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Revolution RV16 Installation & Operation Manual Download Page 15

MAN-000037-00 REV C

  

14 

 

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 

L

iquid 

C

rystal 

D

isplay (

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. 
 

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. 

 

 

 

 

 

Continue on page 15 for RV16 Installation Procedure 

Continue on page 20 for RV24 Installation Procedure 

 

 

 

 

WARNING 

Summary of Contents for RV16

Page 1: ...MAN 000037 00 REV C RV16 and RV24 Models Installation Operation Manual ...

Page 2: ...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 RETU...

Page 3: ...ings 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 settin...

Page 4: ... 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 bei...

Page 5: ...ust 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 informa...

Page 6: ... 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 ...

Page 7: ...6 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 ...

Page 8: ...MAN 000037 00 REV C 7 Figure 1 REVOLUTION RV16 and RV24 Battery Charger Features LCD keypad Knockout for input wiring Output Cables Dual Cable Single Cable ...

Page 9: ...0 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...

Page 10: ... 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...

Page 11: ...ICIENCY 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...

Page 12: ...IENCY 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 Op...

Page 13: ...2kW Max 23 4kW Max 26 0kW 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 I...

Page 14: ... 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 DataL...

Page 15: ...e is apparent contact the shipping carrier Do not install or operate the charger if it has any visible damage 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 o...

Page 16: ...unt the charger vertically observing the minimum spacing shown below Figure 2 RV16 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 ...

Page 17: ...and any adjacent walls or barriers and 12 of spacing between the bottom of the charger and the floor or any other obstruction This is to allow for service and tool access to the Charger Figure 3 RV16 minimum spacing Ambient Temperature Range 0 40 C Ambient Humidity Range 10 90 RH non condensing ...

Page 18: ...directly mounted to masonry or concrete structural framing channels or onto the Floor Stand purchased separately see Appendix B Figure 4 RV16 mounting height Charger should be fastened to the mounting surface using 5 16 hardware User provided Threaded mounting studs protruding from surface are recommended for ease of installation Charger Weight 210 lbs maximum ...

Page 19: ...tion area The Charger IS NOT designed to be transported in any position other than horizontal Remove the cardboard box cover from the pallet DO NOT REMOVE the Shipping Spacer it is necessary to prevent damage to the Charger when lifting Figure 5 RV16 Box Removal The Charger s output cables not shown for clarity will be coiled at the base of the charger ...

Page 20: ...attach a chain or strap to the lifting eyes at the top of the charger and pick it up off the pallet Position the Charger on the installation location and fasten the charger permanently Figure 7 RV16 Lifting Once the Charger has been permanently mounted the Shipping Spacer can be removed and electrical installation can be completed Continue on page 25 for Charger Electrical Installation ...

Page 21: ...unt the charger vertically observing the minimum spacing shown below Figure 8 RV24 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 ...

Page 22: ...and any adjacent walls or barriers and 12 of spacing between the bottom of the charger and the floor or any other obstruction This is to allow for service and tool access to the Charger Figure 9 RV24 minimum spacing Ambient Temperature Range 0 40 C Ambient Humidity Range 10 90 RH non condensing ...

Page 23: ...irectly mounted to masonry or concrete structural framing channels or onto the Floor Stand purchased separately see Appendix B Figure 10 RV24 mounting height Charger should be fastened to the mounting surface using 5 16 hardware User provided Threaded mounting studs protruding from surface are recommended for ease of installation Charger Weight 300 lbs maximum ...

Page 24: ...tion area The Charger IS NOT designed to be transported in any position other than horizontal Remove the cardboard box cover from the pallet DO NOT REMOVE the Shipping Spacer it is necessary to prevent damage to the Charger when lifting Figure 11 RV24 Box Removal The Charger s output cables not shown for clarity will be coiled at the base of the charger ...

Page 25: ...attach a chain or strap to the lifting eyes at the top of the charger and pick it up off the pallet Position the Charger on the installation location and fasten the charger permanently Figure 13 RV24 Lifting Once the Charger has been permanently mounted the Shipping Spacer can be removed and electrical installation can be completed Continue on page 25 for Charger Electrical Installation ...

Page 26: ... CODES AND STANDARDS 1 The REVOLUTION chargers require a 480 VAC 3 four wire Wye or Delta electrical supply with a separate ground Figure 14 REVOLUTION Model 480 VAC Current Draw Circuit Protection at 125 RV16 30 A 40 A RV24 44 A 60 A Figure 14 AC input wiring diagrams 2 Verify that the source circuit is locked and tagged out before connecting power to the charger GND Typical Delta circuit Wye cir...

Page 27: ...screwdriver remove the four 10 32 screws securing the Charger hinge Figure 15 Figure 15 RV16 Hinge Screw Locations and Detail 4 Open the Charger hinge Determine whether the or conduit hole will be utilized if is desired punch out the outer ring from the KO provided Figures 16 17 ...

