AMETEK/PRESTOLITE POWER EVOLUTION User manual

OWNER’S MANUAL 193111-200
Issued November 23, 2020
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
DO NOT DESTROY
AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

193111-200
TABLE OF CONTENTS
November 23, 2020
TABLE OF CONTENTS
INTRODUCTION 1
How To Use This Manual ................................................................................................... 1-1
Equipment Identification ..................................................................................................... 1-1
Receipt Of Equipment ........................................................................................................ 1-1
SAFETY INSTRUCTIONS AND WARNINGS 2
DESCRIPTION OF EQUIPMENT 3
Operating Modes ................................................................................................................ 3-1
Opportunity Charging ......................................................................................................... 3-1
Evolution Control ................................................................................................................ 3-2
INSTALLATION 4
Location .............................................................................................................................. 4-1
Environmental Characteristics ............................................................................................ 4-1
Grounding ........................................................................................................................... 4-1
Line Connections to Battery Charger ................................................................................. 4-2
Charging Cable Connectors ............................................................................................... 4-3
Pre-operation Checks ......................................................................................................... 4-3
Pre-Operation Changes to the Factory Control Settings .................................................... 4-3
MAINTENANCE 5
OPERATION 6
Preliminary ......................................................................................................................... 6-1
Normal Or Daily Charge .................................................................................................... 6-1
Equalize Or Weekend Charge .......................................................................................... 6-2
Manual Stop ...................................................................................................................... 6-2
AC Power Fail ................................................................................................................... 6-2
Abnormal Shutdowns……………………………………….…………………………….....…. 6-3
EVOLUTION CONTROL FEATURES 7
Main Features .................................................................................................................... 7-1
Description of Features ...................................................................................................... 7-2
Evolution Charge Archive Function .................................................................................... 7-3
Evolution Halo Light Description ….................................................................................... 7-5
NAVIGATING THE EVOLUTION CONTROL 8
Home Screen…………………………………………. ......................................................... 8-1
Dashboard ……………………............................................................................................ 8-2
Archive Records ...........…………....................................................................................... 8-3
Statistics App …………………………………………………………………………………….. 8-5
Settings App …………………………………………………………….……………………….. 8-6
PROGRAMMING SETTINGS 9
General Settings ................................................................................................................ 9-1
Start Mode ......................................................................................................................... 9-2
Charge Curve and Parameters ………………………………………………………………… 9-3
BID Settings …………………………………...……………………………………………..….. 9-3
Equalize and Refresh Charge …………………………………………………………………. 9-4
No Gassing Time and Battery Watering ……………………………………………………… 9-5
DIAGRAMS
WARRANTY

193111-200
INTRODUCTION
November 23, 2020 1-1
INTRODUCTION
How To Use This Manual
IMPORTANT: It is especially
important that all charger
internal components be kept
clean and dry, and all
electrical connections
tightened. Replace any
precautionary or instruction
label that cannot be easily
read.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:
WARNING gives information
regarding possible personal
injury. Warnings will be
enclosed in a box such as this.
CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.
NOTE offers helpful information concerning
certain operating procedures. Notes will be
shown in italics.
Equipment Identification
The unit's identification number (specification, model,
serial number) appears on a nameplate attached to
the front panel.
Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If
there is any damage, notify the carrier immediately to
file a claim. Furnish complete information concerning
damage claims or shipping errors to the company
shown on the cover of this manual. Include all
equipment identification numbers and group part
numbers (if any) as described above along with a full
description of the parts in error.
Move the equipment to the site of installation before
uncrating. Use care to avoid damaging the equipment
when using bars, hammers, etc., to uncrate the unit.
Additional copies of this manual are available on the
company website.
www.prestolitepower.com

NOTE: Information regarding obtaining additional copies of this manual is located in the Introduction
chapter of this manual.
A battery charger is identified by model number. Incorporated into the model number is the
ampere-hour capacity, case size, module count, and number of cells in battery for which
charger is intended. The following example explains the basic model numbering arrangement.
Model 750 EH 2 - 18 P
Rated - P = Opportunity
Number of Cells
Module Count (1, 2 or 3)
Case Type
Nominal AH Size
NOTE: This information is required for ordering certain replacement/service parts.

