Revolution RV05 Installation & Operation Manual
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Revolution RV05 Installation & Operation Manual

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RV05, RV08 and RV12 Models
Installation & Operation Manual
MAN-000036-00 REV D

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Summary of Contents for Revolution RV05

  • Page 1 RV05, RV08 and RV12 Models Installation & Operation Manual MAN-000036-00 REV D...

  • Page 2: Table Of Contents

    MODELS REVOLUTION RV05 480 VAC ......8 PECIFICATIONS FOR THE MODELS 12V REVOLUTION Chargers ................8 24V, 36V and 48V REVOLUTION Chargers ............9 80V REVOLUTION Chargers ................10 REVOLUTION RV08 480VAC ......11 PECIFICATIONS FOR THE MODELS 24V, 36V and 48V REVOLUTION Chargers ............11 80V REVOLUTION Chargers ................

  • 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

    Replace cracked or worn cables immediately.  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. ...
  • 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 RV05 Model Numbers RV05-1.5kW-90A-12V RV05-6kw-150A-36V-F RV05-5kw-36V RV05-2kW-120A-12V RV05-4kw-75A-48V-C RV05-6kw-36V RV05-2.5kW-150A-12V RV05-5kw-100A-48V-C RV05-4kw-48V RV05-4kw-90A-36V-C RV05-6kw-125A-48V-C RV05-5kw-48V RV05-5kw-120A-36V-C RV05-4kw-75A-48V-P RV05-6kw-48V RV05-6kw-150A-36V-C RV05-5kw-100A-48V-P RV05-4kw-80V RV05-4kw-90A-36V-P RV05-6kw-125A-48V-P RV05-5kw-80V RV05-5kw-120A-36V-P RV05-4kw-75A-48V-F RV05-6kw-80V RV05-6kw-150A-36V-P RV05-5kw-100A-48V-F RV05-6kW-48V-1/0-208 RV05-4kw-90A-36V-F RV05-6kw-125A-48V-F RV05-6kW-48V-1/0-240 RV05-5kw-120A-36V-F RV05-4kw-36V RV08 Model Numbers...

  • Page 8: Specifications For The Revolution 208 Vac Models

    Specifications for the REVOLUTION 208 VAC models SPECIFICATIONS RV05-6KW-48V RV08-10KW-48V Nominal Volt (V) / 48V / 112A 48V / 180A Maximum Current (A) 36V / 125A 36V / 200A INPUT SPECIFICATIONS Voltage 208 VAC, ± 10%, 3-phase Current 21.3A rms/ph 34.1A rms/ph...

  • Page 9: Specifications For The Revolution 240 Vac Models

    Specifications for the REVOLUTION 240 VAC models SPECIFICATIONS RV05-6KW-48V RV08-10KW-48V Nominal Volt (V) / 48V / 112A 48V / 180A Maximum Current (A) 36V / 125A 36V / 200A INPUT SPECIFICATIONS Voltage 240 VAC, ± 10%, 3-phase Current 18.5A rms/ph 29.6A rms/ph...

  • Page 10: Specifications For The Revolution Rv05 480Vac Models

    Specifications for the REVOLUTION RV05 480VAC models 12V REVOLUTION Chargers SPECIFICATIONS RV05-1.5kW-12V RV05-2kW-12V RV05-2.5kW-12V Nominal Volt (V) / 12V/90A 12V /120A 12V /150A Maximum Current (A) INPUT SPECIFICATIONS Voltage 480 VAC, ± 10%, 3-phase 2.8A rms/ph 3.7A rms/ph 4.6A rms/ph Current >0.85 nominal...

  • Page 11: 36V And 48V Revolution Chargers

    24V, 36V and 48V REVOLUTION Chargers RV05-4kw- RV05-5kw- RV05-6kw- RV05-4kw- RV05-5kw- RV05-6kw- SPECIFICATIONS Nominal Volt (V) / 48V / 67A 48V / 90A 48V / 112A 36V / 90A 36V / 120A 36V / 150A Maximum Current (A) 36V / 75A...

  • Page 12: Revolution Chargers

    80V REVOLUTION Chargers SPECIFICATIONS RV05-4kw-80V RV05-5kw-80V RV05-6kw-80V Nominal Volt (V) / 80V /39A 80V /52A 80V /65A Maximum Current (A) INPUT SPECIFICATIONS Voltage 480 VAC, ± 10%, 3-phase Current 5.5A rms/ph 7.4A rms/ph 9.2A rms/ph Power Factor >0.92 Breaker Rating...

  • Page 13: Specifications For The Revolution Rv08 480Vac Models

    Specifications for the REVOLUTION RV08 480 VAC models 24V, 36V and 48V REVOLUTION Chargers RV08-6KW- RV08-8KW- RV08-9KW- RV08-10KW- RV08-6KW- RV08-8KW- RV08-9KW- RV08-10KW- SPECIFICATIONS Nominal Volt (V) / 48V / 112A 48V / 135A 48V / 157A 48V / 180A 36V / 150A...

