Webasto ProCore Edge 9 Installation, Operation And Maintenance Manual
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Webasto ProCore Edge 9 Installation, Operation And Maintenance Manual

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

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Summary of Contents for Webasto ProCore Edge 9

  • Page 1 ProCore™ Edge North America Installation, Operation, and Maintenance Manual...
  • Page 2 ProCore Edge North America IOMM © 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    Wall-Mount Installation ........11 Floor-Stand Installation ........12 AC Power Connection ........16 DC Battery Connection ........21 Remote Battery Connections (Option) ....27 Ten-way Screw Terminal Connector ....27 Optional Features .......... 30 31241-03-01 Page iv of viii Webasto Charging Systems, Inc.
  • Page 5 Operating Instructions ........3333 Battery Display ..........35 Buttons ............41 Maintenance ............43 Power Module Replacement ......43 Air Filter Replacement ........53 Preventive Maintenance Activities ....53 Faults and Warnings ..........56 Webasto Charging Systems, Inc. Page v of viii 31241-03-01...
  • Page 6 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 31241-03-01 Page vi of viii Webasto Charging Systems, Inc.
  • Page 7 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 Webasto Charging Systems, Inc. Page vii of viii 31241-03-01...
  • Page 8 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 31241-03-01 Page viii of viii Webasto Charging Systems, Inc.

  • Page 9: Installation, Operation, And Maintenance Manual

    Scope This manual is intended for use by personnel trained to install and use chargers for charging batteries in a safe and correct manner. Page 1 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 10: Acronyms, Abbreviations, And Symbols

    Degrees Fahrenheit Amp(s)/Ampere(s) Alternating Current American Wire Gauge BMID Battery Monitor and Identifier Battery Management System Circuit Breaker Canadian Standards Association Depth Direct Current European Union Foot or Feet Height Hertz Page 2 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 11 Kilowatt(s) Length Pound(s) (Latin) (Libra Pondo: [a] Pound [by] Weight) Max. Maximum Min. Minimum Millimeter(s) Square Millimeter(s) NEMA National Electrical Manufacturers Association Newton-metre/meter Oll Korrect [sic]: Facetious Alteration of All Correct Page 3 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 12 Cable Type (Service) and the Agents against Which It Protects (Oil-resistant Insulation, Oil-resistant Jacket, and Water resistant) To Be Announced Underwriters Laboratories Volt(s) Volt(s) Alternating Current Volt(s) Direct Current Width WCSI Webasto Charging Systems, Inc. Page 4 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 13: Required Tools

    The number of modules and module type determine the maximum output power rating. The 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. Page 5 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 14 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 Stated output currents require connectors and electrical cables of adequate capacity. Page 6 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 15: Installation

    Figure 1 Side-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). 18 in. (46 cm) Figure 2 Standard Side-to-Side Charger Spacing Page 7 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 16: Figure 3 Side-To-Side Charger Spacing With Dividers

    Figure 3 Side-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 4 Offset 45-degree Angle Charger Installation Page 8 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 17: Installation Precautions

    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. Page 9 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 18: Positioning The Charger

    (Figure 5). Remove the filler screws with a 4-mm hex key before attaching the lifting eyebolts. Figure 5 Attaching Points for M8 Lifting Eyebolts, Top-panel View Page 10 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 19: Wall-Mount Installation

    Figure 6 Charger, Wall, Wall-Mount Hanger, Bottom Bracket, and Screw with an M6 Thread Figure 7 Figure 8 Charger on the Bottom Bracket Mounted Wall-Mount Hanger to the Charger with a Tightening Torque of 52.22 in.-lb. (5.9 N-m) Page 11 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 20: Floor-Stand Installation

    ProCore Edge North America IOMM Floor-Stand Installation Bottom bracket for a three-bay charger Bottom bracket for a five-bay charger Hole for a pogo stick Figure 9 Floor Stand Page 12 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 21: Figure 10 Predrilled Holes For Bolting The Base To The Floor