November 23, 2020 2-1
193111-200
SAFETY INSTRUCTIONS AND WARNINGS
SAFETY INSTRUCTIONS AND WARNINGS
FOR OPERATION OF BATTERY
CHARGING EQUIPMENT
IMPORTANT – READ AND
UNDERSTAND THESE
I NSTRUCTIONS. DO NOT
LOSE THEM. ALSO READ
OPERATING/INSTRUCTION
MANUAL BEFORE
INSTALLING, OPERATING,
OR SERVICING THIS
EQUIPMENT.
A. General
Battery charging products can cause serious injury or
death, or damage to other equipment or property, if the
operator does not strictly observe all safety rules and
take precautionary actions.
Safe practices have developed from experience in the
use of charging equipment. These practices must be
learned through study and training before using this
equipment. Anyone not having extensive training in
battery charging practices should be taught by
experienced operators.
Only qualified personnel should install, use, or
service this equipment.
B. Shock Prevention
Bare conductors, or terminals in the output circuit,
or ungrounded, electrically live equipment can
fatally shock a person. To protect against shock,
have a certified electrician verify that the
equipment is adequately grounded and learn what
terminals and parts are electrically HOT.
The body’s electrical resistance is decreased when
wet, permitting dangerous current to flow through the
body. Do not work in damp area without being extreme-
ly careful. Stand on dry rubber mat or dry wood and
use insulating gloves when dampness or sweat cannot
be avoided. Keep clothing dry.
1. Installation and Grounding of Electrically Powered
Equipment – Electrical equipment must be installed
and maintained in accordance with the National
Electrical Code, NFPA 70, and local codes. A
power disconnect switch must be located at the
equipment. Check nameplate for voltage and
phase requirements. If only 3-phase power is
available, connect single-phase equipment to only
two wires of the 3-phase line. DO NOT CONNECT
the equipment grounding conductor (lead) to the
third live wire of the 3-phase line as this makes the
equipment frame electrically HOT, which can cause
a fatal shock.
If a grounding lead (conductor) is part of the power
supply cable, be sure to connect it to a properly
grounded switch box or building ground. If not part
of the supply cable, use a separate grounding lead
(conductor). Do not remove a ground prong from
any plug. Use correct mating receptacles. Check
ground for electrical continuity before using
equipment.
The grounding conductor must be of a size equal
to or larger than the size recommended by Code or
in this manual.
2. Charging Leads – Inspect leads often for damage
to the insulation. Replace or repair cracked or worn
leads immediately. Use leads having sufficient
capacity to carry the operating current for long
periods of time without overheating.
3. Battery Terminals – Do not touch battery terminals
while equipment is operating.
4. Service and Maintenance – Shut OFF all power at
the disconnect switch or line breaker before
inspecting, adjusting, or servicing the equipment.
Lock switch OPEN (or remove line fuses) so that
the power cannot be turned ON accidentally.
Disconnect power to equipment if it is to be left
unattended or out of service.
Disconnect battery from charger.
Keep inside parts clean and dry. Dirt and/or
moisture can cause insulation failure. This failure
can result in high voltage at the charger output.

193111-200
SAFETY INSTRUCTIONS AND WARNINGS
2-2 November 23, 2020
C. Burn and Bodily Injury Prevention
The battery produces very high currents when short
circuited, and will burn the skin severely if in contact
with any metal conductor that is carrying this current.
Do not permit rings on fingers to come in contact with
battery terminals or the cell connectors on top of the
battery.
Battery acid is very corrosive. Always wear correct eye
and body protection when near batteries.
D. Fire and Explosion Prevention
Batteries give off explosive flammable gases which
easily ignite when coming in contact with an open flame
or spark. Do not smoke, cause sparking, or use open
flame near batteries. Charge batteries only in
locations which are clean, dry, and well ventilated.
Do not lay tools or anything that is metallic on top of
any battery. All repairs to a battery must be made only
by experienced and qualified personnel.
E. Arcing and Burning of Connector
CAUTION: To prevent arcing and burning of the con-
nector contacts, be sure the charger is OFF before con-
necting or disconnecting the battery (If the charger is
equipped with an ammeter, the ammeter should not
indicate current flow).
F. Medical and First Aid Treatment
First aid facilities and a qualified first aid person should
be available for each shift for immediate treatment of
electrical shock victims.
EMERGENCY FIRST AID: Call
physician and ambulance
immediately. Use First Aid
techniques recommended by the
American Red Cross.
DANGER: ELECTRICAL SHOCK
CAN BE FATAL. If person is
unconscious and electric shock
is suspected, do not touch
person if he or she is in contact
with charging leads, charging
equipment, or other live electrical
parts. Disconnect (open) power
at wall switch and then use
First Aid. Dry wood, wooden
broom, and other insulating
material can be used to move
cables, if necessary, away from
person. IF BREATHING IS
DIFFICULT, give oxygen. IF NOT
BREATHING, BEGIN ARTIFICIAL
BREATHING, such as mouth-to-
mouth. IF PULSE IS ABSENT,
BEGIN ARTIFICIAL CIRCULATION,
such as external heart massage.
IN CASE OF ACID IN THE EYES, flush with
clean water and obtain professional
medical attention immediately.
G. Equipment Warning Labels
Inspect all precautionary labels on the equipment.
Order and replace all labels that cannot be easily
read.

193111-200
DESCRIPTION OF EQUIPMENT
November 23, 2020 3-1
DESCRIPTION OF EQUIPMENT
Figure 3-1
The basic charging circuit is the IGBT inverter high
frequency-type with isolating transformer (s). This
design regulates charging current by allowing the
battery to determine its own charge cycle rate in
accordance with its state of discharge. It provides a
constant current-constant voltage-constant current (IEI)
charge that eliminates the possibility of overcharging,
even with line voltage variations of ± 10% and allows
the battery to finish at the proper current regardless of
battery age or gravity type.
The Evolution provides battery charging over a wide
range of environmental conditions. The charger will
precisely charge your battery based on battery
temperature, type, and size; by automatically adjusting
its own output charge characteristic within the power
limits of the charger’s power circuit.
When applied with the Prestolite Power optional Battery
Identification Module (BID), the Evolution Charger
identifies a battery selected for charging at the time of
connection and adjusts its output for that specific
battery. During the charge cycle, or duration of
connection, the Evolution continuously monitors the
battery’s temperature via the BID and adjusts its output
to match the battery temperature as it changes
throughout the charge cycle.
Upon connection of the battery, the Evolution control
reads the information programmed into the BID and
identifies the battery’s AH rating, cell size, type of
construction, electrolyte temperature, and programmed
method of charge and adjusts its output curve based on
this information.
The Evolution is internally protected against overload
and short circuits by both input and output fusing, plus
Prestolite’s unique curve monitoring circuit measures
the output curve to ensure that the voltage and current
are within the limits set at the factory.
Operating Modes
The Evolution reads the information that was
programmed into the BID Module during installation
and charges the battery based on an opportunity
charging profile or a profile designed to recharge a
fully discharged battery in 8 hrs. Valve regulated
batteries of several types can also be recharged at
the 8 hour rates when equipped with a properly
programmed BID Module.
The Evolution always defaults to the BID mode
when an installed BID Module is detected. The
charger automatically adjusts its output to match the
battery information programmed into the module.
The BID Module allows users with various cell size
batteries to charge any battery on any charger
without the fear of mismatching batteries and
chargers.
Opportunity Charging
In applications utilizing opportunity charging, the
high current output of the Evolution returns
significant capacity to the battery during short
periods such as breaks, lunch and shift changes.
In many applications battery changing can be
eliminated completely.

