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Revolution RV16 Installation & Operation Manual

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RV16 and RV24 Models
Installation & Operation Manual
MAN-000037-00 REV C

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Summary of Contents for Revolution RV16

  • Page 1 RV16 and RV24 Models Installation & Operation Manual MAN-000037-00 REV C...

  • Page 2: Table Of Contents

    ..................14 HARGER NSTALLATION RV16 Models Installation ................... 15 RV24 Models Installation ................... 20 ............... 25 HARGER LECTRICAL NSTALLATION RV16 & RV24 Electrical Instructions ..............26 OPERATION PROCEDURE ..................28 ............. 28 HARGER ONTROLS AND NTERFACE ................29 ASIC HARGE...

  • Page 3: Revolution Series

    Additionally, the REVOLUTION chargers may be tailored to meet the needs of any battery chemistry, including lithium, flooded, gel, and Absorbed Glass Mat (AGM), Thin Plate Pure Lead (TPPL) 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 damaged. Grounding. The charger must be connected to an AC power supply incorporating an ...
  • 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 Use 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 (CEC compliant versions add –CEC suffix) RV16 Model Numbers RV16-21kW-400A-48V-F RV16-18kW-350A-48V-F-SC RV16-13kW-300A-36V-F RV16-21kW-350A-48V-F-SC RV16-14kW-330A-36V-F RV16-21kW-400A-48V-F-SC RV16-15kW-360A-36V-F RV16-15kW-48V RV16-18kW-420A-36V-F RV16-18kW-48V RV16-21kW-480A-36V-F RV16-21kW-48V RV16-18kW-420A-36V-F-SC RV16-18kW-48V-SC RV16-20kW-450A-36V-F-SC RV16-21kW-48V-SC RV16-13kW-36V RV16-18kW-182A-80V-SC RV16-14kW-36V RV16-20kW-195A-80V-SC RV16-15kW-36V RV16-21kW-208A-80V-SC RV16-18kW-36V RV16-21kW-36V RV16-18kW-36V-SC RV16-20kW-36V-SC RV16-15kW-300A-48V-F...
  • Page 8 LCD/keypad Output Cables Dual Single Cable Cable Knockout for input wiring Figure 1: REVOLUTION RV16 and RV24 Battery Charger Features MAN-000037-00 REV C...

  • Page 9: Specifications For The Revolution Rv16 480Vac / 36V Models

    Specifications for the REVOLUTION RV16 480VAC / 36V models. RV16- RV16- RV16- RV16- RV16- RV16- RV16- SPECIFICATIONS 18KW- 20KW- 13KW-36V 14KW-36V 15KW-36V 18KW-36V 21KW-36V 36V-SC 36V-SC Nominal Volt (V) / 36 V / 300 A 36 V / 330 A...

  • Page 10: Specifications For The Revolution Rv16 480Vac / 48V Models

    Specifications for the REVOLUTION RV16 480VAC / 48V models. RV16-15KW- RV16-18KW- RV16-21KW- RV16-18KW- RV16-21KW- RV16-21KW- SPECIFICATIONS 48V-SC 48V-SC 48V-SC Nominal Volt (V) / 48V / 270A 48V /315A 48V / 360A 48V / 315A 48 V/ 350A 48V/ 360A Maximum Current (A)

  • Page 11: Specifications For The Revolution Rv16 480Vac / 80V Models

    Specifications for the REVOLUTION RV16 480VAC / 80V models. RV16-18KW- RV16-20KW- RV16-21KW- SPECIFICATIONS 80V-SC 80V-SC 80V-SC Nominal Volt (V) / 80V / 182A 80V /195A 80V / 208A Maximum Current (A) INPUT SPECIFICATIONS Voltage 480VAC, 3-phase±10% Current 25.9A rms/ph 27.7A rms/ph 29.6A rms/ph...

  • Page 12: Specifications For The Revolution Rv24 480Vac / 36V Models

    Specifications for the REVOLUTION RV24 480VAC / 36V models. SPECIFICATIONS RV24-23KW-36V RV24-26KW-36V RV24-29KW-36V RV24-31KW-36V Nominal Volt (V) / 36V / 540A 36V / 600A 36V / 660A 36V / 700A Maximum Current (A) INPUT SPECIFICATIONS INPUT SPECIFICATIONS Voltage 480VAC, 3-phase ± 10% Current 33.3A rms/ph...

  • Page 13: Specifications For The Revolution Rv24 480Vac / 48V Models

    Specifications for the REVOLUTION RV24 480VAC / 48V models. RV24- RV24-26KW- RV24-29KW- RV24-31KW- RV24-23KW-- RV24-26KW-- SPECIFICATIONS 23KW-48V 48V-SC 48V-SC Nominal Volt (V) / 48V / 405A 48V / 450A 48V / 495A 48V / 540A 48 V / 400 A...

