R/Evolution RV05 Bedienungsanleitung

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

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

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