3-2 November 23, 2020
193111-200
DESCRIPTION OF EQUIPMENT
EVOLUTION Control
The Evolution control is the standard charge control for
the Evolution Charger. It utilizes either a voltage/time
(VT) charge termination or a patented dV/dT charge
termination technique which eliminates excessive gas-
sing returning approximately 107% of the amp hours
removed from the battery.
Features of the Evolution Control include auto start/
stop, manual equalize, manual stop, back-up timer pro-
tection, two charge termination methods, manual or
automatic (with optional BID module) battery tempera-
ture compensation, AC power fail recovery, selectable
output profiles, and charge cycle data archiving.
The backlit touch screen display and bright LEDs on
the top panel indicate the status of a normal charge
cycle. The screen will display “80% Charged” when the
battery current is reduced to approximately 8.2 amps
per 100 AH of battery rating. The battery voltage at the
80% charged point will vary with charge profile setting
and/or manual or automatic temperature settings.
“Charge Complete” will display only if the battery has
completed the charge cycle and is ready for use.
The LEDs will flash red if the charger terminates a
charge prematurely. See the Evolution Control Fea-
tures chapter of this manual to determine the cause of
the fault. The screen will display “Equalize” when an
equalize charge is requested by pressing the equalize
push button. The LEDs will rapidly flash Green and
White when the charger is equalizing the battery.
WARNING: Do not connect a bat-
tery to this charger if the screen is
not lit. Do not disconnect a battery
from this charger while a charge is
in progress. Otherwise, damage to
charger, arcing and burning of con-
nector parts or a battery explosion
may result. Batteries produce ex-
plosive gases. Keep sparks, flame,
and cigarettes away. Ventilate when
charging in an enclosed area. Al-
ways shield eyes when working
near batteries.

Location
For best operating characteristics and longest unit life,
take care in selecting an installation site. Avoid
locations exposed to high humidity, dust, high ambient
temperature, or corrosive fumes. Moisture can
condense on electrical components, causing corrosion
or shorting of circuits (especially when dirt is also
present).
Adequate air circulation is needed at all times in order
to assure proper operation. Provide a minimum of 12
inches of free air space at the top and front of the unit.
Make sure that ventilation openings are not obstructed.
Always remove the charger shipping skid from the unit
before installation. The charger must be installed over
a noncombustible surface such as concrete or metal.
Keep the charging area clear of all combustible materi-
al such as wood, paper, and cloth. When moving the
charger after the packing skid and box have been
removed, make sure that lifting forks do not damage
the charger panels or cables.
WARNING: SPARKS OR MOLTEN METAL
falling through open bottom can cause fire or
explosion.
•Install over noncombustible material such as
concrete or metal.
•Keep charging area clear of combustible
material.
Environmental Characteristics
Operating Characteristics 0°C to 40°C
(32°F to 104°F)
Operating Altitude To 2000 Meters
(6562 Feet)
Operating Humidity 80% up to 31°c,
decreasing to 50% at
40°C, non-condensing
80% up to 88°F
decreasing to 50% at
104°F, non-condensing
Grounding
The frame of the power source must be grounded for
personnel safety. Where grounding is mandatory un-
der state or local codes, it is the responsibility of the
user to comply with all applicable rules and regulations.
Where no state or local codes exist, it is recommended
that the National Electrical Code be followed.
In addition to the usual function of protecting personnel
against the hazard of electrical shock due to fault in the
equipment, grounding serves to discharge the static
electrical charges which tend to build up on the
surfaces of equipment. These static charges can
cause painful shock to personnel, and can lead to the
erroneous conclusion that an electrical fault exists in
the equipment.
If a charger is to be connected to the AC power supply
with a flexible jacketed cable, one having a separate
grounding conductor should be used. When included
in cable assembly, grounding conductor will be green,
green with a yellow stripe, or bare. When connecting
input power to charger (as instructed in Line Connec-
tion to Battery Charger section of this manual), connect
grounding conductor to equipment grounding terminal,
taking care to make a good electrical connection. Con-
nect other end of grounding conductor to the system
ground.
If, for any reason, an input cable which does not in-
clude a grounding conductor is used, the equipment
must be grounded with separate conductor. Minimum
size and color coding requirements must be in accord-
ance with any applicable state or local code, or the Na-
tional Electrical Code.
If metallic armored cable or conduit is used, the metal
sheathing or conduit must be effectively grounded as
required by state or local code, or the National Electri-
cal Code.
If a system ground is not available, the charger frame
must be connected to a driven ground rod (at least 8 ft
[2438 mm] long), or to a water pipe that enters the
ground not more than 10 ft (3048 mm) from the
charger. A grounding conductor must be connected to
the rod or pipe in a manner that will assure a
permanent and effective ground. The conductor must
be sized in accordance with any applicable state or
local code, or by the National Electrical Code. If in
doubt, use the same size conductor as is used for the
conductors supplying power to the charger.
November 23, 2020 4-1
193111-200
INSTALLATION
INSTALLATION
WARNING: ELECTRIC SHOCK
HAZARD- Under no circumstance
should you use a grounding
conductor with a current carrying
capacity less than the ampere
rating shown in Table 4-1.

