Webasto PosiCharge ProCore Service Manual
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Webasto PosiCharge ProCore Service Manual

Webasto PosiCharge ProCore Service Manual

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PosiCharge ProCore
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Summary of Contents for Webasto PosiCharge ProCore

  • Page 1 PosiCharge ProCore Service Manual...
  • Page 2 ProCore are products 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 A NOTE ABOUT CUSTOMER SUPPORT To ensure superior service, please write down the unit’s serial number in the owner’s record above and have it available when contacting Webasto customer support. The serial number can be found on the nameplate rating label on the left side of the unit.

  • Page 4: Table Of Contents

    Contents 1 SERVICE ........................1 1.1 Symbol Usage ....................2 1.2 General Safety Precautions ................3 1.3 About This Manual ..................4 1.4 Replace the Charging Module ..............4 1.5 Replace the Output Cable ................4 1.6 Replace the System Controller/Display............6 1.7 Replace the Backplane Fuses ...............8 1.8 Replace Control Power Transformer ............8 1.9 Replace Backplane Board ................9 1.10 Update Firmware ....................9...

  • Page 5: Service

    C h A P T E R 1 SERVICE...

  • Page 6: Symbol Usage

    1.1 SYMBOL USAGE The PosiCharge ProCore is designed with safety as the highest priority. Installation must comply with all local codes and the following safety precautions must be read and observed. Indicates information about safety practices which, if not followed, may result in serious injury or death.

  • Page 7: General Safety Precautions

    1.2 GENERAL SAFETY PRECAUTIONS BEFORE YOU BEGIN • Read the important safety instructions below. • Only qualified personnel should install, use, or service this unit. • Read and understand these manufacturer’s instructions and your employer’s safety practices manual. ELECTRIC ShOCK CAN KILL •...

  • Page 8: About This Manual

    1.3 ABOUT ThIS MANUAL This service manual provides instructions for replacing certain components of PosiCharge ProCore battery chargers. The procedures should only be performed by trained and qualified technicians to enhance safety and protect equipment integrity. The following procedures are described: •...
  • Page 9 Figure 1: Output Connector Bolts 8. See Figure 2. Unplug the four-pin Molex Comm cable connector from the bottom left corner of the backplane. You may need to unbolt the cable on the bus bar above it to access the connector. Figure 2: Comm Cable Connector 9.

  • Page 10: Replace The System Controller/Display

    Figure 4: Strain Relief Nuts 11. Pull cables out of the cabinet. 12. Reverse above procedure to install new cable as follows. 13. Thread cables through cabinet openings and secure the strain relief nuts to the cabinet. 14. Loop the Comm cable and reinstall snap-on ferrite filter onto Comm cable as shown in Figure 3.
  • Page 11 Figure 5: Removing the System Controller/Display Cover 9. Unplug the ribbon cable from the connector on the controller board. 10. See Figure 6. Remove controller board/display assembly from cabinet. Figure 6: Removing the System Controller/Display 11. Reverse the above procedure to reinstall.

  • Page 12: Replace The Backplane Fuses

    1.7 REPLACE ThE BACKPLANE FUSES 1. Unplug any vehicles connected to the charger. 2. Turn OFF AC power at the breaker and lock it out. 3. Wait five minutes for capacitor voltages to bleed down. 4. Remove left side panel. 5.

  • Page 13: Replace Backplane Board

    1.9 REPLACE BACKPLANE BOARD 1. Unplug any vehicles connected to the charger. 2. Turn OFF AC power at the breaker and lock it out. 3. Wait five minutes for capacitor voltages to bleed down. 4. Remove right side panel. 5. The charging module weighs 35 lbs. If you have difficulty holding that weight, get assistance before you attempt to remove the module from the cabinet.
  • Page 14 2. Contact WCSI Customer Support to download the PilotTerm utility. Install PilotTerm on a Windows laptop with PilotTerm software. 3. Save the update .AVB file to the Desktop of the laptop. 4. Connect the laptop to the charger using an A-B (printer-type) USB cable.
  • Page 15 This page left intentionally blank.
  • Page 16 Webasto Charging Systems, Inc. 1333 S. Mayflower Ave., Ste 100 Monrovia, CA 91016 Corporate headquarters: Friedrichshafener Str. 9 82205 Gilching Germany...

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