Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for Revolution RV05-4kW-90A-36V-P
Summary of Contents for Revolution RV05-4kW-90A-36V-P
- Page 1 A NEW ERA IN CHARGING TECHNOLOGY 480VAC Models RV05-4kW-90A-36V-P RV05-4kW-75A-48V-P RV05-5kW-120A-36V-P RV05-5kW-100A-48V-P RV05-6kW-150A-36V-P RV05-6kW-125A-48V-P Installation & Operation Manual 4005 Felland Road, Suite 116 Madison, WI 53718 © Power Designers USA LLC MAN-000020-00 REV A...
-
Page 2: Table Of Contents
TABLE OF CONTENTS REVOLUTION™ SERIES ...................... 1 SAFETY PRECAUTIONS ....................... 2 REVOLUTION™ SPECIFICATIONS ..................5 INSTALLATION PROCEDURE ..................... 8 ....................... 8 HARGER NSTALLATION ................14 HARGER LECTRICAL NSTALLATION OPERATION PROCEDURE ....................17 ..............17 HARGER ONTROLS AND NTERFACE ..................18... -
Page 3: Revolution™ Series
Finish and equalize cycles may be programmed to automatically run on certain days of the week. Additionally, the REVOLUTION™ chargers may be tailored to meet the needs of any battery chemistry, including flooded, gel, and Absorbed Glass Mat (AGM) lead-acid batteries. -
Page 4: Safety Precautions
Improper Connections. If the charger is incorrectly wired to input or output devices or wiring is not in accordance with local safety codes and standards, the Revolution™ charger and/or its components are at risk of being destroyed. Grounding. The charger must be connected to an AC power supply incorporating an earth or ground. - Page 5 WARNING Chemical Hazard. Working with lead-acid batteries may result in exposure to highly corrosive acid. To protect eyes and skin, use the required Personal Protective Equipment (PPE) as mandated by your employer and local regulations. At a minimum, wear safety goggles and skin protection while connecting the battery charger or working in the vicinity of lead-acid batteries.
- Page 6 Federal Codes 29CFR1926.441 Batteries and Battery Chargers 29CFR1910.305 (j) Wiring Methods, Components and Equipment for General OSHA Directive STD 01-08-002, including 29CFR1910.151(c) Medical Services and First Aid; 29CFR1926.50 and 29CFR1926.51, Medical Service and First Aid, and Sanitation, respectively; applicable to electric storage battery charging and maintenance areas.
-
Page 7: Revolution™ Specifications
REVOLUTION™ SPECIFICATIONS Model Numbers RV05-4kW-90A-36V-P / RV05-4kW-75A-48V-P RV05-5kW-120A-36V-P / RV05-5kW-100A-48V-P RV05-6kW-150A-36V-P / RV05-6kW-125A-48V-P LCD/keypad Knockout for input wiring Strain reliefs for output cables Figure 1: REVOLUTION™ RV05 Battery Charger Features MAN-000020-00 REV A... - Page 8 Specifications for the REVOLUTION™ RV05 480VAC / 48V models. RV05-6kW-125A- Specifications RV05-4kW-75A- RV05-5kW-100A- 48V-P 48V-P 48V-P Nominal VA Ratings 48 V / 75 A 48 V / 100 A 48 V / 125 A Input Specifications Voltage 480VAC, 3-phase +10% Current 5.6A rms/ph...
- Page 9 Specifications for the REVOLUTION™ RV05 480VAC / 36V models. RV05-6kW-150A- Specifications RV05-4kW-90A- RV05-5kW-120A- 36V-P 36V-P 36V-P Nominal VA Ratings 36 V / 90 A 36 V / 120 A 36 V / 150 A Input Specifications Voltage 480VAC, 3-phase +10% Current 5.6A rms/ph...