193111-200
INSTALLATION
4-2 November 23, 2020
Table 4-1 Recommended AC Input and Branch Fusing
LINE AMPS DISCONNECT
SWITCH *
COPPER CABLE SIZE AWG * *
BRANCH FUSE SIZE
(AMPERES) POWER GROUND
0-2.5 30A 5No. 14 No. 14
2.6-4.5 30A 7No. 14 No. 14
4.6-7.5 30A 10 No. 14 No. 14
7.6-12 30A 15 No. 14 No. 14
12.1-16 30A 20 No. 12 No. 12
16.1-18 30A 25 No. 10 No. 10
18.1-22 30A 30 No. 10 No. 10
22.1-24.5 60A 35 No. 8 No. 10
24.6-32.5 60A 40 No. 8 No. 10
32.6-40 60A 50 No. 8 No. 10
40.1-45 60A 60 No. 6 No. 10
45.1-57.5 100A 80 No. 4 No. 8
57.6-78 100A 100 No. 2 No. 8
78.1-102.5 200A 125 No. 2 No. 6
102.6-135 200A 150 No. 1/0 No. 6
The above table (Table 4-1) is based on 75°C (167°F) rated conductors and 40°C (104°F) ambient temperatures.
Refer to National Electrical Code (2008) Tables 310-16 corrected to 40°C (104°F).
* For 115, 208, and 230-volt lines, use 250-volt disconnect switch.
For 440-480, 575-volt lines, use 600-volt disconnect switch.
* * Two conductors and ground conductor required for single phase.
Three conductors and ground conductor required for three phase.
Recommended minimum size of grounding conductors (based on National Electrical Code 2008 – Table 250-95).
Line Connections to Battery Charger
Follow local code requirements if different than
instructions in this manual.
1. Turn charger OFF.
2. Be sure charger is connected correctly for available
line voltage as instructed above.
3. On charger nameplate, note the AC input amperes
corresponding to the line voltage to which charger
is to be connected. Use that ampere value to select
the proper disconnect switch, fuse, and power cable
sizes from Table 4-1.
4. Route AC power input cable in through knockout
provided in side panel of charger cabinet. Securely
fasten cable wires to a power input terminal inside
charger. Refer to Grounding section of this manual
for proper connection of grounding conductor.
5. With disconnect switch (on AC input power line)
in “OPEN” or “OFF” position, connect power
cable coming from charger, to the switch. Install
fuses in switch.
AC Supply Input Conditions:
Supply voltage should not exceed +/-10% of rated
input voltage value. Consistent power should
be provided with fluctuations not to exceed
1200VAC (850Vrms) for a duration longer than 25
Microseconds.
WARNING
At all times, safety must be considered
an important factor in the installation,
servicing and operation of the product
and skilled, qualified technical assis-
tance should be utilized.

193111-200
INSTALLATION
November 23, 2020 4-3
Special Considerations
Generators and Backup Power Systems
On site power generation and backup power systems
create special considerations both because of the pow-
er quality itself and the way the load is transferred be-
tween mains and backup (and reversion to mains).
If this installation will incorporate either on – site gener-
ation or some other form of backup power, please con-
sult AMETEK Engineering for a review of the planned
system prior to implementation. AMETEK
Charging Cable Connectors
If connectors are already attached to charging cables,
make sure that they are attached so that positive
charger polarity will connect to positive battery terminal.
If connectors must be attached to charging cables,
follow instructions supplied with connectors.
CAUTION: Make sure connectors are
securely attached to cables (good
solder joint or well tightened set screws,
whichever is applicable). Be certain
that positive charger cable will connect
to positive battery terminal. If necessary,
trace cables into charger to determine
polarity. The use of a DC voltmeter may
show polarity. Improper connections
will “blow” output fuse and may cause
other damage.
Pre-operation Checks
1. Inspect charger thoroughly for damage; loose
screws, nuts, or electrical connections.
WARNING: ELECTRICAL SHOCK
HAZARD – Before inspecting or
cleaning inside cabinet, turn OFF
and remove fuses of disconnect
switch (supplying AC power to
charger) and disconnect battery.
2. Remove all special tags that are tied to charger.
Keep tags with this manual for future reference.
Leave all precautionary and instruction labels in
place on charger. Carefully read and follow
instructions on all tags and labels. Make sure all
labels remain visible to anyone operating charger.
3. Make sure all charger cabinet panels are fastened
in place, to assure proper flow of ventilating air
through cabinet.
Pre-Operation Changes To The Factory
Control Settings
Typically few changes are required to be made if the
amp hour rating is sized to the battery and the voltage
rating is equal to or greater than the battery. However,
in some applications, some changes to the
programmable control settings may be desirable. The
most common changes are listed below:
TIME Factory Setting for Time can be set to the
desired time zone
NOTE: It is advisable to check the day of the week,
date, month, and year for accuracy
NO GASSING HOURS
Factory Setting is 2 hours
MAX BATTERY TEMPERATURE
Factory Setting is 150° F
AUTO EQUALIZE
Factory setting is ON
AUTO EQUALIZE TYPE
Factory setting is by Cycle
AUTO EQUALIZE COUNT
Factory setting is 05
Other functions are available for programming the
Evolution Control to meet your specific charging needs.
Programming these functions is described in the
Programming the Evolution Control chapter of this
manual.

