R/Evolution RV05-4kW-90A-36V-P User manual

MAN-000020-00 REV A
480VAC Models
RV05-4kW-90A-36V-P
RV05-5kW-120A-36V-P
RV05-6kW-150A-36V-P
RV05-4kW-75A-48V-P
RV05-5kW-100A-48V-P
RV05-6kW-125A-48V-P
Installation & Operation Manual
4005 Felland Road, Suite 116
Madison, WI 53718
USA
© Power Designers USA LLC
A NEW ERA IN CHARGING TECHNOLOGY

MAN-000020-00 REV A
TABLE OF CONTENTS
REVOLUTION™ SERIES ...................................................................................................... 1
SAFETY PRECAUTIONS....................................................................................................... 2
REVOLUTION™ SPECIFICATIONS.................................................................................... 5
INSTALLATION PROCEDURE............................................................................................. 8
CHARGER INSTALLATION ....................................................................................................... 8
CHARGER ELECTRICAL INSTALLATION ................................................................................ 14
OPERATION PROCEDURE................................................................................................. 17
CHARGER CONTROLS AND USER INTERFACE..................................................................... 17
BASIC CHARGE CYCLE OPERATION.................................................................................... 18
GETTING STARTED .............................................................................................................. 20
CHARGER MAIN MENU ........................................................................................................ 24
TROUBLESHOOTING.......................................................................................................... 31
RETURN MATERIAL PROCESS......................................................................................... 37
LIMITED WARRANTY........................................................................................................ 38
SOFTWARE LICENSE AGREEMENT................................................................................ 40
APPENDIX A –WALL MOUNT DIMENSIONS AND CLEARANCES........................... 41
APPENDIX B –POST STAND DIMENSIONS ................................................................... 42
APPENDIX C –SHELF STAND DIMENSIONS................................................................. 43
APPENDIX D –NOTES ON TEMPERATURE COMPENSATION................................... 44
APPENDIX E –RECOVERY CYCLE FOR SULFATED BATTERY CURRENT AND
TIMER SETTINGS................................................................................................................ 45
CONTACTING POWER DESIGNERS USA LLC............................................................... 46

MAN-000020-00 REV A 1
REVOLUTION™SERIES
The REVOLUTION™Series features very high charge cycle efficiencies and state-
of-the-art MOSFET soft-switching technology resulting in lower energy costs, smaller
sizes, and lighter weight units. The REVOLUTION™chargers maintain the charging
efficiency greater than 90% over the entire charge cycle. This results in true energy
savings of 6% or greater as compared to leading HF chargers. For a typical
36V/850Ahr battery, these savings will translate into approximately 1.5kWhr per
charge cycle. In a typical application, the savings can be greater than 400kWHr per
battery per year.
The REVOLUTION™chargers are the lightest and most-efficient chargers available
on the market.
The REVOLUTION™chargers can support standard, opportunity, and fast charge
cycles. The REVOLUTION™chargers also offer programmability. All charger
settings and features can be easily customized to match workloads and schedules.
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.
The REVOLUTION™480VAC Battery Charger

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SAFETY PRECAUTIONS
BEFORE ATTEMPTING TO INSTALL AND OPERATE THE CHARGER, READ
THIS MANUAL CAREFULLY
This manual contains important instructions for the REVOLUTION™series product
line that shall be followed during installation and operation of the charger. Only
qualified personnel should install, operate, or service this equipment.
SAVE THESE INSTRUCTIONS
High Voltages. Lethal voltages are present within the charger enclosure
whenever the AC line is energized and/or the battery/load is connected. The heat
sinks and other internal components present the risk of electric shock.
Stored Energy. To avoid the risk of electric shock, wait at least two minutes after
de-energizing the AC line and disconnecting the battery/load before removing the
cover.
High Current Levels. Do not touch uninsulated battery connectors or terminals.
All tools should be adequately insulated to avoid the possibility of shorting
connections. Inspect cables often for damage to the insulation. 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 destroyed.
Grounding. The charger must be connected to an AC power supply
incorporating an earth or ground. The grounding conductor must be of a size
equal to or larger than the line (phase) conductors.
Explosive Gases.Working in the vicinity of a lead-acid battery is dangerous.
Batteries generate explosive gases during charge and discharge. To reduce the
risk of ignition, follow these safety instructions as well as those published by the
battery manufacturer. To minimize the potential for arcing and to reduce the risk
of damage to the connector contacts, it is preferable to connect and disconnect a
battery when the charger output is OFF.
WARNING