  • Page 14: Revolution Chargers

    80V REVOLUTION Chargers RV08-6kw-80V RV08-8kw-80V RV08-9kw-80V RV08-10kw-80V SPECIFICATIONS Nominal Volt (V) / 80V /65A 80V /78A 80V /91A 80V /91A Maximum Current (A) INPUT SPECIFICATIONS 480 VAC, ± 10%, 3-phase Voltage 9.2A rms/ph 11.1A rms/ph 12.9A rms/ph Current Power Factor >0.92...

  • Page 15: Specifications For The Revolution Rv12 480Vac Models

    Specifications for the REVOLUTION RV12 480 VAC models 24V, 36V and 48V REVOLUTION Chargers RV12-10KW- RV12-12KW- RV12-13KW- RV12-14KW- RV12-15KW- RV12-10KW- RV12-12KW- RV12-13KW- RV12-14KW- RV12-15KW- SPECIFICATIONS Nominal Volt (V) / 48V / 180A 48V /202A 48V / 225A 48V / 247A...

  • Page 16: Revolution Chargers

    80V REVOLUTION Chargers RV12-10kw- RV12-12kw- RV12-13kw- RV12-14kw- RV12-15kw- SPECIFICATIONS Nominal Volt (V) / 80V /104A 80V /117A 80V /130A 80V /143A 80V /156A Maximum Current (A) INPUT SPECIFICATIONS Voltage 480 VAC, ± 10%, 3-phase 14.8A rms/ph 16.6A rms/ph 18.5A rms/ph 22.2A rms/ph...

  • Page 17: 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 18: Rv05 Models Installation

    RV05 Models Installation • Mount the charger vertically, observing the minimum spacing shown below: Figure 1: RV05 NEC minimum spacing Ensure that the charging area is well ventilated, dry, and clean. • Do not expose the charger to rain or snow.
  • Page 19 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 2: RV05 minimum spacing Ambient Temperature Range 0 – 40° C • •...
  • Page 20 The Charger may be directly mounted to masonry or concrete, structural framing channels, or onto the Floor or Shelf Stand (purchased separately; see Appendix B or C). Figure 3: RV05 mounting hole / bolt pattern Charger should be fastened to the mounting surface using 5/16” hardware (User •...
  • Page 21 • to the bottom surface and set aside. Shift the cover slightly toward the top of the charger (about 1.5”) as shown: Figure 4: RV05 Cover Fastener Removal Lift the cover up and off, set aside: • Figure 5: RV05 Cover Removal...
  • Page 22 3. Mounting the Charger Pick up the Charger (a second person is recommended) and fasten the Charger to • the mounting surface: Figure 6: 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! Continue on page 33 for 208 VAC Charger Electrical Installation Continue on page 34 for 240 VAC Charger Electrical Installation...

  • Page 23: Rv08 Models Installation

    RV08 Models Installation • 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 or Shelf Stand (purchased separately; see Appendix B or C).
  • Page 24 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 25 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 or Shelf Stand (purchased separately; see Appendix B or C).
  • Page 26 IMPORTANT Figure 10: Fastener Height Restriction • Note that the mounting bracket fasteners cannot extend beyond the Charger mounting surface on the mounting brackets. Charger Weight: 85 lbs. Maximum • 2. Mounting the Charger: The hooks, studs, and locking tabs of the mounting bracket mate to matching slots in •...
  • Page 27 Lift the charger (2 people, 1 on each side) onto the 4 hooks of the mounting bracket. • Be sure all 4 hooks and studs are mated to their respective slots, and allow the charger to drop onto the hooks. The locking tabs will engage in their slots, and will lock the charger temporarily to the charger mounting bracket.
  • Page 28 Swing the Charger open to expose the studs of the Mounting Bracket, and the plastic • bag containing the mounting nuts: Figure 13: RV08 Cover open • Remove the nuts from the bag, and use them to secure the Charger. Tighten to 60 in-lb +/- 2 in-lb: Figure 14: RV08 Permanent Attachment Once the Charger has been securely mounted, electrical installation can proceed.

  • Page 29: Rv12 Models Installation

    RV12 Models Installation Mount the charger vertically, observing the minimum spacing shown below: • Figure 15: RV12 NEC minimum spacing Ensure that the charging area is well ventilated, dry, and clean. • Do not expose the charger to rain or snow. •...
  • Page 30 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 31 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). Unpack the RV12 Mounting Bracket, and use it as a template to position the mounting •...
  • Page 32 IMPORTANT Figure 18: Fastener Height Restriction Note that the mounting bracket fasteners cannot extend beyond the Charger • mounting surface on the mounting brackets. Charger Weight: 120 lbs. Maximum • 2. Mounting the Charger: • The hooks, studs, and locking tabs of the mounting bracket mate to matching slots in the Charger: Figure 19: RV12 Rear View Lift the charger (2 people, 1 on each side) onto the 4 hooks of the mounting bracket.
  • Page 33 3. Fastening the Charger On the left side of the Charger, remove the 2 (10-32) screws securing the Charger • door: Figure 20: RV12 Cover Removal • Swing the Charger open to expose the studs of the Mounting Bracket, and the plastic bag containing the mounting nuts: Figure 21: RV12 Cover open Remove the nuts from the bag, and use them to secure the Charger.
  • Page 34 Figure 22: RV12 Permanent Attachment • Once the Charger has been securely mounted, electrical installation can proceed. mounting and CAUTION: Do not allow debris to fall inside the Charger during the installation process! Continue on page 33 for 208 VAC Charger Electrical Installation Continue on page 34 for 240 VAC Charger Electrical Installation Continue on page 35 for 480 VAC Charger Electrical Installation MAN-000036-00 REV D...