5-1 November 23, 2020
193111-200
MAINTENANCE
WARNING: ELECTRICAL SHOCK
HAZARD — Before inspecting or
cleaning inside cabinet, turn OFF
and remove fuses of disconnect
switch (supplying AC power to
charger) and disconnect battery.
Inspection And Cleaning
For uninterrupted, satisfactory service from this
charger, it's necessary to keep unit clean, dry, and
well ventilated. At least every three months, or
more often as necessary, wipe and blow out all
dirt from unit's interior components, with clean,
dry air of not over 25 psi (172 kPa) pressure. Use
a hand bellows if compressed air isn't available.
A certified technician can remove modules and
clean the heat sink with compressed air or a wire
brush, if necessary.
Check and tighten all electrical connections as
necessary to eliminate unnecessary losses and to
avoid subsequent trouble from overheating or open
circuits. Check for broken wiring or damaged
Insulation on wiring.
WARNING: ELECTRICAL SHOCK
HAZARD — Failure to keep internal
parts clean and dry may allow
transformer (s) to short out,
causing secondary circuits to
carry dangerously high voltage.
Be sure to close all charger cabinet panels after
any servicing, to assure proper flow of cooling air
through unit and to protect internal components.
WARNING: ELECTRICAL SHOCK
HAZARD — All cabinet panels must
be closed to protect personnel from
contact with hazardous voltages.
Lubrication
None required.
Fuse Replacement
The input and output of the Evolution modules are
protected by ‘fast clearing’ fuses. Three AC fuses on
the input and a DC fuse on the output.
CAUTION: The use of any other type
fuse besides the “fast-clearing” type
may cause damage to silicon diodes.
MAINTENANCE

November 23, 2020 6-1
193111-200
OPERATION
OPERATION
The operating procedure given here explains the
operation of a Prestolite Evolution Charger equipped
with the Evolution Control.
NOTE: If this charger is equipped with
certain optional features, the operating
procedure may be modified.
Preliminary
1. Make sure that charger is installed and grounded as
instructed in this manual.
2. Turn on main fused disconnect switch that supplies
AC power to charger.
3. Maintain electrolyte level in batteries to be charged,
as instructed by battery manufacturer. The volume
of electrolyte will expand during the charge.
Therefore, to avoid overfilling, do not add water
until the battery has received at least an 80%
charge. This will usually be reached at the time
gassing starts.
Normal or Daily Charge
(For batteries with ampere-hour capacity within the
range shown on charger nameplate)
1. Insure that battery size matches the charger and/or
charger setting. (Number of cells is equal to or less
than the charger nameplate rating and ampere-hour
capacity is within charger nameplate rating.)
2. Securely engage the battery and charger
connectors. The charger will go to the Dashboard
view.
3. The charger will display “Detecting BID Device”
as it looks for BID modules.
4. After a short delay, the charger will turn on, the fans
will run and the halo of LEDs will blink green. The
touch screen display will indicate the cell size and
amp hour settings for the charge cycle.
5. The halo will blink green slowly and become faster
when the battery reaches 80%.
6. When the charge termination point is reached, the
charger will turn off and the blinking green light will
become solid. If an equalize charge has been
selected, the lights will blink fast green/white during
the Equalize portion of the charge cycle.
NOTE: To disconnect battery from charger before
charge is complete, press the “Stop” button on the
charger front panel.
NOTE: While not normally required, the
charging rate may be adjusted to compensate for
unusual ambient temperature, age of battery, etc.
WARNING: EXPLOSION HAZARD
- Do not connect or disconnect a
battery unless the Halo is a solid
Green: otherwise, damage to
charger, arcing and burning of
connector parts or a battery explo-
sion may result (batteries produce
explosive gases). Keep sparks,
flame, and cigarettes away. Venti-
late when charging in and en-
closed area. Always shield eyes
when working near batteries. Dis-
connect battery if charger is to be
turned off for prolonged periods
of time.

