Vision REVO Product User Manual
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Vision REVO Product User Manual

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REVO
Product user manual
Date
Prepared By
Checked By
Approved By
2021.05.10
Ben
Alan
Neil
1

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Table of Contents

Troubleshooting

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Summary of Contents for Vision REVO

  • Page 1 REVO Product user manual Date Prepared By Checked By Approved By 2021.05.10 Alan Neil...
  • Page 2 Term definition The following acronyms meaning used in this manual Battery Management System State Of Charge State Of Health Uninterruptible Power Supply Over temperature Over voltage Under voltage Human Machine Interface Charge OC Charge over current Discharge OC Discharge over current Cell OV Cell over voltage Pack OV...

  • Page 3: Table Of Contents

    Contents 1.Overview ........................6 2.Product description ....................7 3.Safety instruction ....................8 3. 1 Label description........................8 3.2 Installation tools ........................9 3.3 Attention Ietms ........................10 4. MODULE .......................13 4.1 Module description........................ 13 4.2 Module size ....................
  • Page 4 LCD Touch screen display troubleshooting ................44 11.2.3 Routine maintenance ........................ 48 12.System Monitoring .....................54 12.1 VISION APP Download and installation ................54 12.2 Monitor software ......................... 51 12.3 HMI Mornitor ........................55 13.Firmware upgrade ....................66 13.1 Prepare before upgrade ................
  • Page 5 CBMS replacement ........................77 15.Appendix .......................82 15.1 Factory Warranty ............................82 15.2 Limitation of Liability ............................ 82 15.3 About VISION ............................. 83 16.Related annex .......................84 16.1 About storage ............................. 84 16.2 Maintenance ............................... 84...

  • Page 6: Overview

    1 Overview Range of application This manual introduces VISION REVO series product information, operation and maintenance and others .VISION REVO system developed by SHENZHEN CENTER POWER TECH.CO.,LTD. is suitable for high-voltage lithium battery system, which is widely used in UPS backup Power, large energy storage and other applications.

  • Page 7: Product Description

    Product functions and advantages REVO series has four levels of safety protection to ensure the safety and reliability of the system throughout the life cycle; adopts a three-level management architecture design to accurately monitor the status of each component in the system to ensure stable system performance and ensure the safety of user load power supply .

  • Page 8: Safety Instruction

    3 Safety instruction 3.1 Label description In order to ensure the users personal safety when using this product, the manual provides relevant identification information and uses appropriate symbols to remind users. Please read carefully the following list of symbols used in this manual. Table 3.1 safety symbols Low potential danger, if not avoided, that may result in mild or moderate injury .

  • Page 9: Installation Tools

    3.2 Installation tools Table 3.2 tools Tools prepared before installation as follow: Items Tools Multi-meter Protective gloves Insulated shoes Tools Protection suit Safety goggles ESD wrist strap Electric screwdriver Cross screwdriver Socket spanner slot type screwdriver wire stripper Installation tools Clamp meter Laptop Test tools...

  • Page 10: Attention Ietms

    3.3Attention Items 3.3.1 Manual custody This manual contains important information about REVO series Lithium battery. Reading this manual carefully before the operation of REVO series products will help you get familiar with this product.  This manual should be placed in good storage, to ensure that maintenance personnel and other personnel easy to access at any time.
  • Page 11 3.3.4 Personnel requirement  Only qualified personnel can carry out various operations on the product  Operators should be fully familiar with the entire REVO series of product system composition and working principle  3.3.5 Battery protection...

  • Page 12: Module

    The maintenance operation cannot be carried out until the equipment cut off and the charging or discharging has been completed . 4 Module 4.1 Module Specification VISION REVO TP series back up batteries adopt the industry high capacity, high safety...