-
Page 10: Installation Procedure
Charger Unpacking and Inspection Upon receipt of a REVOLUTION™ charger, ensure that there is no physical damage to the chassis, the Liquid Crystal Display (LCD)/keypad, or the DC cables. If any damage is apparent, contact the shipping carrier. - Page 11 Mount the charger vertically, observing the minimum spacing shown below: Figure 2: RV05 NEC minimum spacing Ensure that the charging area is well ventilated, dry, and clean. Do not expose the charger to rain or snow. The charger is NOT designed for outdoor use. MAN-000020-00 REV A...
- Page 12 There must be at least 2” of spacing between the sides of the charger and any adjacent walls or barriers, and 12” of spacing between the bottom of the charger and the floor or any other obstruction. Figure 3: RV05 minimum spacing ...
- Page 13 2. Preparing the Mounting Area: Figure 4: RV05 mounting hole / bolt pattern Charger should be fastened to the mounting surface using 1/4” or 5/16” hardware (User provided). Threaded mounting studs protruding from surface are recommended for ease of installation. ...
- Page 14 3. Preparing the Charger: With the Charger laying on its back, remove the (2) 8-32 screws securing the cover to the bottom surface and set aside. Shift the cover slightly toward the top of the charger (about 1.5”) as shown: Figure 5: RV05 Cover Fastener Removal ...
- Page 15 4. Hanging the Charger Pick up the Charger (a second person is recommended) and fasten the Charger to the mounting surface: Figure 7: Mounting the Charger Once the Charger has been securely mounted, electrical installation can proceed. CAUTION: Do not allow debris to fall inside the Charger during the mounting and installation process! MAN-000020-00 REV A...
-
Page 16: Charger Electrical Installation
VERIFY THAT INPUT AND OUTPUT WIRING ADHERES TO ALL LOCAL SAFETY CODES AND STANDARDS. 1. The REVOLUTION™ RV05 chargers require a 480 VAC 3, four-wire Wye or Delta electrical supply with a separate ground (Figure 8). Nameplate 480 VAC current draw is 10 A; circuit protection at 125% should be 15 A. - Page 17 Figure 9: KO location 4. Pass the 480 VAC input power wires through, using the appropriate conduit or strain relief fittings per local and national codes. 5. Crimp a #10 ring tongue terminal to the ground (GND) wire and connect it to the GND terminal (Figure 9).
- Page 18 Figure 10: RV05 terminal block location 7. Verify the line and ground connections of the outlet or junction box/disconnect. 8. Energize the source circuit and verify proper AC voltage to the Charger. All line- to-line voltages should be 480 VAC ± 10% and matched within 10 VAC. De- energize the source circuit.
-
Page 19: Operation Procedure
OPERATION PROCEDURE Charger Controls and User Interface Users operate the REVOLUTION™ series of chargers through each charger’s front panel LCD/keypad (Figure 11). This is the main user interface for viewing operation and fault messages. It also allows limited charger programming options. (For programming information, see Charger Main Menu, page 24 of this manual.) -
Page 20: Basic Charge Cycle Operation
Basic Charge Cycle Operation Figure 12: Typical charge cycle – charge modes The charge cycle for an opportunity charger consists of the first three modes on a daily basis, with all five modes occurring on a weekly basis. A brief description of the various modes is listed below and all modes are shown above in Figure 14. - Page 21 Finish: Finish mode will hold the current into the battery constant, and the battery voltage will slowly rise. The charge cycle will terminate when one of three conditions exists: The charger has been in the finish mode for the full duration of the finish timer, the Finish dV/dt is reached, or the Finish Voltage is achieved.
-
Page 22: Getting Started
Getting Started The LCD display on REVOLUTION™ series presents various screens and SCREEN MESSAGES. 1. Powering the Charger Energize the AC mains at the main panel (turn the local AC disconnect switch to the ON position, if one exists). - Page 23 2. Starting a Charge Cycle a. Connect the battery to the charger. Once the battery is detected, one of two messages appears on the LCD: The LCD displays the PUSH START screen. If Charge Autostart is enabled, the charger automatically starts the charge cycle, and briefly displays an AUTO START with a timer count-down message as shown below.