6-2 November 23, 2020
193111-200
OPERATION
Equalize or Weekend Charge
Batteries may need periodic equalizing to correct for
inequalities between cells that result from daily or
frequent cycling. An equalizing charge should be given
if any of the following conditions exist:
1. The specific gravity of any cell at the end of charge
is 20 points less than the average.
2. The on-charge voltage of any cell at the end of
charge is 20 MV less than the average.
3. The battery has been stored for 30 days.
4. A large volume of water has been added.
When the equalize mode is desired, follow the
operation outlined for a normal charge but switch the
Equalize toggle to the on position.
NOTE: The Evolution Control is shipped from the
factory set to the Auto Equalize by Cycle
mode, and will automatically provide an
equalize charge every 5 complete cycles. Auto
Equalize prevents manual equalizing.
Manual Stop
To stop any charge cycle before charge complete,
press the “Stop” key.
WARNING: Do not connect a
battery to this charger if any
error is displayed. Do not dis-
connect a battery from this
charger while a charge is in
progress. Otherwise, damage
to charger, arcing and burning
of connector parts or a battery
explosion may result. Batteries
produce explosive gases. Keep
sparks, flame, and cigarettes
away. Ventilate when charging
in an enclosed area. Always
shield eyes when working near
batteries.
AC Power Fail
The Evolution Control will resume the charge where it
left off when the AC power failure occurred, virtually
unaffecting charge time.
As power is returned, if a charge cycle was in progress,
the display will show “delayed start due to power fail-
ure” and will restart based on cycle run times. This will
prevent multiple chargers from restarting all at once,
minimizing peak restart power.
NOTE: If a battery is disconnected from the
charger during an AC power failure and
discharged, reconnecting it or any other
battery may result in an incomplete charge
cycle.
WARNING: ELECTRICAL
SHOCK HAZARD – Before
checking electrical
components, turn off and
remove fuses of disconnect
switch (supplying AC power
to charger) and disconnect
battery.

Abnormal Shutdowns:
High Battery Reject- Initial battery voltage higher
than expected per the charger’s capabilities or
cell count setting. Halo will turn red and screen
will display “High Battery Voltage Detect-
ed Unable to Charge”
Battery Overtemperature- Battery has exceeded
the max temperature setting and is cooling
down. Halo will show solid Red and screen will
display “Battery Over Temperature Detected
Cooling Down”. Once the battery cools down,
charging will continue.
Low Voltage Shutdown- This shutdown will occur
if cell voltage does not rise above the following
levels in the indicated time frame: On screen
message: "Charge Curve Error Minimum
Charge Slope Not Met"
Charge Curve Voltage Error- On screen message
text: "Charge Curve Error Unable to Reach Tar-
get CV". This is to indicate to the user that the
charger cannot charge the battery properly due
to battery problems, charger problems or mis-
matched equipment.
Low Current Shutdown- Predetermined level is
below 2 amps for greater than 30 seconds. On
screen message: “Charge Curve Error Low
Current”
High Current Shutdown- Charger output current
is higher than expected. This error is triggered
when output is 5 amps above the desired out-
put for longer than 30 seconds and the charge
controller is unable to compensate for it. Halo
is solid red. On screen message: "Charge
Curve Error Over Current".
Manual Stop- On screen message: “Manual Stop”.
This should only be present if the Manual Stop
button has been pressed while the charger is
running.
Backup Timer- Charger recognizes that the bat-
tery is not charging properly due to a lack of
increased voltage as the charge occurs. On
screen message: “Charge Session Timeout”.
Over Max AH Returned- Without a BID this will trip
at 125% of total battery amp hour. 150% with a
BID. For an equalize charge, it is 150% without
a bid and 175% with a BID. On screen mes-
sage: “Charge Error Over AH Returned”
Charger Overtemperature Shutdown- Charger
cabinet temperature high, charging
stopped. Halo is solid red, onscreen message:
"Charger Over Temperature Error”
Charge Curve Error DiDt- Indicates an increase in
current over time. Current should decrease
when it hits gassing voltage. On screen mes-
sage "Charge Curve Error DI/DT"
Charge Engine Error- All power modules are of-
fline, unable to charge. Halo is solid red, on
screen message: “Charge Engine Error”
BID Battery Reject- Battery type described by BID/
WBID device is not compatible with this
charger. Halo is solid red, on screen message
reads: "BID Battery Reject”
Arcless Subsystem Error- A problem was detect-
ed in the arcless detection circuit that prevents
the unit from charging. Halo: Solid Red. On
screen message: “Arcless Subsystem Error”
193111-200
OPERATION
November 23, 2020 6-3
Voltage Charge Time (Minutes)
> 1.7VPC 30
>1.8VPC 60
>1.9VPC 90

6-4 November 23, 2020
193111-200
OPERATION
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Main Features
1. Up to 40 A/100AH high rate opportunity charging
output.
4.
5.
6.
7.
15. Failure Mode Diagnostics
- High Battery Reject
- Low Battery Reject
- Module Temperature Warnings
- Battery Over-temperature
- Low Voltage Shut Down
- Charge Curve Error
- Low Current Shut Down
- Backup Timer
- Manual Stop
- Over Maximum Amp Hour Returned Shut Down
- Charger Overtemperature Shutdown
- DIDT Shut Down
- Phase Error
-Arcless Subsystem fault
-Warning/Error Count
EVOLUTION CONTROL FEATURES
193111-200
EVOLUTION CONTROL FEATURES
November 23, 2020 7-1
Figure 7-1

