R/Evolution RV16 User manual

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

MAN-000037-00 REV C
TABLE OF CONTENTS
REVOLUTION SERIES ............................................................................................. 1
SAFETY PRECAUTIONS.......................................................................................... 2
REVOLUTION SPECIFICATIONS ............................................................................ 5
SPECIFICATIONS FOR THE REVOLUTION RV16 480VAC /36V MODELS. .................... 8
SPECIFICATIONS FOR THE REVOLUTION RV16 480VAC /48V MODELS. .................... 9
SPECIFICATIONS FOR THE REVOLUTION RV16 480VAC /80V MODELS. .................. 10
SPECIFICATIONS FOR THE REVOLUTION RV24 480VAC /36V MODELS. .................. 11
SPECIFICATIONS FOR THE REVOLUTION RV24 480VAC /48V MODELS. .................. 12
SPECIFICATIONS FOR THE REVOLUTION RV24 480VAC /80V MODELS. .................. 13
INSTALLATION PROCEDURE............................................................................... 14
CHARGER INSTALLATION .......................................................................................... 14
RV16 Models Installation ................................................................................... 15
RV24 Models Installation ................................................................................... 20
CHARGER ELECTRICAL INSTALLATION ....................................................................... 25
RV16 & RV24 Electrical Instructions.................................................................. 26
OPERATION PROCEDURE.................................................................................... 28
CHARGER CONTROLS AND USER INTERFACE ............................................................. 28
BASIC CHARGE CYCLE OPERATION........................................................................... 29
GETTING STARTED .................................................................................................. 31
CHARGER MAIN MENU ............................................................................................. 35
MODULE REPLACEMENT ..................................................................................... 42
ENUMERATING INSTALLED MODULES .............................................................. 43
TROUBLESHOOTING ............................................................................................ 45
RETURN MATERIAL PROCESS ............................................................................ 52
APPENDIX A – WALL MOUNT DIMENSIONS & CLEARANCES.......................... 53
RV16 MODELS ....................................................................................................... 53
RV24 MODELS ....................................................................................................... 54
APPENDIX B – POST STAND DIMENSIONS & ASSEMBLY INSTRUCTIONS .... 55
RV16 MODELS ....................................................................................................... 55
RV24 MODELS ....................................................................................................... 56
APPENDIX C – NOTE ON TEMPERATURE COMPENSATION ......................... 58
CONTACT INFORMATION ..................................................................................... 59

MAN-000037-00 REV C 1
REVOLUTION SERIES
The REVOLUTION Series features 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 lithium, flooded, gel, and Absorbed Glass Mat (AGM), Thin Plate Pure Lead
(TPPL) batteries.

MAN-000037-00 REV C 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 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

MAN-000037-00 REV C 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-000037-00 REV C 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-000037-00 REV C 5
REVOLUTION SPECIFICATIONS
Model Numbers
(CEC compliant versions add –CEC suffix)
RV16 Model Numbers
RV16-13kW-300A-36V-F
RV16-14kW-330A-36V-F
RV16-15kW-360A-36V-F
RV16-18kW-420A-36V-F
RV16-21kW-480A-36V-F
RV16-18kW-420A-36V-F-SC
RV16-20kW-450A-36V-F-SC
RV16-13kW-36V
RV16-14kW-36V
RV16-15kW-36V
RV16-18kW-36V
RV16-21kW-36V
RV16-18kW-36V-SC
RV16-20kW-36V-SC
RV16-15kW-300A-48V-F
RV16-18kW-350A-48V-F
RV16-21kW-400A-48V-F
RV16-18kW-350A-48V-F-SC
RV16-21kW-350A-48V-F-SC
RV16-21kW-400A-48V-F-SC
RV16-15kW-48V
RV16-18kW-48V
RV16-21kW-48V
RV16-18kW-48V-SC
RV16-21kW-48V-SC
RV16-18kW-182A-80V-SC
RV16-20kW-195A-80V-SC
RV16-21kW-208A-80V-SC
RV24 Model Numbers
RV24-23kW-540A-36V-F
RV24-26kW-600A-36V-F
RV24-29kW-660A-36V-F
RV24-31kW-700A-36V-F
RV24-23kW-540A-36V-F-CN
RV24-23kW-36V
RV24-26kW-36V
RV24-29kW-36V
RV24-31kW-36V
RV24-23kW-36V-CN
RV24-23kW-450A-48V-F
RV24-26kW-500A-48V-F
RV24-29kW-550A-48V-F
RV24-31kW-600A-48V-F
RV24-23kW-450A-48V-F-CN
RV24-26kW-500A-48V-F-CN
RV24-29kW-540A-48V-F-CN
RV24-23kW-400A-48V-F-SC
RV24-26kW-450A-48V-F-SC
RV24-23kW-48V
RV24-26kW-48V
RV24-29kW-48V
RV24-31kW-48V
RV24-23kW-48V-CN
RV24-26kW-48V-CN
RV24-29kW-48V-CN
RV24-23kW-48V-SC
RV24-26kW-48V-SC
RV24-23kW-234A-80V-SC
RV24-26kW-260A-80V-SC
RV24-29kW-286A-80V-SC
RV24-31kW-312A-80V-SC