- Page 24 The Charging … (XX) field in the upper left corner indicates the active charging mode, the XX will indicate TR for trickle, CC for constant current, CV for constant voltage, FI for finish, or EQ for equalize. The screen also displays a charge timer (lower left), a battery icon with % state of charge gauge along with actual readings of charging amps (A), returned amp-hours (AH), and battery voltage (V).
- Page 25 On this screen appears the total charging time and total returned amp-hours along with the final state of charge of the battery. MAN-000020-00 REV A...
-
Page 26: Charger Main Menu
Charger Main Menu From the charger MAIN MENU screen, access is provided to the following list of screens: Manual Equalize Desulfation Cycle Charge History Lifetime Summary Model & SN These screens may only be accessed when the charger is in idle mode (i.e., when either the CONNECT BATTERY or the PUSH START screens are displayed). - Page 27 NOTE: Once an Equalization is activated, it remains active until an equalization cycle has completed. d. Press ENTER key to save selection and return to the main menu. The LCD display now indicates the Equalization charge is activated with an “E” in the upper right corner of the display, and one of the following displays will be observed, depending on the setup of the Charger.
- Page 28 b. While in MAIN MENU, press / until the DESULFATION CYCLE screen appears. c. Press ENTER to access the recovery cycle set-up screens. The first screen selects the appropriate battery voltage. Pressing / toggles the battery voltage setting. Select the correct voltage and select ENTER.
- Page 29 Pressing / allows adjustment of the charge timer setting in 15-minute increments. The charge timer setting must be less than 24 hours. Select the desired value, then select ENTER. Next, the START DESULFATION CYCLE screen appears. e. Push START to initiate the desulfation cycle. Once the cycle is complete, a CYCLE COMPLETED message appears.
- Page 30 3. Charge Cycle History a. While in MAIN MENU, press / until the CHARGE HISTORY screen appears. Press ENTER to access the Charge History screens. b. The first screen that appears is the Charge Cycle history screen as shown below. Users can access the charge history for up to 400 charge cycles, beginning with the most recent charge cycle.
- Page 31 PROFILES lists the profiles activated during the charge cycle. Trickle charge appears as TR, constant current as CC, constant voltage as CV, finish as FI, and equalize as EQ. 4. Lifetime Summary a. While in MAIN MENU, press / until the LIFETIME SUMMARY screen appears.
- Page 32 5. Charger Model a. While in MAIN MENU, press / until the MODEL & SN screen appears. b. Pressing the ENTER key displays the charger model number, manufacturing ID, and firmware revision for reference. MAN-000020-00 REV A...
-
Page 33: Troubleshooting
TROUBLESHOOTING Occasional faults may occur in certain conditions. Please follow the suggested steps. A. Charger Does Not Power Up When the charger is first turned on, the LCD should illuminate and display one of the idle mode messages, typically the CONNECT BATTERY screen. If the LCD is not illuminated after power is applied, perform the following checks: a. - Page 34 B. Charger Fault During Operation The REVOLUTION™ Series features a modular and fault-tolerant design that allows the Charger to continue operation despite the loss of a portion of the modules through temporary or permanent fault conditions. If a module faults during the charging cycle, the fault is recorded, and the charge cycle continues.
- Page 35 module, or by the improper addition of spare or replacement modules. Please contact the Dealer or Power Designers USA LLC to arrange repair. If the number of faulted modules results in the Charger having less than 60% of the “Installed Modules” operational, the charge cycle will be interrupted, and a fault message is displayed.
- Page 36 a. The CYCLE STOPPED screen automatically reverts to the Connect Battery or Push START screens in 30 seconds. b. Select STOP to revert to the Connect Battery or Push START screens. c. Restart the charge cycle by selecting START. d. If the fault persists, contact the Dealer or Power Designers USA LLC. 3.