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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.
Follow the battery manufacturer's published instructions when installing,
charging, and servicing batteries.
Use only with rechargeable batteries. Do not attempt to charge other battery
types; doing so may cause equipment damage and result in serious personal
injury.
Do not expose the charger to rain or snow. The charger is NOT designed for
outdoor use.
Adequate Cooling Required. To prevent damage from overheating, proper
airflow must be ensured. Do not restrict fan inlets or exhaust outlets. Do not
mount the charger in a confined space or where the exhaust air will recirculate.
No User Serviceable Parts.If service is required, contact Power Designers USA
LLC or its service representative.
These instructions assume a certain level of competence by the installer
and/or user. The following practices and codes contain relevant information, and
should be consulted for safe installation, testing, handling, and maintenance of
rechargeable lead-acid batteries. All applicable state and local codes must be
followed.
National Electrical Safety Code (NESC), ANSI/IEEE C2-2007 (or latest
revision). Copies may be obtained by contacting: The Institute of Electrical
and Electronics Engineers, Inc. (IEEE), Publications Office, 10662 Los
Vaqueros Circle, P.O. Box 3014, Los Alamitos, CA 90720
www.ieee.org
National Electrical Code (NEC) NFPA-70 (or latest version) available from:
National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269
www.nfpa.org
CAUTION
WARNING

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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.
EMC Compliance
This device complies with Part 15 section 103 of FCC Rules as a digital
device used exclusively as a power system in public utilities or industrial
plants.
Operation is subject to the following two conditions:
1. This device may not cause harmful interference.
2. This device must accept any interference received, including interference
that may cause undesired operation.

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REVOLUTION™SPECIFICATIONS
Model Numbers
RV05-4kW-90A-36V-P / RV05-4kW-75A-48V-P
RV05-5kW-120A-36V-P / RV05-5kW-100A-48V-P
RV05-6kW-150A-36V-P / RV05-6kW-125A-48V-P
Figure 1: REVOLUTION™RV05 Battery Charger Features
LCD/keypad
Knockout
for input
wiring
Strain reliefs
for output
cables

MAN-000020-00 REV A 6
Specifications for the REVOLUTION™RV05 480VAC / 48V models.
Specifications
RV05-4kW-75A-
48V-P
RV05-5kW-100A-
48V-P
RV05-6kW-125A-
48V-P
Nominal VA Ratings
48 V / 75 A
48 V / 100 A
48 V / 125 A
Input Specifications
Voltage
480VAC, 3-phase +10%
Current
5.6A rms/ph
7.4A rms/ph
9.3A rms/ph
Power Factor
>0.92
Breaker Rating
15A
Output Ratings
Voltage
48 V nom. / 65 V max.
Number of Battery Cells
12/18/24
Current
75A Max
100A Max
125A Max
Power
3.9kW Max
5.2kW Max
6.5kW Max
Pk-Pk Voltage Ripple
<1%
Efficiency
Total Charge Cycle Efficiency > 90%
Peak Efficiency > 92%
Input Protection
Under voltage
Over voltage transients
Output Protection
Over current
Over voltage
Charger Over temperature; Battery Over temperature
Battery reverse polarity
Operating Conditions
Ambient Temperature
0–40oC
Humidity
10–90% RH noncondensing
User Interface
LCD/Keypad
Cooling
Forced air (fans)
Mechanical
Dim. WxDxH
12.5” x 8.5” x 20.25”
Weight
Wt.: ~49 lb
Wt.: ~53 lb
Wt.: ~56 lb
Standard Output
Cabling
12’, #2
12’, 1/0
12’, 1/0
Standard Output
Connectors
SBX175
SBX350 or
Euro320
SBX350 or
Euro320
Certifications
UL and cUL Listed

