Iron Edison REVOLT4 User manual
User’s Guide
IE51100RV4
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Cover ..............................................................................
Table of Contents .........................................................
Revision .........................................................
1. Safety Notices ..........................................................
2. Product Introduction ...............................................
2.1 Product Specifications ..........................................
2.2 Battery Specifications ...........................................
2.3 Battery Structure .................................................
3. Storage and Transport ............................................
3.1 Storage ...............................................................
3.2 Transport ............................................................
4. Installation Preparation ..........................................
4.1 Packing List .........................................................
4.2 Product Picture ...................................................
5. Battery Installation ..................................................
5.1 Installation Location .............................................
5.1.1 Environment Requirement ........................
5.1.3 Wall Mount Bracket Installation .................
5.1.4 Battery Pack Installation ...........................
5.2 Cable Connection .................................................
Reference: RJ45 Cable Pin Definition .................
5.2.2 Dip Switches ...........................................
5.2.3 Operating on Voltage Logic .......................
5.2.4 Disconnection Order ................................
6. Commissioning ..........................................................
6.1 Startup Procedure ................................................
6.1.1 Startup for a Single Battery .......................
6.1.2 Startup for Multiple Batteries ....................
6.1.3 Commissioning Inverter/Charger Settings ....
6.2 Battery Information Display ...................................
7. Connecting the REVOLT4Monitor App ..................
8. Troubleshooting .......................................................
9. Datasheet ..................................................................
Table of Contents
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Revision Number v.2.104/14/2022
Any improper operation may lead to electrical shocks, burns and other
personal injury or equipment damage. Please read the important safety
information and strictly abide by all the safety rules of this instruction
manual.
For maximum battery performance and longevity, we recommend
installing the battery in a temperature-controlled environment.
Do not touch the live parts of the equipment without confirming the volt-
age and temperature of the equipment.
Only professional electricians or professionally qualified personnel
should install, operate, overhaul, and maintain the equipment. During the
maintenance or installation, there must be at least two people equipped
with appropriate PPE (personal protective equipment) including but not
limited to safety shoes, protective glasses, insulated gloves and
electrically insulated tools. The personnel must also be trained in how to
recognize electrical hazards and how to mitigate them.
Warning: Violation of these provisions may result in personal injury or
equipment damage.
When moving, transporting and placing equipment at rest, the equipment
must be placed horizontally ('on its back'). This will prevent the battery
from tipping over. The battery should ideally be installed on a fire-
retardant material.
Do not place flammable materials inside or on top of the battery
enclosure.
Do not leave cloth, paper, metal shavings, tools or other foreign objects
inside the battery enclosure.
In non-emergency cases, do not stop the operation of the monitoring
system by connecting and disconnecting input power cables.
1. Safety Notices
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2. Product Introduction
The battery enclosure can be cleaned using a soft cloth.
To ensure proper operation over the life of the battery, use the
monitoring software to check that each battery is operating properly. No
regular maintenance needs to be performed inside the enclosure.
Electrostatic Warning
Any personnel who comes into contact with the circuit boards or internal
components needs to wear a good anti-static grounding bracelet. In the
event of replacing circuit boards, please hold the edge in order to prevent
damage from static electricity. In addition, static electricity can be elimi-
nated by contacting electrically conductive bodies such as metal sheets.
Reminders/Notifications
When debugging the battery and solar system, please pay attention to
the messages displayed on the touch screen.
When in doubt, please call Iron Edison Tech Support at 720-432-6433.
This Lithium Iron Phosphate battery system is integrated with an ad-
vanced Battery Management System (BMS) which includes charge/
discharge management, thermal management, communication man-
agement, balance management, and data management. This system
also allows for remote battery performance monitoring, remote device
management and system maintenance.
The product features a long lasting lithium iron phosphate battery chem-
istry. This high efficiency system is compact in size, comparably light
weight, and provides stable long-term performance. The product is safe
and eco-friendly, while also being adaptable and usable in high altitude
environments.
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2.1 Product Specifications
System Model (see nameplate) IE51100RV4
Model Code
IE
Nominal Voltage
51.2
Nominal Capacity
100 Ah
Battery Type
LiFePO4
Model Number
REVOLT4
2.2 Battery Specifications
Item
Specification
Battery Type
LiFePO4
Nominal Voltage
51.2
Nominal Capacity
100Ah
Nominal Energy
5.12 kWh
Standard Charge Voltage
55.2 V
Recommended Float Charge Voltage
53.4 V
Maximum Continuous Charge Current
100
A
Maximum Continuous Discharge Current
100
A
Peak Discharge Current (3 seconds)
300
A
Maximum Continuous discharge power
5 kW
Peak Discharge Power (3 seconds)
15 kW
Weight
127
LBS
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4. Installation Preparation
3.1 Storage
The battery should be stored in a dry, clean, shaded and well-ven-
tilated area.
