Webasto ProCore Edge 9 Manuel utilisateur

ProCoreTM Edge 9/15

North America

Installation, Operation and

Maintenance Manual

Rev 05/18/23

ProCore Edge North America

31241-03-0202 Webasto Charging Systems, Inc.

IOMM

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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.

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.

posicharge.com | posichargeprocore.com

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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]

Owner’s Record

Model: ProCore™ Edge

Serial Number (SN):

Installation date:

Output power:

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Contents

1. Installation, Operation and Maintenance Manual ............9

1.1. Scope.............................................................................9

1.2 Acronyms, Abbreviations and Symbols ........................10

2. Required Tools...................................................................12

3. Technical Specications for 48V and 80V

Modules Fitted with 3- or 5-Bay Cabinets ...........................12

4. Installation..........................................................................14

4.1. Multi-Charger Installation Schemes .............................14

4.2 Installation Precautions.................................................16

4.3 Positioning the Charger ...............................................17

4.4 Wall-Mount Installation..................................................18

4.5 Floor Stand Installation .................................................19

5. Remote Battery Connections (Option) ............................34

5.1. Ten-way Screw Terminal Connector.............................34

Table 1 Bare-Ended Signal Connections ............................36

5.2 Optional Features .........................................................37

6. Putting Back the DC-Panel and Top Covers ...................37

6.1. DC-panel Cover ...........................................................37

6.2. Top Cover.....................................................................37

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7. Charger Light Bar .............................................................38

8. Operating Instructions .....................................................40

8.1. Battery Display.............................................................42

8.2 Buttons..........................................................................47

9. Maintenance.......................................................................49

9.1 Power Module Replacement ........................................49

9.2. Air Filter Replacement (TBA – not yet available) .........60

9.3. Preventive Maintenance Activities ...............................60

Table 2 Preventative Maintenance Schedule .....................61

10. Faults and Warnings .......................................................63

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1. Installation, Operation and Maintenance Manual

1.1. Scope

This manual is intended for use by personnel trained to install and

use chargers for charging batteries in a safe and correct manner.

NOTE

Read and understand these manufacturer instructions and all safety

practices.

This manual covers the installation, operation, and maintenance of the

charger, and charger accessories.

This manual provides important information on how to install the charger

and should be carefully read.

This manual is based on information available at the time of publication.

The information herein, while e󰀨orts have been made to be accurate,

does not cover all details of, or variations in, the hardware or software;

or provide for every possible

contingency in connection with installation.

Features described herein may not be present in all systems.

NOTE

Each ProCore Edge has been assembled and programmed for each

customer. Webasto recommends that you contact Webasto Technical

Support before making any modications and/or additions (such as

additional modules) to your ProCore Edge.

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1.2 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

GCAN (G-CAN) Ground Controller Area Network

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)

in-lbs Inch Pounds

IP Ingress Protection (Rating)

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Acronym,

Abbreviation or

Symbol

Meaning

kg Kilogram(s)

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

Nm 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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2. Required Tools

• Hex key, 4 mm, for the ller screws on the charger top panel

• TORX TX30 for the charger top panel

• Flathead screwdriver for the terminal screws

• TORX TX25 for the DC output power cable panel

3. Technical Specications for 48V and 80V Modules Fitted

with 3- or 5-Bay Cabinets

Technical Specications

Model ProCore Edge 9 ProCore Edge 9 ProCore Edge 15 ProCore 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. 50/60Hz

Cabinet size 3-bay 5-bay

Max. input amps (3-phase

480VAC) 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 ― ―

1The number of modules and module type determine the maximum output power rating.

2The 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.

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Model ProCore Edge 9 ProCore Edge 9 ProCore Edge 15 ProCore 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. 50/60Hz

Cabinet size 3-bay 5-bay

Max. output amperage:

48V battery @ 2.4 V/cell 104 A 156 A 80 A 120 A 208 A 260 A 160 A 200 A

Max. output amperage:

72V battery @ 2.4 V/cell ― ― 76 A 114 A ― ― 151 A 189 A

Max. output amperage:

80V battery @ 2.4 V/cell ― ― 69 A 104 A ― ― 139 A 173 A

Max. output amperage:

96V lithium-ion battery @

full charge

― ― 56 A 83 A ― ― 111 A 139 A

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 in. × 21 in. × 14.7 in.

(473 mm × 534 mm × 374 mm)

24.8 in. × 21 in. × 14.7 in.

(631 mm × 534 mm × 374 mm)

Weight 51.8. (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, stand, or oor mounting options

Environment Operating temperature: −20°C to +45°C (−4°F to 113°F)

Storage temperature: −25°C to +65°C (−13°F to 149°F)

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

NOM-208-SCFI-2016

Technical Dictum for exemption of NOM-001-SCFI-2018.

3Stated output currents require connectors and electrical cables of adequate capacity.

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