MAN-000020-00 REV A 7
Specifications for the REVOLUTION™RV05 480VAC / 36V models.
Specifications
RV05-4kW-90A-
36V-P
RV05-5kW-120A-
36V-P
RV05-6kW-150A-
36V-P
Nominal VA Ratings
36 V / 90 A
36 V / 120 A
36 V / 150 A
Input Specifications
Voltage
480VAC, 3-phase +10%
Current
5.6A rms/ph
7.4A rms/ph
9.3A rms/ph
Power Factor
>0.92
Breaker Rating
15A
Output Ratings
Voltage
36 V nom. / 50 V max.
Number of Battery Cells
12/18
Current
90A Max
120A Max
150A Max
Power
3.9kW Max
5.2kW Max
6.5kW Max
Pk-Pk Voltage Ripple
<1%
Efficiency
Total Charge Cycle Efficiency > 90%
Peak Efficiency > 92%
Input Protection
Under voltage
Over voltage transients
Output Protection
Over current
Over voltage
Charger Over temperature; Battery Over temperature
Battery reverse polarity
Operating Conditions
Ambient Temperature
0–40oC
Humidity
10–90% RH noncondensing
User Interface
LCD/Keypad
Cooling
Forced air (fans)
Mechanical
Dim. WxDxH
12.5” x 8.5” x 20.25”
Weight
Wt.: ~49 lb
Wt.: ~53 lb
Wt.: ~56 lb
Standard Output
Cabling
12’, #2
12’, 1/0
12’, 1/0
Standard Output
Connectors
SBX175
SBX350 or
Euro320
SBX350 or
Euro320
Certifications
UL and cUL Listed

MAN-000020-00 REV A 8
INSTALLATION PROCEDURE
Charger Installation
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.
Do not install or operate the charger if it has any visible damage.
1. Preparing for the Installation:
Failure to meet these minimum requirements
may result in a voided warranty.
Adequate Cooling Required –To prevent damage from overheating, proper
airflow must be ensured. Do not restrict fan inlets or exhaust outlets. Do not
mount the charger in a confined space or where the exhaust air will
recirculate.
WARNING

MAN-000020-00 REV A 9
Mount the charger vertically, observing the minimum spacing shown below:
Figure 2: RV05 NEC minimum spacing
Ensure that the charging area is well ventilated, dry, and clean.
Do not expose the charger to rain or snow.
The charger is NOT designed for outdoor use.

MAN-000020-00 REV A 10
There must be at least 2” of spacing between the sides of the charger and
any adjacent walls or barriers, and 12” of spacing between the bottom of the
charger and the floor or any other obstruction.
Figure 3: RV05 minimum spacing
Ambient Temperature Range 0 –40° C
Ambient Humidity Range 10-90% RH non-condensing

MAN-000020-00 REV A 11
2. Preparing the Mounting Area:
Figure 4: RV05 mounting hole / bolt pattern
Charger should be fastened to the mounting surface using 1/4” or 5/16” hardware
(User provided). Threaded mounting studs protruding from surface are recommended
for ease of installation.
Charger Weight: 56 lbs. maximum

MAN-000020-00 REV A 12
3. Preparing the Charger:
With the Charger laying on its back, remove the (2) 8-32 screws securing the cover to
the bottom surface and set aside. Shift the cover slightly toward the top of the
charger (about 1.5”) as shown:
Figure 5: RV05 Cover Fastener Removal
Lift the cover up and off, set aside:
Figure 6: RV05 Cover Removal

MAN-000020-00 REV A 13
4. Hanging the Charger
Pick up the Charger (a second person is recommended) and fasten the
Charger to the mounting surface:
Figure 7: Mounting the Charger
Once the Charger has been securely mounted, electrical installation can
proceed.
CAUTION: Do not allow debris to fall inside the Charger during the
mounting and installation process!

