POSICHARGE Posi Charge Pro Core Instruction Manual

Posi Charge Pro Core

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Specifications:

• Brand: Ampure
• Product Name: PosiCharge ProCore
• Manufacturer: Ampure
• Weight: 35 lbs

Product Usage Instructions:

1. Unplug any vehicles connected to the charger.

2. Turn OFF the 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. Take hold of the charging module by the hand holes and pull
   firmly until it is disengaged.

7. Slide the module out of the charger.

8. Carefully insert the replacement module into the cabinet until
   the module face is flush with cabinet sill and is connected to the
   bus bar connectors.

9. Replace the right side panel and screws.

10. Remove the lock out and turn on the AC breaker.

FAQ:

Q: Where can I find the serial number of the unit?

A: The serial number can be found on the nameplate rating label
on the left side of the unit.

Q: What should I do if I encounter difficulty holding the

weight of the charging module?

A: It is recommended to seek assistance before attempting to
remove the module from the cabinet.

Q: Can I make changes or modifications to the product

myself?

A: Changes or modifications not completed by an authorized
service provider could void the product warranty. It is advised to
seek professional help for any modifications.

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PosiChargeTM ProCoreTM Service Manual

© Ampure 2024. All rights reserved.
PosiChargeTM and ProCoreTM are products of Ampure. Ampure and the Ampure logo are trademarks of Ampure. Corporate names, trademarks, registered trademarks, service marks, symbols, and logos stated herein are the property of the respective companies.
Changes or modifications 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. Ampure reserves the right to make changes to this manual and/or product without further notice. Specifications are subject to change without notice.
No portion of these materials may be duplicated, used, or disclosed without prior written permission from Ampure.

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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 Ampure Customer Service. The serial number can be found on the nameplate rating label on the left side of the unit.

Customer Support:

IPCService@webasto.com 1­866­767­4242

Parts:

WCSIParts@webasto.com

Owner’s Record
Model: PosiCharge ProCore ———————————————————————————————
Serial Number (S/N): ———————————————————————————————
MAC Address ID: ———————————————————————————————
Installation Date: ———————————————————————————————

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CONTENTS
1 ­ SYMBOL USAGE ……………………………………………………………. 5 2 ­ SAFETY PRECAUTIONS …………………………………………………. 6 3 ­ ABOUT THIS MANUAL …………………………………………………… 7 4 ­ REPLACING THE CHARGING MODULE………………………….. 7 5 ­ REPLACING THE OUTPUT CABLE …………………………………. 8
Figure 1 ­ Output Connector Bolts ……………………………………….. 8 Figure 2 ­ Comm Cable Connector………………………………………. 9 Figure 3 ­ Snap-n Ferrie Filter …………………………………………….. 9 Figure 4 ­ Strain Relief Nuts ……………………………………………… 10 6 ­ REPLACING THE SYSTEM CONTROLLER / DISPLAY…… 11 Figure 5 ­ Removing the System Controller / Display Cover ……11 7 ­ REPLACING THE BACKPLANE FUSES ………………………… 12 Figure 6 ­ Removing the System Controller / Display……………. 12 Figure 7 ­ Backplane Fuses………………………………………………. 12 8 ­ REPLACING THE CONTROL POWER TRANSFORMER … 13 9 ­ REPLACING THE BACKPLANE BOARD ……………………….. 13 10 ­ UPDATING THE FIRMWARE………………………………………… 14 Figure 8 ­Backplane Cables and Connectors ………………………. 14 Figure 9 ­ Standby Switch and USB Connector……………………. 14 Figure 10 ­ PilotTerm Settings Tab……………………………………… 15 Figure 11 ­ Updating Parameters……………………………………….. 15

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1 ­ SYMBOL USAGE The PosiCharge ProCore is designed with safety as the highest priority. The following safety precautions must be read and observed:
DANGER Indicates information about safety practices which, if not followed, may result in serious injury or death.
WARNING Indicates information about safety practices which, if not followed, could result in personal injury, fire, or equipment overheating.
NOTE Indicates helpful information for installation or usage, but does not contain personnel or equipment safety-related information.

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2 ­ SAFETY PRECAUTIONS
WARNING 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.
DANGER ELECTRIC SHOCK CAN KILL
· Touching live electrical parts can cause fatal shocks or severe burns.
· The input power circuitry and internal circuits are live whenever input power is on.
· An incorrectly installed or improperly grounded unit is a hazard.
· Do not operate the unit if there is physical damage to the unit, coupler, or cable.
· Do not subject the cable to damage or stress. · Do not step on the DC output cable. · Do not operate the unit if any access panels are open.

