Revolution RV05-4kW-90A-36V-P, RV05-4kW-75A-48V-P, RV05-6kW-150A-36V-P, RV05-5kW-120A-36V-P, RV05-6kW-125A-48V-P Installation & Operation Manual

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A NEW ERA IN CHARGING TECHNOLOGY

RV05-4kW-90A-36V-P RV05-5kW-120A-36V-P RV05-6kW-150A-36V-P

480VAC Models

RV05-4kW-75A-48V-P RV05-5kW-100A-48V-P RV05-6kW-125A-48V-P

Installation & Operation Manual

Madison, WI 53718

4005 Felland Road, Suite 116

USA

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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

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REVOLUTION™ SERIES

The REVOLUTION™ Series features very high charge cycle efficiencies and stateof-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

WARNING

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.

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CAUTION

WARNING

 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

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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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LCD/keypad

Knockout for input wiring

Strain reliefs for output cables

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

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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

Standard Output Connectors

SBX175

SBX350 or

Euro320

SBX350 or

Euro320

Certifications

UL and cUL Listed

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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

Standard Output Connectors

SBX175

SBX350 or

Euro320

SBX350 or

Euro320

Certifications

UL and cUL Listed

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INSTALLATION PROCEDURE

WARNING

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.

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 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.

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 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

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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

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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:

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Figure 6: RV05 Cover Removal

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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!

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Charger Electrical Installation

GND

Typical Delta circuit

Wye circuit

415V

480V

277V

480V

277V

480V

GND

WARNING

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.

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):

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Figure 8: AC input wiring diagrams

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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.

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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 lineto-line voltages should be 480 VAC ± 10% and matched within 10 VAC. Deenergize 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

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OPERATION PROCEDURE

LCD

Function keys

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.)

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Figure 11: User interface LCD/keypad

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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.

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Finish: Finish mode will hold the current into the battery constant, and the battery voltage will slowly rise. The charge cycle will terminate when one of three conditions exists: The charger has been in the finish mode for the full duration of the finish timer, the Finish dV/dt is reached, or the Finish Voltage is achieved. The Finish dV/dt is reached when the battery voltage rises less than the Finish dV (typically ~5mV/cell) over the length of time defined by the Finish dt (typically ~20 minutes). (Figure 15)

Equalize: The equalize mode ensures that all cells of the battery are equally charged. During charge/discharge, the inner and outer cells of the battery will tend to be at slightly different voltage. The equalize mode charges at a low fixed current (~5%) for a fixed amount of time (Typically ~3-6 hr), and ensures that all cells are fully and equally charged.

Figure 15: Finish charge termination criteria

Opportunity Charging: Opportunity charging utilizes a temperature sensor

(thermistor) on the battery to allow more rapid recharge of the battery, without the risk of damage to the battery. The thermistor may be mounted to an intercell strap or post (external type), or mounted through 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 alter the voltages at which the charger transitions to the CV and Finish/Equalize modes of operation, and to limit the temperature rise of the battery to a safe level. See Appendix D for further details. Installation instructions for the thermistor can be obtained at http://powerdesigners.com/.

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Getting Started

WARNING

The LCD display on REVOLUTION™ series presents various screens and SCREEN MESSAGES.

1. Powering the Charger

 Energize the AC mains at the main panel (turn the local AC disconnect switch

to the ON position, if one exists).

 Verify that the LCD display is lit and displays the CONNECT BATTERY

screens, alternating between the animation and message as shown below.

DANGEROUS 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 for all three phases (AC mains line-to-line) is 480V ± 10%, and matches to within 10VAC or better between phases.

 Restart the charger; if the problem persists, contact the Dealer or Power

Designers USA LLC.

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2. Starting a Charge Cycle

a. Connect the battery to the charger. Once the battery is detected, one of two

messages appears on the LCD: The LCD displays the PUSH START screen.

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 Start” screens are not displayed, the battery has not been detected. Make sure that the battery cables are connected properly.

 If the charger is not set to start automatically, start the charge cycle by

pushing the green START button on the keypad.

 The charge cycle begins and a screen similar to one of the following, showing

the charging operation, appears:

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The Charging … (XX) field in the upper left corner indicates the active charging mode, the XX will indicate TR for trickle, 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, select the STOP button. A PAUSED message

appears.