7-2 November 23, 2020
193111-200
EVOLUTION CONTROL FEATURES
16. Programmed Features and Archive Data
maintained for a minimum of 10 Years
17. Charge Cycle Data and Time-of-Day/Date
maintained for a minimum of 10 Years
18. 5 Programmable Start Modes
- Automatic Start
- Delayed Start
- Time-of-Day Start
- Time-of-Day Blockout
- Timer Mode
19. Programmable Manual Override of Start Modes
20. Password Protection
21. Automatic Equalize by Number of Charger or BID
Cycles, Day of Week
22. Programmable Cool Down Time
23. Staggered Start on A/C Fail Recovery
Description of Features
Multi-Voltage Charging — The Evolution with
Evolution Control provides the capability to charge
batteries of different cell sizes. With the Multi-Cell
Mode ON, the charger automatically selects the
proper output voltage. A 24 cell Evolution will
safely charge 24, 18, and 12 cell batteries.
An 18 cell Evolution will safely charge 18 and 12 cell
batteries.
Fixed mode operation can be selected by
programming Multi-Cell mode to OFF. In this mode
the charger will charge only batteries of the cell size
programmed into the Fixed-Cell size function.
If the battery is equipped with Prestolite BID
Module, the Multi-Cell ON or OFF function will be
overridden and the charger will charge the battery if
it is within the charger output rating.
Temperature Compensation — The Evolution
Control is capable of modifying the output voltage to
compensate for ranges of battery electrolyte
temperatures from 32 to 132 degrees F. Because
the 80% percent point is based on reaching a point
on the charge curve rather than a single voltage, it
is automatically adjusted with the output voltage.
CAUTION: Consult your batteries
manufacturer for the recommended
maximum battery temperature for
your battery.
When the battery is equipped with a Prestolite BID
module, the charger automatically reads the battery
temperature throughout the charge cycle and
adjusts the output voltage to match the battery
temperature.
Manual adjustment of the charger output voltage to
match the temperature of the battery is performed
by programming the proper battery electrolyte
temperature into the Fixed Battery Temperature
function (BID readings automatically override the
Fixed Battery Temperature setting).
Max Battery Temperature—The Evolution Control
monitors the battery temperature throughout the
charge cycle. Programming the MAX BATT TEMP
setting of the control to the desired maximum
battery temperature will cause the charger to shut
down if the battery on charge is equipped with a BID
and the temperature exceeds the set point. It will
wait until the battery temperature has decreased to
5 degrees F below the set point before restarting the
charge cycle.
Charge Termination — The Evolution Control
utilizes two types of termination. VT, Voltage Time
termination, will go to charge complete after a timer.
The other way to terminate a charge cycle is to use
DV/DT. DV/DT is a patented proportional time DV/
DT technique in order to determine the charge
termination point. This technique returns
approximately 107% of the amp hours removed
from a battery (regardless of the state of discharge)
and prevents variations in the incoming AC line
voltage from affecting the amount of Energy
returned to the battery. The minimum time required
for a DV/DT charge termination on the Evolution
Control is fifteen minutes. The Control can be
programmed to utilize a voltage-time charge
termination technique. If the DV/DT charge
termination is disabled, the control will terminate the
charge cycle four hours after the battery reaches the
“80% Charged” point.
Touch Screen Display — A backlit touch screen
display is standard on the Evolution Control. Plain
English and easy to understand abbreviations are
used to indicate charge status output current,
voltage and other functions including; archive
information, review information, programming
information, fault information, and operating status.
Review of Charge Cycle — When the charge cycle
is in progress or has been terminated, either by the
Control or the operator, the charge cycle history can
be automatically read out by Statistics App.
See the EVOLUTION Charge Statistics Feature
section in the next chapter. This feature can greatly
aid in the analysis of charge data and in situations
where troubleshooting is required.