  • Page 14: Specifications For The Revolution Rv24 480Vac / 80V Models

    Specifications for the REVOLUTION RV24 480VAC / 80V models. SPECIFICATIONS RV24-23KW-80V-SC RV24-26KW-80V-SC RV24-29KW-80V-SC RV24-31KW-80V-SC Nominal Volt (V) / 80V / 234A 80V / 260A 80V / 286A 80V / 312A Maximum Current (A) INPUT SPECIFICATIONS INPUT SPECIFICATIONS Voltage 480VAC, 3-phase ± 10% Current 33.3A rms/ph...

  • Page 15: Installation Procedure

    The following procedure describes proper installation of the REVOLUTION series of chargers. 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 16: Rv16 Models Installation

    RV16 Models Installation • Mount the charger vertically, observing the minimum spacing shown below: Figure 2: RV16 NEC minimum spacing • Ensure that the charging area is well ventilated, dry, and clean. • Do not expose the charger to rain or snow.
  • Page 17 12” of spacing between the bottom of the charger and the floor or any other obstruction. This is to allow for service and tool access to the Charger. Figure 3: RV16 minimum spacing • Ambient Temperature Range 0 – 40° C • Ambient Humidity Range 10-90% RH non-condensing...
  • Page 18 The Charger may be directly mounted to masonry or concrete, structural framing channels, or onto the Floor Stand. (purchased separately; see Appendix B) Figure 4: RV16 mounting height Charger should be fastened to the mounting surface using 5/16” hardware (User provided).
  • Page 19 • Remove the cardboard box cover from the pallet. DO NOT REMOVE the Shipping Spacer; it is necessary to prevent damage to the Charger when lifting. Figure 5: RV16 Box Removal The Charger’s output cables (not shown, for clarity) will be coiled at the base of the charger.
  • Page 20 • Remove the 8 screws securing the Charger to the pallet: (Figure 6) Figure 6: RV16 Shipping Screw Removal • Using a hoist, forklift, or other appropriate lifting equipment, attach a chain or strap to the lifting eyes at the top of the charger and pick it up off the pallet. Position the Charger on the installation location and fasten the charger permanently.

  • Page 21: Rv24 Models Installation

    RV24 Models Installation • Mount the charger vertically, observing the minimum spacing shown below: Figure 8: RV24 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.
  • Page 22 • There must be at least 12” 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. This is to allow for service and tool access to the Charger.
  • Page 23 1. Preparing the Mounting Area: • The Charger must be mounted vertically as illustrated, using 5/16” hardware. (User provided) The Charger may be directly mounted to masonry or concrete, structural framing channels, or onto the Floor Stand. (purchased separately; see Appendix B) Figure 10: RV24 mounting height •...
  • Page 24 2. Unpacking the Charger: • Move the Charger’s pallet to the installation area. DO NOT remove Charger from pallet until at the installation area. The Charger IS NOT designed to be transported in any position other than horizontal! • Remove the cardboard box cover from the pallet. DO NOT REMOVE the Shipping Spacer;...
  • Page 25 • Remove the 8 screws securing the Charger to the pallet: (Figure 12) Figure 12: RV24 Shipping Screw Removal • Using a hoist, forklift, or other appropriate lifting equipment, attach a chain or strap to the lifting eyes at the top of the charger and pick it up off the pallet. Position the Charger on the installation location and fasten the charger permanently.

  • Page 26: Charger Electrical Installation

    INSTALLATION, USING PROPER EQUIPMENT AND PROCEDURES. VERIFY THAT INPUT AND OUTPUT WIRING ADHERES TO ALL LOCAL SAFETY CODES AND STANDARDS. 1. The REVOLUTION chargers require a 480 VAC 3∅, four-wire Wye or Delta electrical supply with a separate ground (Figure 14). REVOLUTION...

  • Page 27: Rv16 & Rv24 Electrical Instructions

    3. With a #2 Phillips screwdriver, remove the four 10-32 screws securing the Charger hinge: (Figure 15) Figure 15: RV16 Hinge Screw Locations and Detail 4. Open the Charger hinge. Determine whether the ½” or ¾” conduit hole will be utilized;...
  • Page 28 Field Wiring GND Stud Terminals Figure 17: RV16 Electrical Connections 6. Crimp a #10 ring tongue terminal to the ground (GND) wire and connect it to the GND terminal (Figure 17). Tighten the nut to 15 in-lb +/- 2 in-lb.

  • Page 29: Operation Procedure

    THE CHARGER IS NOW READY FOR OPERATION OPERATION PROCEDURE Charger Controls and User Interface Users operate the REVOLUTION series of chargers through each charger’s front panel LCD/keypad (Figure 18). This is the main user interface for viewing operation and fault messages. It also allows limited charger programming options.