  • Page 13: Module Size

    LFP battery pack integration. Modules are divided into TP series,TPH series,TPL series. Integrated high-precision BMU units within the module, real-time monitoring and acquisition module voltage and temperature. Realize intelligent temperature control at electric core level and intelligent balance function of battery cell. Thus improving system efficiency and battery cycle life.
  • Page 14 battery current detection, data collection and analysis, alarm and protection control, communication with upper and lower levels, etc. CBMS consists of main circuit circuit breaker, charging and discharging dual-circuit control switch circuit, high-voltage isolation detection circuit, parallel processing circuit, high-voltage power supply and DC starting circuit, LCD display screen, CBMS chassis and related wiring harness.
  • Page 15 LUF16S14D250A-D-7 5.3 CBMS appearance Figure 5.2 CBMS appearance LUF16S10D630A-D-7 CBMS This picture is for reference only, the specific appearance is subject to the actual object. ： The panel specification is illustrated with the example of LUF16S10D250A-D-7 Figure 5.3 CBMS Define mark...
  • Page 16 Table 5.3 CBMS Define Description Item Name Description Remark Address field Dial switch Set up CBMS ID address 0-16) update firmware LAN interface monitor software COM1 COM2 interface with GBMS (Parallel use)/ UPS(Not communication Parallel use) communication Indicator Indicates the current working Charge light status of CBMS...

  • Page 17: Size And Weight

    static, fault state power CBMS power supply supply AC 220V interface public electricity Start up press DC Switch DC start switch 1-3s Communic Interface for communication Communicatio ation with battery modules n interface interface 24VDC output 24V DC output for GBMS and used for power supply GBMS power...
  • Page 18  The picture of the above model LUF16S10D630A-D-7 is for your reference. The specific size is subject to the actual object Table 5.2 CBMS type Size （mm） Type Weight(KG) 650*442*222 LUF16S10D630A-D-7 LUF16S10D250A-D-7 600*440*178.5 LUF16S14D250A-D-7 5.5 LED Indicator status and definition As a human-computer interface, LED indicator indicates the current working status of lithium battery system.

  • Page 19: Breaker

    Normal ● ● Normal discharge Discharge ● ● Warning or Protect Stop ● ● charging and Failure discharging ● Black out，●A red light is always on，●A green light is always on ●Red light flashing ●Green light flashing 5.6 Breaker Each CBMS models are equipped with a circuit breaker to control the DC terminal (P+/P-/N) output .

  • Page 20: Gbms Specification

    After tripping, MCB rotates counterclockwise to the reset position,turn the breaker RESET： to be normal,as follow： In order to prevent the circuit breaker from being damaged, it is forbidden to switch on again within 5 minutes after the circuit breaker trip 6 GBMS specification 6.1 GBMS overview GBMS is the top layer BMS of lithium battery system and it is integrated display for the all...
  • Page 21 In order to unify the manual, this manual is written according to the GBMS version with cloud box, but it is an optional product without cloud box by default. Figure 6.1 GBMS Define Description Item Designation Description Remarks CBMS The connector port with interface CBMS LAN interface...

  • Page 22: Communication Scheme

    , provide the whole system running safety, communications with CAN and RS485 communication type. RS485 protocol can support the MODBUS RTU MODBUS/TCP protocol, the communication signal of REVO I lithium electricity system is as the following figure: Figure 6.1 GBMS description...

  • Page 23: Ethernet

    7.2 Ethernet communication series lithium battery system can support Ethernet communication mode. Single or REVO multiple lithium battery systems can directly connect the RJ45 interface on GBMS LAN port through network cable. Real-time monitoring schematic diagram is conducted by PC monitoring software.
  • Page 24 PC/Latop 8 Junction box (Optional) 8. Junction box overview DC COMBINER BOX used for UPS power back up system ensure the system is easy to cut off the electrical connection during the installation or maintenance, ensure the personnel safety, and at the same time reduce the connecting line between lithium batteries and UPS, reduce the problems point, and it is convenient for maintenance, improve reliability.In general big system ,it need a combiner box in the lithium battery system...

  • Page 25: System Installation

    REVO lithium battery system has passed test and quality control strictly and completely before leaving the factory. Please make a detailed inspection of the products before signing the receipt. If anything is damaged, please contact with Vision and provide details of the damage .

  • Page 26: Loading List

     Please Check whether the package material is intact or damaged .  Please check the quantity of the goods and type on packing list  Please check the internal equipment (including modules, main control box, GBMS, etc.) for any damage Loading list Take the TP200(512V100Ah) module with GBMS (display screen) as an example.