Automatic or Push-to-Start Operation — In the
automatic start mode, the charger will start 5-15
seconds after the battery is connected. The display
will display “Reading BID Device Data” and then
display upcoming cycle information. In delayed,
blockout, or time-of-day start mode, the charger will
not start the charge cycle until “Start Mode
Override” is toggled ON.
Manual or Automatic Equalize — An equalize
charge is a prolonged charge cycle (by 3 hours)
used to correct any inequalities of voltage and
specific gravity which may have developed between
the cells during service. Evolution Controls are
shipped from the factory with the automatic equalize
feature enabled. There are three modes of
automatic equalize. See the Equalize section of
chapter 9 of this manual for further details. When
the automatic equalize feature is active, the
“Equalize” switch on the touch screen display is
disabled. When automatic equalize is disabled, an
equalize charge is requested by switching the
“Equalize” toggle on the touch screen display before
or after the charge cycle has started. If this toggle
switch is turned off during the charge cycle, the
equalize request will be canceled if the equalize
period has not begun.
Refresh Charge Feature — A refresh charge of a
storage battery is a charge given to charged, wet
type batteries, which are in storage or inactive for
long periods to replace losses due to limited action
and to insure that every cell is brought periodically
to a full state of charge. The Evolution Control has
an adjustable 0 to 99 hour refresh charge timer
(programmed through the “Refresh” icon in the
settings app) which starts with a normal charge
complete, either DV/DT or voltage time. If a battery
is left connected to the charger for the Programmed
number of hours after a charge complete, the
control will automatically begin a refresh charge
cycle. The control will start automatically even if
programmed for time-of-day start, delayed start or
push-to-start operation. The Evolution will not start
the charge cycle during a time-of-day blockout
period. It will automatically request an equalize
cycle if it is programmed to equalize on that day.
Charge cycle data is not affected by a refresh
charge. The charge termination technique for a
refresh charge will be DV/DT regardless of how the
control is user programmed, and the 0-80% back-up
timer will be four hours and fifteen minutes during a
refresh charge. This feature will insure that any
battery left connected to the charger for extended
periods of time will not be damaged due to self-
discharge, and will be kept in a fully charged state.
80% Charged Point — An Evolution Control will
blink the LEDs a faster green and enable the
charge termination routine when the battery voltage
reaches the gassing voltage and the charging has
decreased below start current. The gassing voltage
is nominally 2.40 volts/cell and is adjusted
automatically when the charger output voltage is
modified to charge batteries of different
temperatures.
Time-of-Day Start — The Evolution Control can be
programmed to delay the start of a charge cycle
until a specific time of day. Any time of day, in one
minute increments, can be used for the time-of-day
start time.
When a Control is programmed for time-of-day start,
and a battery is connected to the charger, the
programmed start time will be displayed. This
feature can be used to save on energy costs,
provide a battery cool down period, or to prevent
opportunity charging.
Delayed Start — The Evolution Control can be
programmed to delay the start of a charge cycle for
a specific period of time. Any time period from 1
minute to 23 hours and 59 minutes, in one minute
increments, can be used for the delayed start
period.
When an Evolution is programmed for delayed start,
and a battery is connected to the charger, the
programmed delay time will be displayed.
The time displayed will be decremented once per
minute so that the time displayed is always the
amount of time remaining before the start of charge.
This feature can be used to save on energy costs,
provide a battery cool down period, or to prevent
opportunity charging.
Time-of-Day Blockout — The Evolution Control
can be programmed to disable the charger during a
specific time of day. The charger will turn off at the
beginning of the block-out period, and resume the
charge cycle at the end of the block-out period. Any
period of time of day, in one minute increments, can
be used for the time-of-day block-out period. When
an Evolution is programmed for time-of-day block-
out, and a battery is being charged when the block-
out period occurs, the programmed end of block-out
time will be displayed. This feature can be used to
save on energy costs, provide a battery cool down
period, or to prevent opportunity charging.
Manual Override of Programmed Start Modes —
An Evolution Control, when programmed for time-of-
day start, delayed start, or time-of-day block-out,
can be manually overridden by toggling the override
switch on the display while the start of the charge
cycle is being automatically delayed by the control.
This manual override feature can be disabled
through the “Start Override” programming function.
The manual override feature allows the operator to
193111-200
EVOLUTION CONTROL FEATURES
November 23, 2020 7-3

7-4 November 23, 2020
193111-200
EVOLUTION CONTROL FEATURES
start a charge cycle immediately if a battery is
needed sooner than the programmed start time
would allow.
Automatic Equalize — The Evolution Control can
be programmed for 3 different types of automatic
equalize. Controls are shipped from the factory
programmed to automatically provide an equalize
charge to every fifth complete charger cycle. The
number of cycles between equalize requests can
be varied from 0 to 30. If the Evolution Control is
programmed to automatically provide an equalize
cycle every zero cycles, then an equalize charge
cannot be requested manually and will never be
provided automatically. The second type of
automatic equalize mode is when an equalize
charge is desired on a particular day of the week.
When programmed for automatic equalize by day of
week, the Evolution will provide an equalize charge
to any battery which is connected to the charger on
the programmed equalize day. Additionally, any
battery which is connected the charger previous to
the day of week equalize day will be given an
equalize charge provided that it is at a charge
complete status when the Evolution’s clock calendar
switches to the equalize day.
The automatic equalize features allow for the
consistent application of equalize charges without
constant attention by the operators. The third type
of equalize is by BID count. When programmed for
this mode, the current complete cycle count is read
from the BID at connect and compared to that of the
equalize cycle counter. An equalize will be
requested when the BID count equals the equalize
cycle count programmed into the control.
For further information on programming and
reviewing the Evolution Control features, refer to the
Programming Settings chapter.
Programmable Cool Down Time — A
programmable cool down feature allows the battery
to cool down for 0 to 8 hours before the charger
signals charge complete. During the cool down
period the display reads “Cool Down”. This feature
allows the battery to cool down before
being returned to use and can be used to minimize
the battery maximum temperature during operation.
No Gassing Time– A programmable time that
effects how long from the start of a charge cycle
before the gassing portion can begin. If the battery
on charge reaches the finish portion of the curve
and the gassing time has not elapsed, the charger
will shutoff and display “No Gassing”. This
minimizes any battery gassing that may occur
during an opportunity charge cycle. Once the start
gassing time has passed, the charger will restart at
the standard finish current and complete the charge
cycle.
Maximum Battery Temperature — The Evolution
Control can be programmed to interrupt the charge
cycle if the battery temperature exceeds the limit
programmed into function. The temperature may be
programmed from 80°F to 150°F. Once the battery
cools down past the trip temperature the charge
cycle will be resumed. The display will show
“Battery Cooling” if the charge has been interrupted
and the cooling period is taking place. A BID must
be in use to utilize this function.
Password — The user can turn on a 4 number
password for use in keeping programming functions
protected. Any time the user tries to access the
settings, they will be prevented from doing so until
the password is entered. The user will have to enter
the password on the dashboard screen to enable
settings modifications.
WARNING: Enabling the Finish Cell
Forming feature will cause the charger to
continue to run for a period of time if the
battery has been disconnected before
Charge Complete or pressing the Manual
Stop key. This condition will continue
until the programmed number of cycles
have been completed. The battery
should never be disconnected while a
charge is in progress.