R/Evolution RV05 User manual

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

MAN-000036-00 REV D
TABLE OF CONTENTS
REVOLUTION SERIES ............................................................................................. 1
SAFETY PRECAUTIONS.......................................................................................... 2
REVOLUTION SPECIFICATIONS ............................................................................ 5
SPECIFICATIONS FOR THE REVOLUTION 208 VAC MODELS ....................................... 6
SPECIFICATIONS FOR THE REVOLUTION 240 VAC MODELS ....................................... 7
SPECIFICATIONS FOR THE REVOLUTION RV05 480 VAC MODELS ............................. 8
12V REVOLUTION Chargers............................................................................... 8
24V, 36V and 48V REVOLUTION Chargers........................................................ 9
80V REVOLUTION Chargers............................................................................. 10
SPECIFICATIONS FOR THE REVOLUTION RV08 480VAC MODELS ............................ 11
24V, 36V and 48V REVOLUTION Chargers...................................................... 11
80V REVOLUTION Chargers............................................................................. 12
SPECIFICATIONS FOR THE REVOLUTION RV12 480VAC MODELS ............................ 13
24V, 36V and 48V REVOLUTION Chargers...................................................... 13
80V REVOLUTION Chargers............................................................................. 14
INSTALLATION PROCEDURE............................................................................... 15
CHARGER INSTALLATION .......................................................................................... 15
RV05 Models Installation ................................................................................... 16
RV08 Models Installation ................................................................................... 21
RV12 Models Installation ................................................................................... 27
CHARGER ELECTRICAL INSTALLATION ....................................................................... 33
208 VAC 3∅.................................................................................................................................. 33
240 VAC 3∅.................................................................................................................................. 34
480 VAC 3∅.................................................................................................................................. 35
OPERATION PROCEDURE.................................................................................... 39
CHARGER CONTROLS AND USER INTERFACE ............................................................. 39
BASIC CHARGE CYCLE OPERATION........................................................................... 40
GETTING STARTED .................................................................................................. 42
CHARGER MAIN MENU ............................................................................................. 46
TROUBLESHOOTING ............................................................................................ 54
RETURN MATERIAL PROCESS ............................................................................ 61
APPENDIX A – WALL MOUNT DIMENSIONS AND CLEARANCES .................... 62
RV05 MODELS ....................................................................................................... 62
RV08 MODELS ....................................................................................................... 63
RV12 MODELS ....................................................................................................... 64
APPENDIX B – POST STAND DIMENSIONS AND ASSEMBLY INSTRUCTIONS65
RV05 MODELS ....................................................................................................... 65
RV08 MODELS ....................................................................................................... 67
RV12 MODELS ....................................................................................................... 67
APPENDIX C – SHELF STAND DIMENSIONS ...................................................... 69
RV05 MODELS ....................................................................................................... 69
RV08 MODELS ....................................................................................................... 69
APPENDIX D – NOTE ON TEMPERATURE COMPENSATION ............................ 70
CONTACT INFORMATION ..................................................................................... 71

MAN-000036-00 REV D 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 Series is a combination of cutting edge charging and energy
management technologies, with a smaller footprint, lower acquisition costs, easy
maintenance, and flexible configurations.
The REVOLUTION chargers can support conventional, 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 RV05, RV08 and RV12 Battery Charger

MAN-000036-00 REV D 2
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 damaged.
Grounding. The charger must be connected to an AC power supply incorporating an
earth 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 recommended to connect and disconnect a battery when the charger
output is OFF.
WARNING

MAN-000036-00 REV D 3
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 Sibex 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

MAN-000036-00 REV D 4
•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.