The battery needs to be charged to at least 70% before storing it.
Store the battery modules for no longer than 6 months.
Keep the battery from dropping, turning over and any other seri-
ous impact.
Keep away from children and pets.
3.2 Transport
Lithium-ion batteries are hazardous goods. Therefore the fol-
lowing points must be observed when transporting the battery
modules:
•
Observe the general transport regulations based on the
mode of transport as well as all legal regulations for haz-
ardous goods.
•
Keep batteries face up and do not allow them to fall over.
Batteries in their boxes should not be stacked more than
three tall.
•
Check the battery immediately after transport.
•
If the user finds shell deformation or damage to the
battery pack, do not use it and immediately contact Iron
Edison.
4.1 Check the packing list
Item
Specification
Communication cable RJ45+RJ45 150mm length
1pcs
Terminal matching resistance 120 ohm RJ45
1pcs
Wall mounting bracket
1pcs
Expanding screw
10pcs
3. Storage and Transport
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Please follow the steps below to install the battery system.
-Read this manual
-Find your installation location (5.1.1)
-Install wall mounting bracket (5.1.3)
-Install the battery pack (5.1.4)
-Connect the cables (5.2)
-Commission the system (6.0)
-Setup the REVOLT4 Monitor App (7.0)
Normal Operation should begin when the inverter protocols are set in the
REVOLT4 Monitor Application. If not, please refer to 8.0 (Troubleshooting)
-Set parameters in inverter/charger (6.1.3)
(If the inverter is not powered by the batteries, try setting up the REVOLT4
Monitor app first. Some inverters are powered exclusively by the
batteries, and some inverter protocol settings in the monitoring app may
prevent the batteries from powering them. If this is the case, setting those
inverter protocols will allow the inverter to power up for commissioning.
Battery charge parameters are found on 9.0 Datasheet. Questions?
Contact technical support at 720-432-6433. Please consult your inverter/
charge controller manuals for parameters unrelated to battery charging)
5. Battery Installation
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5.1 Installation Location I
n
s
t
a
l
l
a
t
i
o
n
l
o
c
a
t
i
o
n
5.1.1 Environment Requirement
Application Scenarios Residential Battery
Operating Environment Indoors and out of range from
strong electromagnetic radiation
Operating Temperature 0 to 45 C (32 - 110 F)
IP Grade
IP
55
Storage Temperature Short time (<1 month) -20 to 45 C
(-4 to 110 F)
Long time (>1 month) 15 to 35 C
(59 to 95 F)
Operating Humidity
0-85%
Max discharge current vs. Altitude
100 Amps @ < 2000 meters
(<6561ft.) 90 Amps @ 2000
meters - 4000 meters
(6561 ft - 13,123 ft.)
Case Ground Requirement Use at least 2mm2 (#14 AWG)
copper wire with the resistance
of less than 1 ohm
The total weight of the battery is 58kg (127lbs). Please
ensure that the wall or load-bearing wall studs are
strong enough to withstand hanging the battery.
Spanning several studs using a 3/4" thick sheet is
acceptable.
Recommended Clearances:
300mm (8in) left
300mm (8in) top
300mm (8in) right
500mm (12in) bottom
Minimum Clearances:
Note: Using just minimum clearances may
result in difficulty accessing the QR code
for Monitoring App registration without a
pocket mirror. Please plan accordingly.
100mm (4in) left
100mm (4in) top
100mm (4in) right
200mm (8in) bottom
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Attention
The battery should be installed and ventilated in a cool, dry place.
Ensure the battery is installed away from any heat source or direct
sunlight.
For maximum battery performance and longevity, we highly
recommend installing the battery in a temperature-controlled
environment (air conditioned spaces for warm climates and heated
spaces for cold climates).
Failure to follow these instructions may result in the battery cutting
off power output or system failure due to over or under temperature.
Keep the battery 24" from any strong electromagnetic fields to
prevent problems with either the battery communication and/or the
internal power supply. Common sources of electromagnetic
interference are inverters, chargers, and transformers. Keep away
from flammable and explosive materials.
An Important Note on Battery Lifespan
Battery life, longevity, and consistent operation are effected most
by two factors: operating temperature, and voltage range. For best
results, operate only in temperatures from 5°C to 40°C (41°F to 104°
F) and between 48v and 55.6v. The battery will tolerate (with
proportionately accelerated degradation) temperatures from 0°C to
49°C, and voltages from 47 to 56. The BMS will protect the battery
from overvoltage by cutting off charge, but cannot protect against
self-discharge to dangerously low voltage. When the battery
reaches 0% SOC or 47v, stop all discharging and recharge as soon as
possible.