    IOMM ProCore Edge North America Figure 10 Predrilled Holes for Bolting the Base to the Floor Figure 11 Pogo Stick (Optional) Attached to the Pogo Bracket Page 13 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 22: Figure 12 Charger Hung On The Floor Stand

    ProCore Edge North America IOMM Figure 12 Charger Hung on the Floor Stand Page 14 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 23: Figure 13 Bottom Bracket Mounted To The Charger And

    IOMM ProCore Edge North America M6 screw Figure 13 Bottom Bracket Mounted to the Charger and Floor Stand with a Tightening Torque of 52.22 in.-lb. (5.9 N-m) Page 15 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 24: Ac Power Connection

    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! • Page 16 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 25: Figure 14 Six M6 Panel Crews, Top-Panel View

    Remove the six M6 screws on the top panel of the charger (Figure 14), with a TORX TX30, and then remove the panel. Figure 14 Six M6 Panel crews, Top-panel View Page 17 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 26: Figure 15 Ac Service Entrance

    Figure 17), which is the hole located near the top left corner of the charger. NOTE The USB connector is located in the top left corner of the charger (Figure 15). AC Service Entrance Figure 15 AC Service Entrance Page 18 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 27: Figure 16 Ac Service Entrance For The Three-Bay Cabinet

    IOMM ProCore Edge North America Ground and power cables service entrance Figure 16 AC Service Entrance for the Three-bay Cabinet Ground and power cables service entrance Page 19 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 28: Figure 17 Ac Service Entrance For The Five-Bay Cabinet

    22.2 in.-lb. (2.5 N-m) to 26.4 in.-lb. (3 N-m), respectively. AC line input positions are interchangeable because the three-phase input is not phase specific. Ensure that the cable gland or conduit clamp has been properly tightened. Page 20 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 29: Dc Battery Connection

    DO NOT ATTEMPT TO CHARGE NON-RECHARGEABLE BATTERIES. 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. Page 21 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 30 10 to 14 AWG (6–2.5 mm ). The minimum and maximum screw-tightening torque is 22.2 in.-lb. (2.5 N-m) and 26.4 in.-lb. (3 N-m), respectively. Page 22 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 31 IOMM ProCore Edge North America DC output power cables are provided with the charger. Anderson Euro, SB, or SBX connectors are used. Please contact WCSI Customer Support, 1–866–767–4242, for more information. Page 23 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 32: Figure 18 Two Torx Tx25 Screws Securing The Dc Output Power Cable Panel

    (Figure 18), and pull the panel up and away from the charger cabinet. Figure 18 Two TORX TX25 Screws Securing the DC Output Power Cable Panel Page 24 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 33: Figure 19 Three- And Five-Bay Bus Bar Arrangement

    (red) DC output power cable and one for the negative (black) DC output power cable (Figure 19). Figure 19 Three- and Five-bay Bus Bar Arrangement Page 25 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 34 53.1 in.-lb (6 N-m), to secure them for strain relief. (Figure 19) NOTE Ensure, prior to fastening the lower clamp, that the grey protective rubber sleeve (F igure 19) is on the upper side of the DC output power cables. Page 26 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 35: Remote Battery Connections (Option)

    A 10-way screw terminal connector (Figure 20) is provided behind the DC output power cable panel. Figure 20 Ten-way Screw Terminal Connector This connector facilitates the connection of battery-related signals (battery communications). Page 27 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 36: Figure 21 Battery Communication Wires Connected To The Screw Terminal

    “pilot (interlock)”—to the screw terminal, per Table 1, and tighten the terminal screws with a torque of 5.31 in.-lb. (0.6 N-m). (Figure 21) Figure 21 Battery Communication Wires Connected to the Screw Terminal Page 28 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 37: Table 1 Bare-Ended Signal Connections

    24-VDC WATERING VALVE Pin 2 Negative lead to the SPARE RELAY Pin 1 Positive lead to the SPARE RELAY The connector can accept up to a 16-AWG wire. CAUTION Use only copper wires. Page 29 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 38: Optional Features

