Webasto ProCore Edge Guide d'installation et d'utilisation
ProCoreTM Edge
North America
Installation, Operation, Service & Maintenance
Rev 04/27/23
Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 2 of 112
© Webasto Charging Systems, Inc., 2023. All rights reserved.
ProCoreTM Edge 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 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.
Installation, Operations, Service & MaintenanceProCore Edge
Part Number 5911110 A02Webasto Charging Systems, Inc. Page 3 of 112
Owner’s Record
Model: ProCore™ Edge
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]
Continued on next page.
Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 4 of 112
In addition, please have the following information on hand before you call:
1. Failed charger SKU number and serial number
2. Failed module SKU number and serial number
3. Customer name (for our reference)
4. Problem description, including any fault codes
5. Data download from the charger, including charge logs and fault logs
6. Ship-to contact name
7. Ship-to phone number (if possible, include a cell phone number for text
messaging) and email address
8. Ship-to company address
We also recommend taking pictures using your cell phone in case you
need to send them to Webasto Customer Support via text message or email
– we can use the images to help diagnose any problems.
Installation, Operations, Service & MaintenanceProCore Edge
Part Number 5911110 A02Webasto Charging Systems, Inc. Page 5 of 112
Contents
Warnings and Cautions ............................................................................. 7
Installation and Operation ......................................................................... 9
Acronyms, Abbreviations and Symbols............................................... 10
Required Tools for 3-Bay and 5-Bay Cabinets .................................... 13
Technical Specications for 3-Bay and 5-Bay Cabinets ...................... 13
Required Tools for 10-Bay Cabinet ..................................................... 15
Technical Specications for 10-Bay Cabinet ....................................... 15
Positioning the Charger ...................................................................... 17
Choosing to Wall-Mount or Floor-Mount the Charger ......................... 18
AC Power Connection......................................................................... 29
DC Power Output ................................................................................ 35
Battery Connections for 3-Bay and 5-Bay Cabinets (Optional)........... 39
Battery Connections for 10-Bay Cabinet (Optional) ............................ 41
Connection and Description for 3-Bay and 5-Bay Cabinets................ 43
Charger Light Bar for 3-Bay, 5-Bay and 10-Bay Cabinets................... 46
Operating Instructions............................................................................. 48
Battery Display .................................................................................... 49
Alternate Battery Display..................................................................... 52
Faults and Warnings – Hardware Diagnostics .................................... 55
Initial Software Setup .......................................................................... 61
Required Equipment ........................................................................... 62
Procedure ........................................................................................... 62
Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 6 of 112
Service / Maintenance.............................................................................. 65
Preventative Maintenance Schedule ...................................................... 65
Replacing a Module............................................................................. 69
Replacing the Output Cable ............................................................... 81
Replacing the Controller PCBA........................................................... 85
Replacing the Door Panel ................................................................... 87
Removal .............................................................................................. 87
Installation .......................................................................................... 90
Interface Board Communication Connectors / Replacing the Fuse .... 91
Firmware Updates............................................................................... 95
Voltage Driven vs BMID Communications........................................... 99
Power Module Firmware Update........................................................... 101
Required Software ................................................................................. 101
Required Hardware................................................................................. 101
Denitions and Acronyms ..................................................................... 102
Procedure Log ....................................................................................... 102
Setup Instructions.................................................................................. 103
Setup Procedure ............................................................................... 103
Firmware Update .................................................................................... 109
Installation, Operations, Service & MaintenanceProCore Edge
Part Number 5911110 A02Webasto Charging Systems, Inc. Page 7 of 112
DANGER
Only qualied service personnel should remove the DC output power
cable panel and service the charger.
DANGER
RISK OF ELECTRIC SHOCK
DANGER
BATTERIES CAN BE DANGEROUS.
DANGER
DO NOT ATTEMPT TO CHARGE
NON-RECHARGEABLE BATTERIES.
Electric shock can cause death or serious injury.
• Do not touch the uninsulated portion of the output power cable, battery
connector or other live electrical parts, or uninsulated battery terminals.
• Disconnect the charger from the input power and battery before servicing.
Batteries generate explosive gases during normal charging and usage. Always
follow charging instructions and those of the battery manufacturer to reduce the
risk of battery explosion.
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.
Warnings and Cautions
WARNING
FLAMMABLE
• Keep batteries away from re.
• Do not smoke, use an open ame, or cause sparks near a battery.
Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 8 of 112
WARNING
CAUTION
Use only copper wires.
CAUTION
Every ProCore Edge is assembled and programmed for each
customer’s specic needs. Webasto recommends that you contact
Webasto Technical Support before making any modications and/or
additions (such as modules) to your ProCore Edge.
Connecting a high-voltage battery (80 V or higher) to a low-range charger
(24 V – 48 V) may damage the charger.
Use voltage-keyed connectors on the chargers and batteries if your facility has
mixed battery voltages.
NOTE
Three- and ve-bay cabinets have eld wiring terminal blocks that can
accept a input wire gauge range from 10 to 14 AWG (6–2.5 mm2).
• The minimum and maximum screw-tightening is 22.2 in-lb
(2.5 Nm) and 26.4 in-lb (3 Nm) of torque, respectively.
• DC output power cables are provided with the charger.
• Anderson Euro, SB or SBX connectors are used.
• For more information, contact WCSI Customer Support at
1-866-767-4242.
The 10-bay cabinet has eld wiring terminal blocks that can accept
a input wire gauge range from #10 AWG to #4 AWG. Refer to the
Torque Specications Label on page 33 for the appropriate torque
value for the screws for each wire size.
Installation, Operations, Service & MaintenanceProCore Edge
Part Number 5911110 A02Webasto Charging Systems, Inc. Page 9 of 112
Installation and Operation
Read and understand these manufacturer instructions and all safety practices.
This manual provides important information for installing the charger and should
be carefully read.
This manual is based on information available at the time of publication. While
eorts have been made for the information to be accurate, it does not cover all
details of or variations in the hardware or software, nor provide for every possible
contingency in connection with installation.
The features described may not be included in all systems.
Always press the STOP button on the ProCore Edge battery display before
disconnecting SB cables from a battery. Pressing the STOP button will prevent
the possibility of electrical arcing.
NOTE
NOTE
NOTE
NOTE
This manual provides instructions for the installation and operation of the
ProCore Edge Charging System, as well the maintenance and service of select
components.
The procedures should only be performed by trained and qualied technicians
to enhance safety and protect equipment integrity.
Please refer to the Table of Contents on pages 5-6 for the list of procedures
included in this manual.
Installation, Operations, Service & Maintenance ProCore Edge
Part Number 5911110 A02 Webasto Charging Systems, Inc.
Page 10 of 112
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 Identier
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
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)
IP Ingress Protection (Rating)
kg Kilogram(s)
Table des matières
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