Selecting STOP for the second time stops the charger completely and defaults to the PUSH START screen. Selecting START 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.

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On this screen appears the total charging time and total returned amp-hours along with the final state of charge of the battery.

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Charger Main Menu

From the charger MAIN MENU screen, access is provided to the following list of screens:

 Manual Equalize  Desulfation Cycle  Charge History  Lifetime Summary  Model & SN

These screens may only be accessed when the charger is in idle mode (i.e., when either the CONNECT BATTERY or the PUSH START screens are displayed).

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 screen

appears.

b. Press ENTER to access screen.

c. Press / to select YES or NO.

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NOTE: Once an Equalization is activated, it remains active until an equalization cycle has completed.

d. Press ENTER key to save selection and return to the main menu. The LCD

display now indicates the Equalization charge is activated with an “E” in the

upper right corner of the display, and one of the following displays will be observed, depending on the setup of the Charger.

2. Desulfation Cycle

One of the unique features of this charger is the ability to run a safe, tailored recovery cycle for sulfated batteries. This can easily be done through the DESULFATION CYCLE screen.

a. Connect the battery to be recovered. If the charger is set to auto-start the

charge cycle, press the stop button until you are back on the “Push Start”

screen.

NOTE: Do not attempt to recover a battery with a capacity of less than 250 amp-hours.

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b. While in MAIN MENU, press / until the DESULFATION CYCLE screen

appears.

c. Press ENTER to access the recovery cycle set-up screens. The first screen

selects the appropriate battery voltage.

Pressing / toggles the battery voltage setting. Select the correct voltage and select ENTER. The Battery Capacity screen appears.

Pressing / allows the user to enter the correct battery amp-hour capacity. The recovery charge current is fixed at 5A /100 Ahrs (5% of rated capacity).

d. Press the ENTER key once the correct value is selected. The Cycle

Duration timer screen appears.

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Pressing / allows adjustment of the charge timer setting in 15-minute increments. The charge timer setting must be less than 24 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. See Appendix E for instructions on how to determine the recovery charge current and timer setting.

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3. Charge Cycle History

a. While in MAIN MENU, press / until the CHARGE HISTORY screen

appears.

Press ENTER to access the Charge History screens.

b. The first screen that appears is the Charge Cycle history screen as shown

below. Users can access the charge history for up to 400 charge cycles, beginning with the most recent charge cycle. Pressing / allows scrolling through the saved charge cycles, from the most recent cycle to the earliest (Charge 0), in descending order.

The first screen of the charge 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 for an overvoltage fault).

Press ENTER to access the second screen of the charge history which shows the profiles that were activated in the charge cycle, and any Charger faults. Pressing ENTER again will return to the first screen. Pressing the BACK key returns to the CHARGE HISTORY screen from the first screen only.

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PROFILES lists the profiles activated during the charge cycle. Trickle charge appears as TR, constant current as CC, constant voltage as CV, finish as FI, and equalize as EQ.

4. Lifetime Summary

a. While 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 different chargers.

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5. Charger Model

a. While in MAIN MENU, press / until the MODEL & SN screen appears.

b. Pressing the ENTER key displays the charger model number, manufacturing

ID, and firmware revision for reference.

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TROUBLESHOOTING

CAUTION

WARNING

Occasional faults may occur in certain conditions. Please follow the suggested steps.

A. Charger Does Not Power Up

When the charger is first turned on, the LCD should illuminate and display one of

the idle mode messages, typically the CONNECT BATTERY screen.

If the LCD is not illuminated after power is applied, perform the following checks:

a. Verify that the service disconnect switch (if provided) and the main panel

breaker is in the ON position.

b. Cycle the switch to the 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 to 10 VAC or better.

d. If the fault persists, contact the Dealer or Power Designers USA LLC.

DANGEROUS VOLTAGES AND CURRENTS ARE PRESENT IN THE AC MAINS WHEN ENERGIZED. ONLY TRAINED PERSONNEL SHOULD PERFORM THESE CHECKS, USING PROPER EQUIPMENT AND PROCEDURES.

DO NOT ATTEMPT TO SERVICE THE CHARGER!

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B. Charger Fault During Operation

The REVOLUTION™ Series features a modular and fault-tolerant design that

allows the Charger to continue operation despite the loss of a portion of the modules through temporary or permanent fault conditions. If a module faults during the charging cycle, the fault is recorded, and the charge cycle continues. The Charger will continue to operate, so long as 60% of the installed modules are operational.

