Introducing the REVOLUTION Charger

Introducing the REVOLUTION Charger
Introducing the
REVOLUTION Charger
This material is provided by Power Designers USA LLC
www.powerdesigners.com
Company Confidential
4/25/2017
1
Revolution Series
Features
Scalable, Light Weight Efficient, Customizable, Programmable, and
Reliable full line of Smart Battery Chargers
+ Three Basic Building Blocks,
RV05, RV08, RV12 configurable
from 4-31kW
+ Multi-voltage, (24V, 36V, 48V) on
a single charger when combined
with the PowerTrac
+ Modular design allows for easy
configuration and servicing
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Revolution Series
Efficiency
+
+
+
+
Maintain charge efficiency greater than
90% over the entire charge cycle
Small and lightweight construction
Supports conventional, opportunity,
and fast charge applications
Customizable through software and
hardware configuration
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Revolution Series
Modularity
+
+
Individual 1.3kW power modules
BPUs are either 36/24 volt or 48/36/24 volt
output
• 36 volt BPU produces 30 amps
• 48 volt BPU produces 22.5/25 amps
+
+
Modules can be configured to meet the exact
needs of the customer
Fault tolerant design that allows the charger to
continue operation if a power module fails
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Revolution Series
Modularity
Base Power Unit
(BPU) Front View
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Cooling Fans
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Revolution Series
Redundancy
+
+
+
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.
A Warning Symbol will be displayed on the
upper right of the display while the charge
cycle is under way.
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Revolution Series
Quiz Time
What are the 3 basic building block chassis sizes of the Revolution series charger?
The RV05, RV08, and RV12; a 5 module, 8 module and 12 module chassis respectively
As output power decreases, charger efficiency increases or decreases?
Decreases
The Revolution series maintains efficiency above______ percent as power decreases?
90%
The modular design provides two benefits, what are they?
Scalability and Redundancy
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Revolution Series
Charger Display
While the battery is disconnected the charger will display the Connect Battery screens,
alternating between the animation and message
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Revolution Series
Charger Display
Connect the battery to the charger. Once the battery is detected, one of
two messages appears on the LCD:
1. The LCD displays the PUSH START screen.
If the charger is not set to start automatically, start the charge cycle
by pushing the green START button on the keypad.
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Revolution Series
Charger Display
2. 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.
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Revolution Series
Charger Display
The charge cycle begins and a screen similar to one of the following, showing the charging
operation, appears:
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Revolution Series
Charger Display
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
+ EQ for equalize
The screen also displays:
+ Charge timer (lower left)
+ Battery icon with % state of charge gauge
+ Charging amps (A)
+ Returned amp-hours (AH)
+ Battery voltage (V)
+ Thermometer icon with the current battery temperature (°F or °C) (lower right)
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Revolution Series
Charger Display
+
+
+
To stop the charge cycle, select the STOP button. A PAUSED message appears.
Selecting START from the PAUSED screen will resume the charge cycle.
The cycle can be terminated by pressing stop a second time. Disconnecting the
battery while paused also terminates the cycle.
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Revolution Series
Charger 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.
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Revolution Series
Charger Display Menu
From the charger MAIN MENU screen, access is provided to the following list of
menus screens:
+ Manual Equalize
+ Desulfation Cycle
+ Charge History
+ Lifetime Summary
+ Model & SN
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Revolution Series
Charger Display Menu
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.
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Revolution Series
Charger Display Manual Equalize
While in MAIN MENU, press /
until the MANUAL EQUALIZE screen
appears.
Press ENTER to access screen.
Press / to select YES or NO.
Press ENTER key to save selection and
return to the main menu.
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Revolution Series
Charger Display Manual Equalize Selected and Active
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.
NOTE: Once an Equalization is activated, it remains active until an equalization cycle has
completed.
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18
Revolution Series
Charger Display Desulfation Cycle
A unique feature of the all Power Designers chargers is the ability to run a safe, tailored
recovery cycle for sulfated batteries. This can easily be done through the DESULFATION
CYCLE screen.
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.
While in MAIN MENU, press / until the DESULFATION CYCLE screen appears.
Press ENTER to access the recovery cycle set-up screens.
NOTE: Do not attempt to recover a battery of less than
250 amp-hours.
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19
Revolution Series
Charger Display Setting the Desulfation Cycle
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).
Press the ENTER key once the correct value is selected.
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Revolution Series
Charger Display Setting the Desulfation Cycle
The Cycle Duration timer screen appears. 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. Push START to initiate the desulfation
cycle.
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Revolution Series
Charger Display Setting the Desulfation Cycle
Charger screen during 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 of the manual for instructions on how to determine the recovery charge current and
timer setting.
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Revolution Series
Charger Display Charge History
While in MAIN MENU, press / until the CHARGE HISTORY screen appears. Press ENTER to
access the Charge History screens.
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.
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Company Confidential
4/25/2017
23
Revolution Series
Charger Display Charge History
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
+ 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 over voltage fault).
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Revolution Series
Charger Display Charge History
Press ENTER to access the second screen of the charge history which shows:
+ The profiles that were activated in the charge cycle
+ 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.
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.
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4/25/2017
25
Revolution Series
Charger Display Lifetime Summary
While in MAIN MENU, press / until the LIFETIME SUMMARY screen appears.
Pressing the ENTER key will display a screen summarizing charger lifetime summary statistics
since installation.
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Revolution Series
Charger Display Model and Serial Number
While in MAIN MENU, press / until the MODEL & SN screen appears.
Pressing the ENTER key displays the charger model number, manufacturing ID, and firmware
revision for reference.
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Revolution Series
Another Short Quiz
The charger history saves and displays how many cycles?
400
Manual Equalize remains active for how long?
Until an Equalize cycle is completed
What is shown on the display to indicate Manual Equalize?
An “E” in the corner of the display
Name the one feature of all Power designers chargers not found elsewhere?
Desulfation cycle
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Thank You
On Behalf of
Power Designers
For Your
Participation
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