- Page 37 Possible Causes Blocked air flow to the charger. Failed cooling fan. Room temperature above 104˚F. Troubleshooting a. Select STOP to revert to the Connect Battery or Push START screens. b. Allow the charger to cool down. c. Make sure there are no airflow restrictions to the intake or exhaust of the charger.
- Page 38 6. Battery Over-Temperature The following screen will appear the first 5 times the battery over-temperature limit is exceeded during any charge cycle. On the first instance of detecting a battery over- temperature, the Charger will wait until the battery temperature drops approximately 7°C (13°F) and then re-start the charge cycle automatically.
-
Page 39: Return Material Process
RETURN MATERIAL PROCESS In the event that the troubleshooting steps included in this manual do not resolve the problem, a. Record the charger serial number; b. Call Power Designers USA LLC with a description of the problem. Power Designers USA LLC will attempt to resolve the problem over the phone. If the issue cannot be resolved in this manner, a Return Material Authorization (RMA) form must be completed and submitted to Power Designers USA LLC. -
Page 40: Limited Warranty
FOR INDUSTRIAL APPLICATIONS USED IN THE USA & CANADA Power Designers USA LLC (“PD”) hereby warrants each new PowerCharge XP, PowerCharge iHF and REVOLUTION Series battery charger (the “Product”) for industrial application shipped after April 1, 2014 pursuant to the following terms and conditions (the “Product” Limited Warranty): 1. - Page 41 If a “component” or “components” failed due to any cause that the limited warranty does not cover, the owner (Dealer) will be informed of the charges of the repairs before any repairs are performed. If the repairs are approved, PD will repair said product with “new” or “reconditioned to new”...
-
Page 42: Software License Agreement
SOFTWARE LICENSE AGREEMENT This license agreement is a legal agreement between Power Designers USA LLC of Madison, Wisconsin, the author and licensor of the software, and the end user licensee of the software. Installation or other use of this software by the licensee constitutes agreement to all terms and conditions of this license. -
Page 43: Appendix A - Wall Mount Dimensions And Clearances
APPENDIX A – WALL MOUNT DIMENSIONS AND CLEARANCES Recommended mounting hardware: 1/4” or 5/16”. MAN-000020-00 REV A... -
Page 44: Appendix B - Post Stand Dimensions
APPENDIX B – POST STAND DIMENSIONS MAN-000020-00 REV A... -
Page 45: Appendix C - Shelf Stand Dimensions
APPENDIX C – SHELF STAND DIMENSIONS MAN-000020-00 REV A... -
Page 46: Appendix D - Notes On Temperature Compensation
For a valve-regulated lead-acid battery, the temperature compensation factor is 2 mV/°C/VPC. The REVOLUTION™ opportunity charger implements two temperature- compensation coefficients: 1. The battery low compensation coefficient (Batt Low Temp Comp) is activated when the battery temperature is different than 77°F, but lower than the high... -
Page 47: Appendix E - Recovery Cycle For Sulfated Battery Current And
APPENDIX E – RECOVERY CYCLE FOR SULFATED BATTERY CURRENT AND TIMER SETTINGS When running a recovery cycle for a sulfated battery, use this table as a guide when setting currents and timers. Battery Capacity Current Setting Timer Setting HH:MM 16:45 18:45 20:00 18:45... -
Page 48: Contacting Power Designers Usa Llc
CONTACTING POWER DESIGNERS USA LLC Power Designers USA LLC 4005 Felland Road, Suite 116 Madison, WI 53718 www.powerdesigners.com sales@powerdesigners.com service@powerdesigners.com Main Office Phone: 608.231.0450 Main Office Fax: 608.231.9979 Service Department: 608.216.9295 Phones are answered between 9 a.m. and 5 p.m., Monday through Friday Central Time.
Need help?
Do you have a question about the RV05-4kW-90A-36V-P and is the answer not in the manual?
Questions and answers