MAN-000020-00 REV A 14
Charger Electrical Installation
DANGEROUS VOLTAGES AND CURRENTS ARE PRESENT IN THE AC MAINS
WHEN ENERGIZED. ONLY TRAINED PERSONNEL SHOULD PERFORM THE
INSTALLATION, USING PROPER EQUIPMENT AND PROCEDURES.
VERIFY THAT INPUT AND OUTPUT WIRING ADHERES TO ALL LOCAL SAFETY
CODES AND STANDARDS.
1. The REVOLUTION™RV05 chargers require a 480 VAC 3, four-wire Wye or
Delta electrical supply with a separate ground (Figure 8).
Nameplate 480 VAC current draw is 10 A; circuit protection at 125% should
be 15 A.
Figure 8: AC input wiring diagrams
2. Verify that the source circuit is locked and tagged out before connecting
power to the charger.
3. Determine whether the ½” or ¾” conduit hole will be utilized, and carefully punch
out the appropriate piece from the dual KO provided (Figure 9):
GND
DD
Typical Delta circuit
Wye circuit
A
B
C
240V
415V
480V
480V
240V
C
B
A
277V
277V
480V
277V
480V
480V
GND
480V
WARNING

MAN-000020-00 REV A 15
Figure 9: KO location
4. Pass the 480 VAC input power wires through, using the appropriate conduit or
strain relief fittings per local and national codes.
5. Crimp a #10 ring tongue terminal to the ground (GND) wire and connect it to the
GND terminal (Figure 9). Tighten the nut to 15 in-lb +- 2 in-lb.
6. Strip the conductors back 0.5 inch (12 mm) and connect them to the terminal
block (Figure 10, labelled L3 L2 L1). Tighten the terminal screws to 12 in-lb +-
2 in-lb.NOTE: The charger is not phase-rotation sensitive. Be sure any excess
wire is kept away from the fans and output connections.

MAN-000020-00 REV A 16
Figure 10: RV05 terminal block location
7. Verify the line and ground connections of the outlet or junction box/disconnect.
8. Energize the source circuit and verify proper AC voltage to the Charger. All line-
to-line voltages should be 480 VAC ± 10% and matched within 10 VAC. De-
energize the source circuit.
9. Verify that the source circuit is locked and tagged out. Once electrical installation
is complete, the cover and (2) 8-32 screws fastening the cover can be replaced.
THE CHARGER IS NOW READY FOR OPERATION

MAN-000020-00 REV A 17
OPERATION PROCEDURE
Charger Controls and User Interface
Users operate the REVOLUTION™ series of chargers through each charger’s front
panel LCD/keypad (Figure 11).
This is the main user interface for viewing operation and fault messages. It also
allows limited charger programming options. (For programming information, see
Charger Main Menu, page 24 of this manual.)
Figure 11: User interface LCD/keypad
LCD
Function
keys

MAN-000020-00 REV A 18
Basic Charge Cycle Operation
Figure 12: Typical charge cycle –charge modes
The charge cycle for an opportunity charger consists of the first three modes on a
daily basis, with all five modes occurring on a weekly basis. A brief description of the
various modes is listed below and all modes are shown above in Figure 14.
Trickle: Trickle mode is rarely used, as it is typically only encountered when a
battery is extremely discharged (average cell voltage of ~1.85 volts). This mode
charges the battery at a very low current (typically ~3%) until the battery voltage
rises above the trickle voltage setting.
CC: CC mode is where the bulk of the battery charging occurs. This mode is the
Constant Current mode where the current is held steady at ~25% of the battery
capacity. This mode continues until the battery voltage rises to an average cell
voltage of ~2.4 volts (CV voltage), and the charge cycle then transitions into the CV
mode. This voltage is partially inflated above the true battery voltage due to the fact
that current is being pushed into the battery and the internal battery resistance
causes the battery voltage to artificially rise above the resting battery voltage.
CV: CV mode ensures the battery rises to ~85% charged. This mode holds the
voltage of the charge steady at approximately 2.4 volts per cell and allows the
current into the battery to taper off as the battery voltage gets closer to holding itself
at the set voltage. The current will continue to taper off until it reaches the CV Finish
Current, at which time the charge cycle will terminate, unless finish is enabled. If
Finish is enabled, the current will continue to decrease until it reaches the Finish
Current, at which time the charger will transition into Finish mode.