Page 28: ...al Block Tighten the terminal screws to 12 in lb 2 in lb NOTE The charger is not phase rotation sensitive Be sure any excess wire does not get pinched when the Charger door is closed 8 Once the Electrical connections have been made the Charger door should be closed and secured with the 10 32 screws previously removed Tighten the 10 32 screws to 12 in lb 2 in lb 9 Verify the line and ground connect...

Page 29: ... REVOLUTION series of chargers through each charger s front panel LCD keypad Figure 18 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 31 of this manual Figure 18 User interface LCD keypad LCD Function keys ...

Page 30: ...tage 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 95 charged This mode holds the...

Page 31: ...hrough the cover of the cell to monitor the electrolyte temperature directly internal type The thermistor is connected to the charger through the auxiliary contacts of the battery connector The charger uses the temperature that is calculated from the thermistor to adjust the voltages at which the charger transitions to the CV and Finish Equalize modes of operation and to limit the temperature rise...

Page 32: ...S VOLTAGES AND CURRENTS ARE PRESENT IN THE AC MAINS WHEN ENERGIZED ONLY TRAINED PERSONNEL SHOULD PERFORM THESE CHECKS USING PROPER EQUIPMENT AND PROCEDURES If the charger does not power up carefully verify the source circuit and wiring to the charger and correct any problems If appropriate check that all fuses in the local disconnect switch box on the wall are intact and that the supply voltage fo...

Page 33: ...ceed using the displayed values Following this display one of two messages appears on the LCD The LCD displays the PUSH START screen Or if Charge Autostart is enabled the charger automatically starts the charge cycle and briefly displays an AUTO START with a timer count down message as shown below The timer will count down from 5 to 1 before the charge cycle starts If either the Start or Auto Star...

Page 34: ...ickle CC for constant current CV for constant voltage FI for finish or EQ for equalize The screen also displays a charge timer lower left a battery icon with state of charge gauge along with actual readings of charging amps A returned amp hours Ah and battery voltage V The right side of the screen has a thermometer icon which gives the current battery temperature F or C To stop the charge cycle se...

Page 35: ...ART from the CHARGING STOPPED screen starts a new charge cycle and the screen will again display the charging operation display Once the charge cycle has completed the charger displays the CYCLE COMPLETED screen On this screen appears the total charging time and total returned amp hours along with the final state of charge of the battery ...

Page 36: ...yed Pushing the ENTER key selects the charger MAIN MENU screens The up down arrow keys scroll between the various screens The BACK button is used to return to the previous screen and or back to the main menu Selecting the ENTER button within a main menu will select a setting go to the next screen or toggle between two screens 1 Manual Equalize a While in MAIN MENU press until the MANUAL EQUALIZE s...

Page 37: ... batteries This can easily be done through the DESULFATION CYCLE screen The operator enters the battery nominal voltage Ah capacity and the cycle duration The charger will output a constant current of 5 of the Ah capacity 05 C for the defined duration in the time range of 6 00 hours to 18 00 hours Any battery capacity above 1200 Ah will have the desulfation current limited to 60A a Connect the bat...

Page 38: ...priate battery voltage Pressing toggles the battery voltage setting Select the correct voltage and select ENTER The Battery Capacity screen appears Pressing allows users to enter the correct battery amp hour capacity The recovery charge current is fixed at 5 A 100 Ahrs 5 of rated capacity d Press the ENTER key once the correct value is selected The Cycle Duration timer screen appears ...

Page 39: ...g can be set up to 18 hours Select the desired value then select ENTER Next the START DESULFATION CYCLE screen appears e Push START to initiate the desulfation cycle Once the cycle is complete a CYCLE COMPLETED message appears NOTE The desulfation cycle is a separate cycle activating it does not affect other charger settings ...

Page 40: ...rge history displays the charge number the date and time when the charge was started the charge duration end battery voltage the total amp hours returned to the battery and the Charger status STATUS indicates whether the cycle was completed successfully COMPLETED interrupted by the user STOPPED interrupted due to a power outage or disconnection TURNED OFF or interrupted due to a fault e g OV FAULT...

Page 41: ...le in MAIN MENU press until the LIFETIME SUMMARY screen appears b Pressing the ENTER key will display a screen summarizing charger lifetime summary stats since installation This screen allows verification of charger usage First charge date and time total charge hours amp hours and kW hours and the total number of cycles completed since installation This information may be used to compare usage on ...

Page 42: ...ufacturing ID and firmware revision for reference 6 Network Settings Ethernet Option Only a While in MAIN MENU press until the Network Settings screen appears b Pressing the ENTER key displays the IP Configuration Screen For further information on network setup see the PowerCharge DataLink User Software P N 014 000324 00 Downloadable from www powerdesigners com ...

