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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:
•
Replace the charging module
•
Replace the output cable
•
Replace the system controller
•
Replace the fuses on the backplane
•
Replace the control power transformer
•
Replace the backplane board
•
Update the firmware
1.4 REPLACE ThE ChARGING MODULE
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. On the right side of the charger, remove the side panel screws, then
remove the 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.
6. Grasp the charging module by the hand holes and pull firmly until
disengaged.
7. Slide the module out of the charger.
8. Carefully insert replacement module into the cabinet until module
face is flush with cabinet sill and has connected with the bus bar
connectors.
9. Replace right side panel and screws.
10. Remove lock out and turn on AC breaker.
1.5 REPLACE ThE OUTPUT CABLE
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(s) from the cabinet. Slide module(s) out of charger.
6. Grasp the charging module by the hand holes and pull firmly until
disengaged.
7. See Figure 1. Using a socket wrench, remove bolts from the output
cable connections.
4
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