If the Serial Numbers of the operating modules do not match the expected numbers, either because they are missing (faulted), or a module has been replaced or added improperly, a Warning Symbol will be displayed on the upper right of the display while the charge 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 USA LLC, make sure to note the specific fault message that is displayed. This will aid in quick identification of the cause and the appropriate fix for the fault.

If the Warning Symbol is displayed while charging, but no faulted modules are listed in the Charge History screen, the problem is that the Serial Numbers of the

modules that are found to be available do not match the stored list of “Installed Modules”. This may have occurred either through complete loss of power to a

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module, or by the improper addition of spare or replacement modules. Please contact the Dealer or Power Designers USA LLC to arrange repair.

If the number of faulted modules results in the Charger having less than 60% of the “Installed Modules” operational, the charge cycle will be interrupted, and a fault message is displayed. Examples of possible faults follow:

1. AC Fault

Possible Causes

 AC line voltage outside of allowable limits. (432VAC-528VAC, AC phases

matched within 10V)

 Fuse blown in AC service.

Troubleshooting

a. Select STOP to revert to the Connect Battery 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 the Dealer or Power Designers USA LLC.

2. Output Over-Voltage Fault

Possible Causes

 Battery disconnected while charging.

Troubleshooting

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a. The CYCLE STOPPED screen automatically reverts to the Connect

Battery or Push START screens in 30 seconds.

b. Select STOP to revert to the Connect Battery or Push START screens. c. Restart the charge cycle by selecting START. d. If the fault persists, contact the Dealer or Power Designers USA LLC.

3. Over-Current / Primary Over-Current Fault

Possible Causes

 Damaged DC (output) cables. (open or short)

Troubleshooting

a. Select STOP to revert to the Connect 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 USA LLC.

4. Charger Over-Temperature

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Possible Causes

 Blocked air flow to the charger.  Failed cooling fan.  Room temperature above 104˚F.

Troubleshooting

a. Select STOP to revert to the Connect Battery or Push START screens. b. Allow the charger to cool down. c. Make sure there are no airflow restrictions to the intake or exhaust of the

charger. d. Restart the charge cycle by selecting START. e. If the fault persists, contact the Dealer or Power Designers USA LLC.

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 in good working condition (i.e., no shorted cells). c. If the fault persists, contact the Dealer or Power Designers USA LLC.

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6. Battery Over-Temperature

The following screen will appear the first 5 times the battery over-temperature limit is exceeded during any charge cycle. On the first instance of detecting a battery overtemperature, the Charger will wait until the battery temperature drops approximately 7°C (13°F) and then re-start the charge cycle automatically. If another overtemperature fault is the encountered, the charger 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.

Troubleshooting

a. Select STOP to revert to the Connect Battery or Push START screens. b. Allow the battery to cool down. c. Restart the charge cycle by selecting START. d. If the fault persists, contact the Dealer or Power Designers USA LLC.

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RETURN MATERIAL PROCESS

In the event that the troubleshooting steps included in this manual do not resolve the problem,

a. Record the charger serial number; b. Call Power Designers USA LLC with a description of the problem.

Power Designers USA LLC will attempt to resolve the problem over the phone. If the issue cannot be resolved in this manner, a Return Material Authorization (RMA) form must be completed and submitted to Power Designers USA LLC.

Upon receipt of the completed RMA form, Power Designers USA LLC 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 USA LLC will either repair or replace the defective components under warranty.

For chargers out of warranty, Power Designers USA LLC, upon receipt of the charger and in consideration of a diagnostic fee, will provide a repair estimate.

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Limited Warranty

MODEL PowerCharge XP, PowerCharge iHF, REVOLUTION SERIES

FOR INDUSTRIAL APPLICATIONS USED IN THE USA & CANADA

Power Designers USA LLC (“PD”) hereby warrants each new PowerCharge XP, PowerCharge iHF and REVOLUTION Series battery charger (the “Product”) for industrial application shipped after April 1, 2014

pursuant to the following terms and conditions (the “Product” Limited Warranty):

1. Subject to the provisions below, PD warrants the Product against defective materials and

workmanship for a period of two (2) years from date of shipment (the “Warranty Period”).

a. On-Site Service during the first year of the term of this limited warranty period. The

company will compensate or provide on-site service during the first year of the limited warranty term. If it is believed there is a defect in the Product, Authorized service can be requested by contacting the PD Service Group at 608-216-9295. If, during the first year of limited warranty period, PD determines on-site limited warranty service is required, PD will arrange for a technician to respond to the service call. For Dealers, PD will provide authorization for the service call based on the limitations in the Service Contract.