MAN-000037-00 REV C7
Figure 1: REVOLUTION RV16 and RV24 Battery Charger Features
LCD/keypad
Knockout
for input
wiring
Output Cables
Dual
Cable
Single
Cable

MAN-000037-00 REV C8
Specifications for the REVOLUTION RV16 480VAC / 36V models.
SPECIFICATIONS RV16-
13KW-36V
RV16-
14KW-36V
RV16-
15KW-36V
RV16-
18KW-36V
RV16-
21KW-36V
RV16-
18KW-
36V-SC
RV16-
20KW-
36V-SC
Nominal Volt (V) /
Maximum Current (A)
36 V / 300 A 36 V / 330 A 36V / 360A 36V / 420A 36V / 480A 36 V / 420 A 36 V / 450 A
INPUT SPECIFICATIONS INPUT SPECIFICATIONS
Voltage
480VAC, 3-phase±10%
Current
18.5A rms/ph 20.3A rms/ph 22.2 rms/ph 25.9A rms/ph 29.6A rms/ph 25.9A rms/ph 27.7A rms/ph
Power Factor
>0.92
Breaker Rating
40A
OUTPUT SPECIFICATIONS OUTPUT SPECIFICATIONS
Voltage
36V nom. / 50V max.
Current
300A Max 330A Max 360A Max 420A Max 480A Max 420A Max 450A Max
Power
13.0kW Max
14.3kW Max
15.6kW Max
18.2kW Max
20.8kW Max
18.2kW Max
19.5kW Max
Peak-to-Peak
Voltage Ripple
< 1%
EFFICIENCY
Total charge cycle efficiency > 90%
Peak charging efficiency > 92%
PROTECTION PROTECTION
Input •Under voltage
•Over voltage transients
Output
•
Over current
•Over voltage
•Charger Over temperature; Battery Over Temperature
•Battery reverse polarity
OPERATING CONDITIONS OPERATING CONDITIONS
Temperature
0–40°C
Humidity
10-90% RH noncondensing
INTERFACE INTERFACE
User Interface
LCD Keypad, DataLink, Ethernet (Optional)
MECHANICAL MECHANICAL
W x D x H
22” x 10” x 48”
Weight
~185 lb
~189 lb
~198 lb
~204 lb
~210 lb
~204 lb
~210 lb
Output Cables
Dual 2/0
Single 4/0, 125°C
Output Connectors
Dual SB350, Dual SBX350 and Dual Euro 320
LV-500
Cooling
Forced air (fans)
Certifications
UL and cUL Listed; CEC Certified
*SB350, SBX350 = 350A UL + CSA limit, Euro320 = 350A UL, 270A CSA limit
+CN models have output restricted to 270A for use with Euro320 connectors in Canada

MAN-000037-00 REV C9
Specifications for the REVOLUTION RV16 480VAC / 48V models.
SPECIFICATIONS RV16-15KW-
48V
RV16-18KW-
48V
RV16-21KW-
48V
RV16-18KW-
48V-SC
RV16-21KW-
48V-SC
RV16-21KW-
48V-SC
Nominal Volt (V) /
Maximum Current (A)
48V / 270A
36V/ 300A
48V /315A
36V / 350A
48V / 360A
36V / 400A
48V / 315A
36V / 350A
48 V/ 350A
36V / 350A
48V/ 360A
36V / 400A
INPUT SPECIFICATIONS
Voltage
480VAC, 3-phase±10%
Current
22.2A rms/ph
25.9A rms/ph
29.6A rms/ph
25.9A rms/ph
29.6A rms/ph
29.6A rms/ph
Power Factor
>0.92
Breaker Rating
40A
OUTPUT SPECIFICATIONS
Voltage
48V nom. / 65V max.
Current
300A max.
350A max.
400A max.
350A max.
350A max.
400A max.
Power
15.6kW max.
18.2kW max.
20.8kW max.
18.2kW max.
20.8kW max.
20.8kW max.
Peak-to-Peak
Voltage Ripple < 1%
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, DataLink, Ethernet (Optional)
MECHANICAL
W x D x H
22” x 10” x 48”
Weight
~198 lb
~204 lb
~210 lb
~204 lb
~210 lb
~210 lb
Output Cables
Dual 2/0
Single 4/0
Single 4/0
Single 4/0
Output Connectors
Dual SB350, Dual SBX350 and Dual Euro 320
SB350, SBX350 and Euro 320
LV500
Cooling
Forced air (fans)
Certifications
UL and cUL Listed; CEC Certified
+CN models have output restricted to 270A for use with Euro320 connectors in Canada