5.1.3 Wall mount bracket Installation
a.
Mark
the
hole
’
s
position
with
a
pen.
b.
Drill holes with a diameter of 12mm (.47in) with an electric
drill
c.
Hammer or screw the M8x60 expansion screws into the
holes.
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5.2 Cable Connection
Caution:
Ensure that battery power is OFF at both the breaker and the power button. A
single short press of the power button will NOT light the LCD screen when the
battery is off. Also ensure while wiring that all power is OFF at inverter.
Never wire to energized circuits.
Use at least AWG 1/0 cable as the battery output power wire.
5.2.1 Wiring Diagram
Inverter Communication Cables Module Communication Cable (RJ45 Connector)
or
Master
Battery
Output
1
st
Slave
Battery
Output
2nd Slave, etc.
Battery
Output
Inverter
+
Inverter
-
Bus-bar/Combiner
120ΩRJ45
120ΩRJ45
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Pin No.
Definition
1
NC
2
NC
3
CANL
4
CANL
5
CANH
6
CANH
7
NC
8
NC
Pin No.
Definition
1
Inverter
RS485B
2
Inverter
RS485A
3
NC
4
NC
5
NC
6
NC
7
BMS debug RS485A
8
BMS debug RS485B
Notes:
1.
Inverters using RS485 protocol should be connected to the MODBUS port of the
master, rather than the CANBUS port as shown above. In all other cases, the
MODBUS ports are left empty.
2.
Use at least AWG 1/0 cable as the battery output power wire.
3.
Each battery should connect to the inverter (or combiner bus-bar) with
identical cable length. This is crucial to the operation and longevity of your
batteries.
4.
In all cases, insert a 120 Ohm resistor into the last battery's right-hand CANBUS
port. When communicating with inverter via CANBUS, the left-most port on the
Master battery will be occupied by that communication cable (RJ45). When
operating without inverter communications, or using MODBUS, insert a 120
Ohm resistor there in the left CANBUS port (in addition to the one at the end of
the chain).
Reference: RJ45 Cable Pin Definition
CANBUS
CANBUS
MODBUS
Both CAN Ports MODBUS (RS485) port
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5.2.2 Dip Switches
Module Number
#1
#2
#3
#4
Single Module
OFF
OFF
OFF
OFF
Master Module
ON
OFF
OFF
OFF
1st Slave Module
OFF
ON
OFF
OFF
2nd Slave Module
ON
ON
OFF
OFF
3rd Slave Module
OFF
OFF
ON
OFF
4th Slave Module
ON
OFF
ON
OFF
5th Slave Module
OFF
ON
ON
OFF
6th Slave Module
ON
ON
ON
OFF
7th Slave Module
OFF
OFF
OFF
ON
8th Slave Module
ON
OFF
OFF
ON
9th Slave Module
OFF
ON
OFF
ON
10th Slave Module
ON
ON
OFF
ON
11th Slave Module
OFF
OFF
ON
ON
12th Slave Module
ON
OFF
ON
ON
13th Slave Module
OFF
ON
ON
ON
Note: When only one battery module is used, set the address as single.
When multiple battery modules are used in parallel, set their address as
Master - 13th Slave. For systems with 15 or more batteries,
contact Technical Support.
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5.2.3 Operating on Voltage Logic
Due to the myriad differences in the communications protocols of the
many 48v inverters on the market, Iron Edison Battery Co. cannot
guarantee the establishment of communications with all third party
equipment. Should communications fail between your particular system
and your batteries, you may simply operate on voltage logic. Set the dip
switches of all batteries to Single Battery per 5.2.2, and disconnect all
communication cables. Every 48v system with programmable charge
parameters is made to operate this way. Your REVOLT4monitoring app
will still work, and you will experience no loss of function or longevity
from your batteries. Call Tech Support if you have any questions.
5.2.4 Disconnection Order
A short circuit will occur in the event of reversing a battery’s negative
and positive cables. Use extreme caution to not reverse polarity when
connecting the battery cables.
Process
No.
Description
1
Stop Charge or Discharge
2
Press each module’s power button until the RUN LED
turns off on each module (about 3 seconds)
3
Open the inverter circuit breaker, then each battery pack
DC breaker at the combiner, then each battery breaker.
4
Disconnect the cables from the battery
5
Disconnect the Inverter and inter-battery comms
cables(RJ45 connector) from the battery module
6
Remove the battery
7
Reset the Dip Switches on the other batteries per 5.2.2
8
Reconnect the comms cablesto the remaining batteries
A short circuit will occur in the event of reversing a battery’s
negative and positive cables. Use extreme caution to not reverse
polarity when connecting or disconnecting the battery cables.