MAN-000036-00 REV D 5
REVOLUTION SPECIFICATIONS
Model Numbers
RV05 Model Numbers
RV05-1.5kW-90A-12V
RV05-2kW-120A-12V
RV05-2.5kW-150A-12V
RV05-4kw-90A-36V-C
RV05-5kw-120A-36V-C
RV05-6kw-150A-36V-C
RV05-4kw-90A-36V-P
RV05-5kw-120A-36V-P
RV05-6kw-150A-36V-P
RV05-4kw-90A-36V-F
RV05-5kw-120A-36V-F
RV05-6kw-150A-36V-F
RV05-4kw-75A-48V-C
RV05-5kw-100A-48V-C
RV05-6kw-125A-48V-C
RV05-4kw-75A-48V-P
RV05-5kw-100A-48V-P
RV05-6kw-125A-48V-P
RV05-4kw-75A-48V-F
RV05-5kw-100A-48V-F
RV05-6kw-125A-48V-F
RV05-4kw-36V
RV05-5kw-36V
RV05-6kw-36V
RV05-4kw-48V
RV05-5kw-48V
RV05-6kw-48V
RV05-4kw-80V
RV05-5kw-80V
RV05-6kw-80V
RV05-6kW-48V-1/0-208
RV05-6kW-48V-1/0-240
RV08 Model Numbers
RV08-6kw-150A-36V-C
RV08-8kw-180A-36V-C
RV08-9kw-210A-36V-C
RV08-10kw-240A-36V-C
RV08-6kw-125A-48V-C
RV08-8kw-150A-48V-C
RV08-9kw-175A-48V-C
RV08-10kw-200A-48V-C
RV08-6kw-150A-36V-P
RV08-8kw-180A-36V-P
RV08-9kw-210A-36V-P
RV08-10kw-240A-36V-P
RV08-6kw-125A-48V-P
RV08-8kw-150A-48V-P
RV08-9kw-175A-48V-P
RV08-10kw-200A-48V-P
RV08-6kw-150A-36V-F
RV08-8kw-180A-36V-F
RV08-9kw-210A-36V-F
RV08-10kw-240A-36V-F
RV08-6kw-125A-48V-F
RV08-8kw-150A-48V-F
RV08-9kw-175A-48V-F
RV08-10kw-200A-48V-F
RV08-6kw-36V
RV08-8kw-36V
RV08-9kw-36V
RV08-10kw-36V
RV08-6kw-48V
RV08-8kw-48V
RV08-9kw-48V
RV08-10kw-48V
RV08-6kw-80V
RV08-8kw-80V
RV08-9kw-80V
RV08-10kw-80V
RV08-10kW-48V-208
RV08-10kW-48V-240
RV12 Model Numbers
RV12-10kw-240A-36V-C
RV12-12kw-270A-36V-C
RV12-10kw-200A-48V-C
RV12-12kw-225A-48V-C
RV12-10kw-240A-36V-P
RV12-12kw-270A-36V-P
RV12-13kw-300A-36V-P
RV12-14kw-330A-36V-P
RV12-15kw-350A-36V-P
RV12-10kw-240A-36V-P-CN
RV12-12kw-270A-36V-P-CN
RV12-10kw-200A-48V-P
RV12-12kw-225A-48V-P
RV12-13kw-250A-48V-P
RV12-14kw-275A-48V-P
RV12-15kw-300A-48V-P
RV12-10kw-240A-36V-F
RV12-12kw-270A-36V-F
RV12-13kw-300A-36V-F
RV12-14kw-330A-36V-F
RV12-15kw-350A-36V-F
RV12-10kw-240A-36V-F-CN
RV12-12kw-270A-36V-F-CN
RV12-10kw-200A-48V-F
RV12-12kw-225A-48V-F
RV12-13kw-250A-48V-F
RV12-14kw-275A-48V-F
RV12-15kw-300A-48V-F
RV12-10kw-200A-48V-F-CN
RV12-12kw-225A-48V-F-CN
RV12-13kw-250A-48V-F-CN
RV12-14kw-270A-48V-F-CN
RV12-10kw-36V
RV12-12kw-36V
RV12-13kw-36V
RV12-14kw-36V

