in Wrenches 2
3 Small Cutting Pliers 1
4 Standard Pliers 1
5 Small Flat-Blade Screwdriver 1
Installation
1. Disconnect the unit from the utility and unplug the output cable from any vehicle or battery pack.
2. Mount the extension bracket (25394) to the water tank bracket with:
• (2) 1/4-20 x 2 bolt (P/N # 04208)
• (2) 1/4-in washer (P/N # 25046 kit)
• (2) 1/4-in lock washer (P/N # 25046 kit)
• (2) 1/4-20 nut (P/N # 25046 kit)
Extension
Bracket
1/4-20 x 1/2 Bolt
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3. Mount the extension bracket (P/N # 25394) to the
pedestal with two 5/16-18x3/4 ange head cap screws
(P/N # 24759) from front of extension bracket, two
5/16-18 Hex nuts (P/N # 06897), and two at washers
(P/N # 05241) to the rear side of pedestal.
4. Attach the garden hose ll hose from the water supply
to the input of the tank.
Two 5/16-18 x 3/4
Flange Head Cap
Screws
Garden Hose Connection
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5. Prepare the valve by attaching the mounting plate to the valve bolts with a 7/16-in wrench.
Mounting Bracket
6. Conrm it is correctly positioned to the strainer as shown below.
Strainer
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7. Mount the valve to the left side of the pedestal
using two 1/4-20 x 1/2 anged bolts (P/N # 01860).
8. Guide the valve wires through the hole with the
strain relief (P/N # 13598), “clicking” it into position
with pliers.
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9. Connect one red wire to the negative (-) and another red wire to the positive (+) electrical connections,
then connect the green wire to the earth/ground connection as shown bellow.
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10. Attach the tank output hose to the tank as shown below on the left, and route the hose to the valve/strainer
and cut o any excess hose. Then slip the hose end over the barbed tting on the strainer and secure it with
the hose clamp as shown below on the right.
NOTE: Be sure to position the valve/strainer so the “IN” mark is located on the top.
Output from Tank
IN
Out
11. Attach the watering hose to the charger output connector with a cable tie as shown below, then secure the
hose to the output cable with a cable tie every two inches. When nished, cut o any excess hose, slip the
hose over the barbed tting on the valve, and secure it with a metal hose clamp.
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12. Use cable ties to secure all the loose hoses to available location on the complete assembly as shown below.
13. Turn the charger ON.
14. Use the charger menu to activate the auto watering function by doing the following:
A. Press Select until “Charger Conguration” is displayed.
B. Press Enter, then press Enter and the down arrow key at the same time until Key Code is displayed.
C. Press Select until “Watering System Conguration” is displayed.
D. Press Enter, then press the up arrow key until “Watering System Enabled ON” is displayed, then
press Enter again to save the selection.
E. “Watering System Type” should then be displayed – press Enter, then use the arrow keys to select
BFS Low Pressure, and press Enter again to save the selection.
F. The watering system is now activated – press Enter until you have completed exited the menu.
The installation is now complete.
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Connecting a Second Port to an Existing Tank
• Use auto watering expansion kit 25047 (DC Valve).
• Use the supplied T adapter to connect the watering valve to the existing tank.
Fill Water Considerations
• The tank should be lled from a continuous supply or manually at least once each week.
• Water containing high levels of certain impurities can damage the battery.
• The ll water supply must be tested to assure that the limits below are not exceeded. This is especially
important if the water supply uses copper piping. If the limits are exceeded, a water lter must be installed
and maintained to remove the impurities and protect the batteries.
Impurity Maximum Allowable PPM
Iron (Fe) 5
Chloride (CI) 10
Manganese (Mn) 0.1
Copper (Cu) 5
Total Fixed Residue (as sulfated ash) 150
Operation
Operators must connect the charger’s watering hose to the truck’s single point watering connection when they
connect to the charger at the end of the week; the charger automatically opens the water supply valve during
the weekly equalization charge to add water to the battery.
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Webasto Charging Systems, Inc.
1333 S. Mayower Ave., Ste 100
Monrovia, CA 91016
USA
Corporate headquarters:
Friedrichshafener Str. 9
82205 Gilching
Germany
Identication No. 25401-76-0202 • 02/2022 • © Webasto Charging Systems, Inc., 2022
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