If PD’s authorized technician determines that the problem with the Product is not covered

by this limited warranty, the customer will be charged for the technician’s travel expenses and labor costs at the then current hourly rate for the technician’s services.

b. Service during the Remaining Term of the Limited Warranty Period. During the

remaining term of the Limited Warranty Period, you must contact the PD Service Group at 608-216-9295 for service. A PD service technician will determine if the unit qualifies for limited warranty repairs.

Once the determination is made to be defective in material or workmanship, the Company will issue you a Returned Material Authorization (RMA) Number. PD will not service any part sent to the company without an RMA Number. After you receive the RMA Number, you must ship the part to

Power Designers USA LLC 4005 Felland Road, Suite 116 Madison WI 53718 Attention: Warranty Service RMA # _______________

The RMA number needs to be clearly marked on the outside of the shipment. The shipper is responsible for shipping the part freight prepaid to PD and for insuring the shipment and accepting the risk of loss or damage during shipment.

c. PD shall determine in its sole discretion when tested under PD’s supervision, whether the

Product contains defective materials or workmanship during the Warranty Period. If PD determines that the Product is defective, it shall, at its option, either (a) repair the Product at its expense, or (b) furnish a suitable replacement Product. Replaced or repaired Product shall be warranted for the remaining term of the original Warranty Period.

d. Upon completion of said repairs, the part will be returned by regular ground shipping,

freight prepaid. If you desire expedited shipping, you must request such from PD and you will be responsible for prepaying the cost of such expedited shipping.

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If a “component” or “components” failed due to any cause that the limited warranty does not cover, the owner (Dealer) will be informed of the charges of the repairs before any

repairs are performed. If the repairs are approved, PD will repair said product with “new”

or “reconditioned to new” parts at PD’s discretion. Outbound freight from PD will be the

responsibility or the owner (Dealer).

2. The occurrence of any of the following events or actions shall render this Product Limited Warranty

void:

a. Improper installation of the Product;

b. Use of the Product for a purpose other than its intended purpose;

c. Failure to follow PD’s instructions concerning proper installation or use of the Product;

d. The negligence of a person or entity other than PD in the installation or use of the Product;

and

e. Repair or modifications of the Product by any party other than PD or one of its authorized

agents.

3. PD MAKES NO OTHER REPRESENTATION OR WARRANTY WHATSOEVER, EXPRESS OR

IMPLIED OR OF ANY NATURE, WITH REGARD TO THE PRODUCT, INCLUDING, WITHOUT LIMITATION, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THE REMEDY SET FORTH IN THIS POWERCHARGE LIMITED WARRANTY IS THE EXCLUSIVE REMEDY FOR ANY BREACH OF WARRANTY.

4. PD SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL,

CONSEQUENTIAL, PUNITIVE OR EXEMPLARY DAMAGES OF ANY KIND, INCLUDING, BUT NOT LIMITED TO, ANY LOST PROFITS AND LOST SAVINGS, LOSS OF USE OR INTERRUPTION OF BUSINESS, HOWEVER CAUSED, WHETHER ARISING IN CONTRACT, TORT (INCLUDING NEGLIGENCE), BREACH OF WARRANTY, STRICT LIABILITY OR OTHERWISE, EVEN IF PD HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. IN NO EVENT WILL PD BE LIABLE FOR THE COST OF PROCUREMENT OF SUBSTITUTE GOODS.