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6.1 Startup Procedure
6.1.1 Startup for a Single Battery
1)
Ensure that battery power is OFF at both the breaker and the
power button. A single short press of the power button will
NOT light the LCD screen when the battery is off. Also ensure
that the breakersto AC loads are open (OFF).
2)
Ensure that all power cables are wired per 5.2.1. Reversing
polarity will cause severe damage to the battery and other
system equipment
3)
Ensure that all battery dip switches are set to the OFF
position per "Single Module" in 5.2.2
4)
Power the battery ON by holding the power button for 3
seconds, then release when battery LEDs flash
5)
Install and set up the REVOLT4 Monitor app per 7.0
6)
Turn ON (close) the battery breaker
7)
Turn ON (close) the inverter breaker/s
8)
Power ON the inverter using its power button (if applicable).
9)
Commission inverter and charge control settings per 6.1.3
10)
Turn ON the PV breakers (if applicable)
11)
Turn AC loads ON
6.Commissioning
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6.1.2 Startup for Multiple Batteries
1)
Ensure that battery power is OFF at both the breaker and
the
power button. A single short press of the power button will
NOT light the LCD screen when the battery is off. Also ensure
that the
breaker to AC loads are OFF
2)
Ensure that all power cables are wired per 5.2.1. Reversing
polarity will cause severe damage to the battery and system
equipment
3)
Ensure that battery dip switches are set to the proper positions
in
5.2.2
4)
Turn
ON
(close)
the
battery
breakers
5)
Power the last slave battery ON by holding the power button for
3
seconds, then release when battery LEDs flash on
6)
Wait 10 seconds, then continue powering up each slave
battery from last to first, waiting 10 seconds between
each, and then
power up the Master battery. At this stage it is
normal to see some flashing green RUN lights and flashing red
ALARM lights as you
power them up
7)
When the Master is powered on, wait 15 seconds, then check
that
all of the RUN LEDs are solid green. Even if they are
not, continue to the next step
8)
Install and set up the REVOLT4 Monitor app per 7.0
9)
Turn ON (close) any/all battery combiner breakers
10)
Turn ON (close) the inverter breaker/s
11)
Power ON the inverter using its power button (if
applicable). If the inverter does not power up and all
battery RUN LEDs are
solid green, consult your inverter
manual
.Pay close attention that the
Inverter Protocol settings
are all identical and appropriate to your
inverter type if
communications were run to the inverter. If
communications
are run between batteries, but not to an inverter,
the inverter
protocol number of each battery must still be identical in
the Wifi App. Set them to 1 in this case.
12)
Commission
inverter
and
charge
control
settings
per
6.1.3
13)
Turn ON the PV breakers (if applicable)
14)
Turn
AC
loads
ON
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6.1.3 Commissioning Inverter/Charger Settings
With so many inverters, charge controllers, and hybrids on the
market, a full description of each commissioning process is
beyond the scope of this manual. Please consult your inverter
and/or charge controller manual, or contact the manufacturers
technical support for help.
At all times, but especially when operating a battery without
communication to the inverter, it is critical that the charge
voltage parameters be set correctly.
Inverter manuals and tech support departments should always
refer you to your battery manufacturer for this small set of
parameters. They are given below, and can be found on the
datasheet at 9.0.
Failing to set proper charge and discharge voltage will almost
certainly damage your batteries and invalidate your warranty.
There is no standardization of language between inverter and
charge controller settings, so Iron Edison has attempted to
include the most common terms for charging parameters among
numerous charge control systems.
If you have questions about the definitions of these
parameters, please contact the manufacturer. If they are
unresponsive, call Iron Edison Tech Support at 720-432-6433.
!! Turn Equalization Off !! Never Equalize Lithium Batteries
Parameter
Recommended
Acceptable Range
Bulk
55.2v
55v-56v
Absorb
55.2v
55v-56v
Absorb Time
6 minutes
5-15 minutes
Absorb End Amps
5a
5a-10a
Float*
53.4v
53v-54v
Recharge/Re-bulk
52.6v
51.6v-52.6v
Generator Start
51v
50.8v-51.2v
Low Batt Cutout
49.4v
48v-50v
*2-stage/no-float is always acceptable, and recommended for
inverter settings when there are charge controllers with float.
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6.2 Battery Information Display
Press the power button to activate the LCD screen (there
is a delay for the screen to activate).
Display
Indicator
Note
Battery voltage
Residual energy
Current power
Negative value indicates
discharging. Positive value
indicates charging.
SOC
State of Charge
Cycle Count
Battery temperature
This manual suits for next models
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