  • Page 35: Charger Electrical 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 208 VAC 3∅, four-wire Wye or Delta electrical supply with a separate ground (Figure 23). REVOLUTION...

  • Page 36: 240 Vac 3

    USING PROPER EQUIPMENT AND PROCEDURES. VERIFY THAT INPUT AND OUTPUT WIRING ADHERES TO ALL LOCAL SAFETY CODES AND STANDARDS. 3. The REVOLUTION chargers require a 240 VAC 3∅, four-wire Wye or Delta electrical supply with a separate ground (Figure 23). REVOLUTION...

  • Page 37: 480 Vac 3

    USING PROPER EQUIPMENT AND PROCEDURES. VERIFY THAT INPUT AND OUTPUT WIRING ADHERES TO ALL LOCAL SAFETY CODES AND STANDARDS. 5. The REVOLUTION chargers require a 480 VAC 3∅, four-wire Wye or Delta electrical supply with a separate ground (Figure 23). REVOLUTION...
  • Page 38 RV05 Electrical Instructions 7. Determine whether the ½” or ¾” conduit hole will be utilized, if ¾” is desired, punch out the outer ring from the knockout (KO) provided (Figure 24): Power stud Figure 24: KO and GND stud location 8.
  • Page 39 Field Wiring Terminals Figure 25: RV05 terminal block location – non CEC Field Wiring Terminals Figure 26: RV05 terminal block location – CEC models 12. Once electrical installation is complete, the cover and (2) 8-32 screws fastening the cover can be replaced.
  • Page 40 RV08 & RV12 Electrical Instructions 3. Determine whether the ½” or ¾” conduit hole will be utilized, if ¾” is desired, punch out the outer ring from the knockout (KO) provided (Figure 27): Figure 27: RV08 KO location 4. Pass the 480 VAC input power wires through, using the appropriate conduit or strain relief fittings per local and national codes.

  • Page 41: 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 28). 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 37 of this manual.)

  • Page 42: Basic Charge Cycle Operation

    Basic Charge Cycle Operation Figure 29: 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 43 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 PowerTracs, 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 AH capacity.

  • Page 44: 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 45 2. Starting a Charge Cycle Connect the battery to the charger. REVOLUTION Chargers can 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 46 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 47 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 •...

  • Page 48: 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 49 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 50 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 51 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 52 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 53 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 54 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-000036-00 REV D...
  • Page 55 6. Network Settings (Ethernet Option Only) A. While in MAIN MENU, press / until the Network Settings screen appears. B. Pressing the ENTER key displays the IP Configuration Screen: For further information on network setup, see the powercharge datalink User Software, P/N 014-000324-00.

  • Page 56: 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 57 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 58 1. AC Fault Possible Causes  AC line voltage outside of allowable limits. (432 VAC-528 VAC, AC phases matched within 10V)  Fuse blown in AC service. Troubleshooting a. Select STOP to revert to the Connect Battery or Push START screens. b.
  • Page 59 3. Over-Current / Primary Over-Current Fault Possible Causes  Damaged DC (output) cables. (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 60 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 61 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 62 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: Examining the Charge History will reveal a screen similar to this:...

  • Page 63: 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 64: Appendix A - Wall Mount Dimensions And Clearances

    Appendix A – Wall Mount Dimensions and Clearances RV05 Models Recommended mounting hardware: 5/16”. MAN-000036-00 REV D...

  • Page 65: Rv08 Models

    RV08 Models Recommended mounting hardware: 5/16”. MAN-000036-00 REV D...

  • Page 66: Rv12 Models

    RV12 Models Recommended mounting hardware: 5/16”. MAN-000036-00 REV D...

  • Page 67: Appendix B - Post Stand Dimensions And Assembly Instructions

    Appendix B – Post Stand Dimensions and Assembly instructions RV05 Models MAN-000036-00 REV D...
  • Page 68 MAN-000036-00 REV D...

  • Page 69: Rv08 Models

    RV08 Models RV12 Models MAN-000036-00 REV D...
  • Page 70 MAN-000036-00 REV D...

  • Page 71: Appendix C - Shelf Stand Dimensions

    Appendix C – Shelf Stand Dimensions RV05 Models RV08 Models MAN-000036-00 REV D...

  • Page 72: Appendix D - 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 73: Contact Information

    CONTACT INFORMATION Power Designers Sibex 430 N. Suncoast Blvd Crystal River, FL 34429 Tel: 352.795.0101 Fax: 352.564.0772 www.powerdesignerssibex.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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