Page 43: ...for lower cover iv Loosen the 2 captive screws securing the upper door closed and swing open the door repeat for lower door 4 Locate the module being removed by the serial number label on the lower front of the module 5 Remove the 1 10 32 screw from the bottom tab of the module 6 Carefully pull the module straight out of the socket Use your thumb or forefinger to grab the round hole at the top of ...

Page 44: ... While in Main Menu press until the Model SN screen appears 3 Pressing the ENTER key displays the charger model number manufacturing ID and firmware revision 4 Press the ENTER key again The serial numbers of the installed modules will be displayed There will be an next to the module s that is not enumerated 5 Press the green START button on the keypad The display will show Save Installed Modules w...

Page 45: ...Up Arrow to select Yes 7 Press the ENTER key to enumerate the modules The serial numbers of the modules will be displayed verify the correct number of serial numbers are listed per installed modules 8 Press the STOP key to exit the menu ...

Page 46: ...OFF position wait 30 seconds and then return it to the ON position c If the charger display still does not illuminate carefully verify the source circuit and wiring to the charger and correct any problems If appropriate check that all fuses in the service disconnect switch box on the wall are intact and also that the supply voltage for all three phases AC mains line to line is 480 V 10 and matches...

Page 47: ...e cycle is under way The Warning Symbol is not displayed once the charge cycle is complete The appearance of the Charge History screen under these circumstances may be similar to The Serial Number of the faulted module is displayed along with a fault code When contacting the Dealer or Power Designers Sibex make sure to note the specific fault message that is displayed This will aid in quick identi...

Page 48: ...or Push START screens b Remove power disconnect the battery and verify the AC supply and connections to the charger c Restart the charge cycle by connecting the battery and selecting START d If the fault persists contact your dealer or Power Designers Sibex 2 Output Over Voltage Fault Possible Causes Battery disconnected while charging Troubleshooting a The CYCLE STOPPED screen automatically rever...

Page 49: ...ct Battery or Push START screens b Verify that the output cables are in good working condition and are properly connected to the battery c Restart the charge cycle by selecting START d If the fault persists contact the Dealer or Power Designers Sibex 4 Charger Over Temperature Possible Causes Blocked air flow to the charger Failed cooling fan Room temperature above 104 F ...

Page 50: ...ler or Power Designers Sibex 5 Charger Timeout Faults The screen indicates which timer has caused the problem TRICKLE CHARGE CC CHARGE or CV CHARGE Possible Causes Programmed charge timers are set incorrectly Programmed charge parameters are set incorrectly Battery has shorted cell s Troubleshooting a Select STOP to revert to the Connect Battery or Push START screens b Verify that the battery is i...

Page 51: ...r waits for an 8 C 14 F drop before re starting the charge cycle The Charger increments the delay until an 11 C 20 F drop is required before restart If the battery temperature limit is exceeded once again the Charger will stop the charge cycle and display the following screen Possible Causes Charge and or discharge rates too high CV and Finish modes running too often Room temperature excessive Tro...

Page 52: ...TracTM is lost while a charge cycle is underway a screen similar to the following will be displayed Examining the Charge History will reveal a screen similar to this Possible Causes Worn or broken auxiliary wires or auxiliary contacts Failure of the PowerTracTM Troubleshooting a Inspect connections on both charger and battery sides of the battery connector Verify auxiliary Wire 1 is connected on t...

Page 53: ...ed to Power Designers Sibex Upon receipt of the completed RMA form Power Designers Sibex will issue an RMA number for the return Based on the serial number of the specific charger s and the particular problem encountered Power Designers Sibex will either repair or replace the defective components under warranty For chargers out of warranty Power Designers Sibex upon receipt of the charger and in c...

Page 54: ...MAN 000037 00 REV C 53 Appendix A Wall Mount Dimensions Clearances RV16 Models Recommended mounting hardware 5 16 ...

Page 55: ...MAN 000037 00 REV C 54 RV24 Models Recommended mounting hardware 5 16 ...

Page 56: ...MAN 000037 00 REV C 55 Appendix B Post Stand Dimensions and Assembly instructions RV16 Models ...

Page 57: ...MAN 000037 00 REV C 56 RV24 Models ...

Page 58: ...MAN 000037 00 REV C 57 ...

Page 59: ...hermistor implements two temperature compensation factors expressed in mv deg C cell 1 The Battery Low Compensation factor Batt Low Temp Comp is activated when the battery temperature varies from 77 deg F but is lower than the high compensation temperature limit High Comp Temp The default value is 2 mv deg C cell 2 The Battery High Compensation factor Batt High Temp Comp is activated when the batt...

Page 60: ... 0101 Fax 352 564 0772 www powerdesigners com sales powerdesigners com service powerdesigners com Phones are answered between 8 a m and 4 p m Monday through Friday Eastern Time After hours calls are answered by voice mail and returned on the next business day Questions and comments can also be submitted via fax or email ...

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