  • Page 30: Basic Charge Cycle Operation

    Basic Charge Cycle Operation Figure 19: Typical charge cycle – charge modes The typical charge cycle for conventional and opportunity chargers consists of the first four modes (TR, CC, CV, FI) on a daily basis, with all five modes (TR, CC, CV, FI, EQ) occurring on a weekly basis.
  • Page 31 See Appendix D for further details. Installation instructions for the thermistor can be obtained at http://powerdesignerssibex.com/. REVOLUTION Chargers can include optional interfaces for communication with the PowerTrac Battery monitoring devices. The PowerTrac, battery data logger option allows the charger to have multi-voltage (24/36/48)* capabilities, giving the charger the ability to automatically adapt to the battery voltage and Ahr capacity.

  • Page 32: 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 33 2. Starting a Charge Cycle • Connect the battery to the charger. REVOLUTION Chargers incorporate a detection circuit that distinguishes between a PowerTrac Battery Monitor and a thermistor. If a PowerTrac is detected when the battery is connected, the LCD will...
  • Page 34 • The charge cycle begins and a screen similar to one of the following, showing the charging operation, appears: 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.
  • Page 35 Selecting STOP for the second time stops the charger completely and defaults to the PUSH START screen. Selecting START from the CHARGING STOPPED screen starts a new charge cycle and the screen will again display the charging operation display. • Once the charge cycle has completed, the charger displays the CYCLE COMPLETED screen.

  • Page 36: 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 • Network Settings 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 37 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 38 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 39 Pressing / allows adjustment of the charge timer setting in 15-minute increments. The charge timer setting can be set up to 18 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 40 3. Charge Cycle History a. While in MAIN MENU, press / until the CHARGE HISTORY screen appears. Press the 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 41 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. b.
  • Page 42 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. 6. Network Settings (Ethernet Option Only) a.

  • Page 43: Module Replacement

    MODULE REPLACEMENT In the event a module needs to be replaced follow the instructions below. 1. Note the serial number of the module that needs to be replaced from the Main Screen under the Charge History. 2. De-energize and lock out the incoming AC line from the charger. Follow all local safety procedures and PPE guidelines.

  • Page 44: Enumerating Installed Modules

    ENUMERATING INSTALLED MODULES After a new module is installed into the charger, the charger must be programmed (enumerated) to communicate properly. From the Idle screen, press the Enter key to enter the menu. While in Main Menu, press / until the Model & SN screen appears. 3.
  • Page 45 6. Press the Up Arrow to select “Yes”. 7. Press the ENTER key to enumerate the modules. The serial numbers of the modules will be displayed; verify the correct number of serial numbers are listed per installed modules. 8. Press the STOP key to exit the menu. MAN-000037-00 REV C...

  • Page 46: 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 47 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 48 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. Examples of possible faults follow: 1. AC Fault Possible Causes AC line voltage outside of allowable limits.
  • Page 49 3. Over-Current / Primary Over-Current Fault Possible Causes Damaged DC (output) cables. (open or short)  Troubleshooting a. Select STOP to revert to the Connect Battery or Push START screens. b. Verify that the output cables are in good working condition and are properly connected to the battery.
  • Page 50 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. d. Restart the charge cycle by selecting START. e.
  • Page 51 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 52 7. PowerTrac Communication Faults The following screen will appear when the battery is connected and the charger detects the presence of a PowerTrac , but is unable to establish a link. This may be due to a poor or reversed connection of the auxiliary wires. If the connection to the PowerTrac is lost while a charge cycle is underway, a screen similar to the following will be displayed:...

  • Page 53: 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 Sibex with a description of the problem. Power Designers Sibex 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 Sibex.

  • Page 54: Appendix A - Wall Mount Dimensions & Clearances

    Appendix A – Wall Mount Dimensions & Clearances RV16 Models Recommended mounting hardware: 5/16”. MAN-000037-00 REV C...

  • Page 55: Rv24 Models

    RV24 Models Recommended mounting hardware: 5/16”. MAN-000037-00 REV C...

  • Page 56: Appendix B - Post Stand Dimensions & Assembly Instructions

    Appendix B – Post Stand Dimensions and Assembly instructions RV16 Models MAN-000037-00 REV C...

  • Page 57: Rv24 Models

    RV24 Models MAN-000037-00 REV C...
  • Page 58 MAN-000037-00 REV C...

  • Page 59: Appendix C - Note On Temperature Compensation

    77 deg. F during normal operation, the charger voltage regulation levels can be automatically adjusted to compensate for temperature variations. The REVOLUTION charger (when used with an optional thermistor) implements two temperature compensation factors expressed in mv/ deg C/cell.

  • Page 60: Contact Information

    CONTACT INFORMATION Power Designers Sibex 430 N. Suncoast Blvd Crystal River, FL 34429 Tel: 352.795.0101 Fax: 352.564.0772 www.powerdesigners.com sales@powerdesigners.com service@powerdesigners.com Phones are answered between 8 a.m. and 4 p.m., Monday through Friday Eastern Time. After- hours calls are answered by voice mail and returned on the next business day. Questions and comments can also be submitted via fax or email.

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