    TORX TX25 screws (Figure 18), for which the torque is 21.24 in.-lb. (2.4 N-m). Top Cover The top cover must be reinstalled by tightening the six M6 screws (Figure 14), for which the torque is 52.22 in.-lb. (5.9 N-m). Page 30 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 39: Charger Light Bar

    32 lights on a 5-bay charger light bar.) If, for example, the battery was 75% charged, then the bottom 75% of the bar would be cascading blue, and the top 25% of the bar would be dark (unilluminated). Page 31 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 40 Cascading Equalizing yellow The charger is undergoing equalization of the charger batteries. Solid yellow Watering The charger is watering the battery. Solid green Completed The charging is 100% completed. Page 32 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 41: Operating Instructions

    (Figure 22) "Connect Vehicle" indicates that there is no vehicle connected to the charger. The charger is idle. NOTE The buttons have no function if the status bar displays “Connect Vehicle.” Page 33 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 42 Charger Displays the power rating for the charger maximum output power The value changes as modules are added or removed. Day and time The ProCore™ Mobile App automatically sets this indicator. Page 34 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 43: Battery Display

    State-of-charge wheel Status bar Equalization schedule Water level indicator Charge current Battery and voltage temperature Equalization schedule Start button button Stop button Figure 23 Graphical Battery Display Page 35 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 44 SOC, as indicated below, allowing the battery charging state to be monitored at a distance. Color Charge Percentage Yellow Less than 80% Blue 80% or greater Green 100% fully charged battery Page 36 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 45 The display can be set to °F or °C, using the ProCore™ Mobile App Charger Setup/Display Options window. If the battery is overtemperature, then the charger faults and displays the battery temperature window as red. Page 37 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 46 Full Charging • Offline • Charging is stopped to use the ProCore™ Mobile App to change the configuration. Fault • Additional information is displayed about the fault or warning. Initialization (Phase) • Page 38 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 47 There is no drop if there is a CAN battery or if there is no BMID (voltage mode). Charge current The charger controls the charging current via and voltage Webasto proprietary charging algorithms. Page 39 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 48: Figure 24 Alternate Tabular Battery Display

    (Figure 24). Repeat this step to return the display to the graphical battery display. Figure 24 Alternate Tabular Battery Display Page 40 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 49: Buttons

    Start button for three seconds again to switch back to the graphical battery display. Stop Press the Stop button (Figure 23) • to stop the charge. The charger displays, on the status bar, “Charge Stopped.” Page 41 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 50 The battery should be able to accept a normal charge after the recovery charge is completed. Page 42 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 51: Maintenance

    Using a flathead screwdriver, turn the latch on the side of the charger clockwise to unlock the door and open it (Figure 25). Figure 25 Latch on the Side of the Charger Page 43 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 52: Figure 26 Disconnected Power Cables

    Disconnect the DC output cable (Figure 26, left) and the three-phase AC input cable (Figure 26, right) from the power module to be replaced by squeezing the clamp releases and pulling. Figure 26 Disconnected Power Cables Page 44 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 53: Figure 27 Ground Cable Disconnection

    Disconnect the power module communication cable(s). The two possible configurations for power module communications are single-cable connection and multicable connection. Sections 9.1.4.1 and 9.1.4.2 explain the directions for disconnecting each configuration. Page 45 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 54: Figure 28 Single-Cable Connection

    Figure 28 Single-Cable Connection NOTE The ribbon cable has a red edging to denote Pin 1. Always, when facing the module, insert the connectors so that the cable red line is on the left. Page 46 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 55: Figure 29 Multicable Connection

    IOMM ProCore Edge North America Multicable Connection Only the communication cables from the module to be replaced need to be disconnected, for a multicable connection (Figure 29). Figure 29 Multicable Connection Page 47 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 56: Figure 30 Power Module Removal

    Turn each mounting screw counterclockwise, using a flathead screwdriver, until the spring ejects and releases the screw from the nut. Carefully pull out the power module. (Figure 30) Figure 30 Power Module Removal Page 48 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 57: Figure 31 Replacement Power Module Insertion