5. PD will defend, indemnify, and hold Buyer harmless from and against any claim, demand, or cause of

action (including expenses, costs and damages related to the same) (each a “Claim”) in an amount not to exceed the Aggregate Limit brought against Buyer by any third party to the extent the Claim is based on the allegation that the Products infringe or violate the intellectual property rights of any third party, provided that (1) Buyer promptly notifies PD in writing of any Claim within 10days after Buyerbecomes aware of any such Claim or the potential that a third party may assert such a Claim; (2) PD has sole control of the defense and all related settlement negotiations; and (3) on PD’s request, Buyer reasonably cooperates with and assists PD in the defense of any such Claim or potential Claim. As used above, the term “Aggregate Limit” means the aggregate dollar amount of the Products bought by the Buyer within the previous 12 month period prior to the date the Buyer notified PD of the Claim. Notwithstanding the above, PD shall have not any obligation to indemnify Buyer hereunder (a) for any settlement of the Claim made by Buyer without PD’ written permission, or (b) if, to the extent, such Claim is based on, in whole or in part, the alteration of the Products not approved by PD or the combination, operation, or use of the Products with devices, materials, parts, or software and documentation not supplied by PD, or (c) any use of the Product which is not customary or in

compliance with PD’s designs, specifications, instructions, User’s Guide, or these terms and

conditions. This states PD’s total responsibilities, liabilities and remedies to Buyer for any actual or

alleged infringement of any intellectual property rights of any third party.

6. This Product Limited Warranty may be assigned to any end-user of the Product by Distributor in

connection with sale of the Product by Distributor to such end-user, but may not be transferred or assigned by any end user or other entity or person.

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SOFTWARE LICENSE AGREEMENT

This license agreement is a legal agreement between Power Designers USA LLC of Madison, Wisconsin, the author and licensor of the software, and the end user licensee of the software.

Installation or other use of this software by the licensee constitutes agreement to all terms and conditions of this license. In the event the licensee does not agree to all terms and conditions of this agreement the software may not be installed or otherwise used.

The following terms apply:

1. Licensee may not redistribute any files, including but not limited to any setup or

installation files created by this software.

2. Licensee may not disassemble or reverse engineer any part of this software.

3. Licensee may not resell, rent or lease the software.

4. Licensor owns all rights in the software including any incorporated images or text.

5. Should the licensee fail to comply with any terms or conditions of this agreement

this agreement will immediately and automatically terminate without notice.

6. The licensor of this software does not guarantee that this software is free from

bugs or free from viruses.

To the maximum extent permitted by applicable law, the software and documentation are provided "as is" and the licensor disclaims all other warranties and conditions, expressed or implied, including, but not limited to, implied warranties of merchantability, fitness for a particular purpose, conformance with description, title and non-infringement of third party rights.

To the maximum extent permitted by applicable law, in no event shall the licensor be liable for any indirect, incidental, consequential, special or exemplary damages or lost profits whatsoever (including, without limitation, damages for loss of business profits, business interruption, loss of business information, or any other pecuniary loss) arising out of the use or inability to use the software product, even if the licensor has been advised of the possibility of such damages. In any case, the

licensors’ cumulative and entire liability to the licensee or any other party for any loss

or damages resulting from any claims, demands or actions arising out of or relating to this agreement shall not exceed the purchase price paid for this license.

Should any term of these terms and conditions be declared void or unenforceable by any court of competent jurisdiction, such declaration shall have no effect on the remaining terms hereof.

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APPENDIX A – WALL MOUNT DIMENSIONS AND

CLEARANCES

Recommended mounting hardware: 1/4” or 5/16”.

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APPENDIX B – POST STAND DIMENSIONS

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APPENDIX C – SHELF STAND DIMENSIONS

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APPENDIX D – NOTE ON TEMPERATURE

COMPENSATION

Temperature compensation is critical to maintaining battery life and performance. If the battery temperature is allowed to drift higher or lower than 77°F during normal operation, the charger constant voltage limit should be adjusted to compensate for temperature variations.

For a valve-regulated lead-acid battery, the temperature compensation factor is 2 mV/°C/VPC. The REVOLUTION™ opportunity charger implements two temperaturecompensation coefficients:

1. The battery low compensation coefficient (Batt Low Temp Comp) is activated when the battery temperature is different than 77°F, but lower than the high compensation temperature limit (High Comp Temp) (Figure C1).

2. The battery high compensation coefficient (Batt High Temp Comp) is activated when the battery temperature is higher than the high compensation temperature limit (High Comp Temp) (Figure D1).

These parameters can be factory or dealer adjusted.

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Figure D1

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APPENDIX E – RECOVERY CYCLE FOR SULFATED

Battery Capacity

Current Setting

Timer Setting

HH:MM

250