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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:
· Replacing the charging module · Replacing the output cable · Replacing the system controller · Replacing the fuses on the backplane · Replacing the control power transformer · Replacing the backplane board · Updating the firmware
4 ­ REPLACING THE CHARGING MODULE
1. Unplug any vehicles connected to the charger. 2. Turn OFF the 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. Take hold of the charging module by the hand holes and pull firmly until it is disengaged. 7. Slide the module out of the charger. 8. Carefully insert the replacement module into the cabinet until the module face is flush with cabinet sill and is connected to the bus bar connectors. 9. Replace the right side panel and screws. 10. Remove the lock out and turn on the AC breaker.

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5 ­ REPLACING THE OUTPUT CABLE
1. Unplug any vehicles connected to the charger. 2. Turn OFF the AC power at the breaker and lock it out. 3. Wait five minutes for the capacitor voltages to bleed down. 4. Remove the 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 the module(s) out of charger. 6. Take hold of the charging module by the hand holes and pull firmly until disengaged. 7. See Figure 1. Using a socket wrench, remove the bolts from the output cable connections.

Figure 1 ­ Output Connector Bolts

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8. See Figure 2. Unplug the four-pin Molex Comm cable connector from the bottom left corner of the backplane.
NOTE: You may need to unbolt the cable on the bus bar above it to access the connector.

Figure 2 ­ Comm Cable Connector
9. See Figures 1 and 3. Inside the cabinet, loosen the strain relief nut for the Comm cable and pull the cable until you can access the ferrite filter. Remove the snap-on ferrite filter from the Comm cable.

Figure 3 ­ Snap-n Ferrie Filter

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10. See Figures 1 and 4. The strain relief nuts are permanently attached to their respective cables. To remove the cables, unscrew the nuts holding them to the cabinet from inside the cabinet.

Figure 4 ­ Strain Relief Nuts
11. Pull the cables out of the cabinet. 12. Reverse the above procedure to install new cable as follows.
A. Thread cables through cabinet openings and secure the strain relief nuts to the cabinet.
B. Loop the Comm cable and reinstall snap-on ferrite filter onto Comm cable as shown in Figure 3.
C. Connect Comm cable to backplane. Reconnect cable to bus bar.
D. Bolt output cables and two ring terminals to filter standoffs, red-tored and black-to-black. See Figure 1. Torque to 72 in-lbs ± 7 in-lbs.
E. Tighten strain relief nuts on all three cables.
F. Pull Comm cable from outside until ferrite filter is next to strain relief. Tighten strain relief.
G. Pull output cable from outside to remove slack inside. Tighten strain relief.
H. Replace modules, reinstall right side panel, remove lockout, turn ON AC power.

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6 ­ REPLACING THE SYSTEM CONTROLLER / DISPLAY
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. 6. Grasp module by hand holes and pull firmly until disengaged. 7. Slide the module out of the charger. 8. See Figure 5. Use a stubby Phillips screwdriver to remove four screws securing the system controller/display as shown below.

Figure 5 ­ Removing the System Controller / Display Cover

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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.
7 ­ REPLACING 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. See Figure 7. Test each fuse with an ohmmeter.

Figure 7 ­ Backplane Fuses

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6. Replace all three fuses due to stress on the others with a correctly-rated fuse (500V, 20A).
7. Replace left side panel. 8. Remove lock out and turn ON AC power.
8 ­ REPLACING THE CONTROL POWER TRANSFORMER
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. Slide the module out of the charger. 6. Unplug the five-pin 24V control power cable from backplane. 7. Unscrew mounting nuts from transformer and remove transformer. 8. Install new transformer on mounting studs and replace nuts. 9. Plug control power cable into backplane. 10. Replace module(s), reinstall right side panel, remove lockout, turn ON AC power.
9 ­ REPLACING THE 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. Slide the module out of the charger. 6. Remove left side panel.

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7. Remove screws securing the backplane.
8. See Figure 8. Tilt backplane board to expose connectors on the opposite side.

Figure 8 ­Backplane Cables and Connectors
9. Unplug all connectors and remove backplane board. 10. Reverse above procedure to install new backplane board.
10 ­ UPDATING THE FIRMWARE 1. See Figure 9. Firmware is updated using the USB port on the left side of the charger under the standby switch.

Figure 9 ­ Standby Switch and USB Connector

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2. Contact Ampure 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.
5. See Figure 10. Start the PilotTerm program and select Settings tab.

Figure 10 ­ PilotTerm Settings Tab
6. Confirm that the correct comm port is selected and click the Connect COM port button.

Figure 11 ­ Updating Parameters
7. See Figure 11. Select Update Firmware tab, click Browse to select the .AVB update, then click the Update Now button.
8. Progress displays on the screen bottom. When update is completed (about five minutes), close PilotTerm and disconnect laptop from the charger.

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Doc ID 24238-78_02 · 06/24 · © Ampure 2024

Ampure 1960 Walker Avenue Monrovia, CA 91016-4847 USA

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