    Insert the replacement power module. Use a flathead screwdriver to tighten the mounting screws by pushing in and turning clockwise. (Figure 31) Figure 31 Replacement Power Module Insertion Page 49 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 58: Figure 32 Power Module Position Selector

    Power Module Positions The power module positions are 1 through 3 for the three-bay and 1 through 5 for the five-bay. The Module 1 position always starts at the top slot. Page 50 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 59: Figure 34 Flat Cable Reconnection To The Power Module

    ProCore Edge North America Reconnect all communication cables that were disconnected in step 9.1.4. Connect the flat cable(s) to the power module (Figure 34). Figure 34 Flat Cable Reconnection to the Power Module Page 51 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 60: Figure 35 Flat Cable Connection To The Termination Block

    ProCore Edge North America IOMM Connect the flat cable to the termination block (Figure 35). Figure 35 Flat Cable Connection to the Termination Block Page 52 of 68 31241-03-01 Webasto Charging Systems, Inc.

  • Page 61: Air Filter Replacement

    Air Filter Replacement TBA, not yet available Preventive Maintenance Activities Table 2 describes the preventive maintenance activities for the first three years of the system life. Page 53 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 62: Table 2 Preventive Maintenance Schedule

    Pay close attention to electronic ProCore™ devices to prevent damage. It may be Interior necessary to vacuum out dust more frequently if the unit is installed in a highly dusty environment. Page 54 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 63 The data contacts in the output cable should last for a minimum of 5000 disconnection cycles. Replace Disconnections Contacts Every per Day Data Contacts “X” Months on Output Connectors Page 55 of 68 Webasto Charging Systems, Inc. 31241-03-01...

  • Page 64: Faults And Warnings

    BAT OVER Fault The battery Check the VOLTAGE voltage is too battery high (i.e., parameters Battery over above the for accuracy. Voltage battery table maximum voltage limit) to charge. Page 56 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 65 The battery is drained to a voltage below a safe level for charging. Recovery charge is needed. Page 57 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 66 Check the Communication communication communication Timeout with the battery wires. was lost over the communication bus. Battery Fault Battery Check the Connection initialization battery Issue failed during communications connection. wiring for damage. Page 58 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 67 A faulty battery Service the cannot accept battery. a high-charge current. An incorrect Use the BMID setting ProCore™ App is resulting to correct the in a faulty BMID settings. battery overheating. Page 59 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 68 2 volts. Battery Voltage Fault Positive and Fix the output Reversed negative cable connection terminals are polarity. reversed on the battery connection. Page 60 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 69 Access read charge configuration settings. DC Line Open Fault The difference Check the between the battery voltage module sensor wiring reported for damage. voltage and local battery voltage exceeds 5 volts. Page 61 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 70 Module General Fault The module Call Webasto Fault faulted with no service. specific reason reported. Module High Warning The module Check for Temperature temperature is obstructed very high. air flow. Page 62 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 71 Module/ The system charger over board Remove the Temperature temperature blockage. sensor is above 80°C. The module temperature is too high to charge. The module Replace the failed. power module. Page 63 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 72 No Battery Fault Configure the Configuration parameters voltage mode have not been settings on the configured for charger, using the voltage the ProCore™ mode charge. mobile app. Page 64 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 73 There is disconnected to clear. a module without overvoltage. opening the pilot. Power Stage Fault There was a Call Webasto Initialization (CAN bus service. Error data) problem during power stage initialization. Page 65 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 74 ProCore Edge North America IOMM Page 66 of 68 31241-03-01 Webasto Charging Systems, Inc.
  • Page 75 IOMM ProCore Edge North America Page 67 of 68 Webasto Charging Systems, Inc. 31241-03-01...
  • Page 76 ProCore Edge North America IOMM Webasto Charging Systems, Inc. 1333 S. Mayflower Ave., Ste 100 Monrovia, CA 91016 Corporate headquarters: Friedrichshafener Str. 9 82205 Gilching Germany Page 68 of 68 31241-03-01 Webasto Charging Systems, Inc.

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