MAN-000036-00 REV D 6
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
Power Factor >0.92
Breaker Rating 30A 45A
OUTPUT SPECIFICATIONS
Voltage 48V nom. / 65V max.
Current 125A max. 200A max.
Power 6.5kw max. 10.4kw max.
# of Battery Cells 12 / 18/ 24
Peak-to-Peak
< 1%
Voltage Ripple
EFFICIENCY
Total charge cycle efficiency > 90%
Peak charging efficiency > 92%
PROTECTION
Input •Under voltage
•Over voltage transients
Output
•Over current
•Over voltage
•Charger Over temperature; Battery Over temperature
•Battery reverse polarity
OPERATING CONDITIONS
Temperature 0–40°C
Humidity 10-90% RH noncondensing
INTERFACE
User Interface LCD & keypad, USB. Optional: Ethernet & wireless via PT Link
MECHANICAL
W x D x H 12.5” x 8.5” x 20.25” 18.5” x 9.5” x 21”
Weight ~56 lbs. ~85 lbs.
Output Cables 10’, #2* or 10’, 1/0 10’, 2/0
Output Connectors SB175, SBX175, SB350, SBX350, Euro160 or
Euro320 SB350, SBX350 or Euro320
Cooling Forced air (fans)
Certifications UL and cul Listed; CEC Certified
*#2 Cable is limited to SB175, SBX175 or Euro160 connectors

MAN-000036-00 REV D 7
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
Power Factor >0.92
Breaker Rating 25A 40A
OUTPUT SPECIFICATIONS
Voltage 48V nom. / 65V max.
Current 125A max. 200A max.
Power 6.5kw max. 10.4kw max.
# of Battery Cells 12 / 18/ 24
Peak-to-Peak
< 1%
Voltage Ripple
EFFICIENCY
Total charge cycle efficiency > 90%
Peak charging efficiency > 92%
PROTECTION
Input •Under voltage
•Over voltage transients
Output
•Over current
•Over voltage
•Charger Over temperature; Battery Over temperature
•Battery reverse polarity
OPERATING CONDITIONS
Temperature 0–40°C
Humidity 10-90% RH noncondensing
INTERFACE
User Interface LCD & keypad, USB. Optional: Ethernet & wireless via PT Link
MECHANICAL
W x D x H 12.5” x 8.5” x 20.25” 18.5” x 9.5” x 21”
Weight ~56 lbs. ~85 lbs.
Output Cables 10’, #2* or 10’, 1/0 10’, 2/0
Output Connectors SB175, SBX175, SB350, SBX350, Euro160 or
Euro320
SB350, SBX350 or Euro320
Cooling Forced air (fans)
Certifications UL and cul Listed; CEC Certified
*#2 Cable is limited to SB175, SBX175 or Euro160 connectors
+ PT Link sold separately

MAN-000036-00 REV D 8
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) /
Maximum Current (A) 12V/90A 12V /120A 12V /150A
INPUT SPECIFICATIONS
Voltage
480 VAC, ± 10%, 3-phase
Current
2.8A rms/ph 3.7A rms/ph 4.6A rms/ph
Power Factor
>0.85 nominal
Breaker Rating
10A
OUTPUT SPECIFICATIONS
Voltage
12V nom. / 16V max.
Current
90A max. 120A max. 150A max.
Power
1.5kw max. 2.0kw max. 2.5kw max.
# of Battery Cells
6
Peak-to-Peak
Voltage Ripple
< 1%
PROTECTION
Input •Under voltage
•Over voltage transients
Output
•Over current
•Over voltage
•Charger Over temperature; Battery Over temperature
•Battery reverse polarity
OPERATING CONDITIONS
Temperature 0–40°C
Humidity 10-90% RH noncondensing
INTERFACE
User Interface LCD & keypad, USB, wireless communication with PT Link+
. Optional: Ethernet
MECHANICAL
W x D x H
12.5” x 8.5” x 20.25”
Weight ~49 lbs. ~53 lbs. ~56 lbs.
Output Cables
10’. 1/0 or #2
Output Connectors SB350, SBX350, Euro160 or Euro320
Cooling Forced air (fans)
Certifications
UL and cul Listed
*#2 Cable is limited to SB175, SBX175 or Euro160 connectors
+ PT Link sold separately