  • Page 27: Mechanical Installation

    blue yarn Power cable 3 95x1550x8,connect with B+， Red and red yarn 95x1000x8，connect with neutral，with SC95-8， Power cable 4 Blue yarn Power output cable 95mm2 Blue insulator cap，Blue insulator cap Power output cable 95mm2 Red insulator cap，Red insulator cap Communication Doubling piece with connector ,Length：...

  • Page 28: Installation Requirements

    REVO series heat dissipation adopts forced air cooling, and the heat dissipation channel is the return air. The REVO series can be installed against the wall. If you need to add ventilation equipment on the top, please contact Center power Technical”.

  • Page 29: Module Handling

    Figure 9.3 Fixed foot installation 9.3.3 Module Handling After determining the position of the cabinet, it is necessary to move the module to the position of the installation point. It is recommended that two people carry the module and wear anti-smash shoes and anti-slip gloves. Manual or machine handling can be decided according to the site situation...

  • Page 30: Cable Connection

    Caution: Pay attention to the weight of the module. It is recommended to carry at least two people to avoid personal safety caused by improper handling. At the same time, wear anti-smashing shoes and anti-slip gloves. 10 Cable Connection 10.1 Connection overview The system is electrically connected to the UPS, including the lithium system to the bus cabinet, and the communication cable connection is shown below,take TP200 as example.

  • Page 31: Terminal Introduction

    Cable connection overview includes power cable, communication cable, BMS ID dial code, etc. 10.2 Terminal introduction 10.2.1 Power terminal The TP20 battery module terminal figure as below： Figure 10.2 terminal overview...

  • Page 32: Electrical Connection Procedure

    10.3 Rack Connection procedure 10.3.1 Electrical connection  Install the main control CBMS and 10pcs TP20 battery modules from bottom to Step top on the specified cabinet, and fix modules on the cabinet with cross head bolts, as shown below Figure 10.3 install overview...
  • Page 33  Step 2： power cables connection for 3 wires Use the provided power cable to connect as shown in the figure. Wear insulation gloves when connecting and use Insolated torque wrench to tighten the bolts. The standard torque is 35 N•m. Figure 10.3 power cable connection overview Note the connection position of the neutral point, as shown in the blue cable above(neutral power cable)
  • Page 34  Module communication cable connection Step 3： The double twisted shielded wire communication cable is shown in the figure below： Figure 10.4 communication cable overview Connect to CBMS from bottom to top according to the communication line connection as shown below, and pay attention to the order of COM1\COM2. Figure 10.5 communication cable connect...
  • Page 35  In order to reduce the signal reflection of communication cables, ensure that the impedance matching continuously in the process of communication, enhance communication stability, in module #10 COM2 connected to 120 Ω terminal resistance.  When multiple cabinets are used in parallel, the battery cabinets...
  • Page 36 should be connected separately, and after the self-checking is successful, confirm that each battery cabinet is normal, then connect to the UPS.  output cables connect for parallels(battery-busbar-UPS) Step Figure 10.6 power cable connect for parallels  GBMS 24V power connection Step Integrated GBMS has been introduced in section 6.2.
  • Page 37 CBMS parallel communication adopts RJ45 physical interface, which is realized by COM1/COM2 of CBMS.Refer to section 5.3 for an introduction to the CBMS interface.The figure below is the schematic diagram of REVO series for parallels. The system realizes communication connection in the form of communication Daisy chain. For...
  • Page 38 Figure 10.8 CBMS parallels communication connection(For cabinet) Figure 10.9 CBMS parallels communication connection(For cabinet) When multiple cabinets are in parallel, the above method has been deduced by analogy, pay attention to enable the CAN/RS485 terminal resistance of CBMS and GBMS is ON...
  • Page 39 AC power connection Step The CBMS main control unit of REVO series system adopts DC and AC double safety power supply mode. When the mains power is normal, the mains power will be supplied by AC first. The specification is 85~264VAC (± 5% variation range), and the frequency is 47~63Hz.
  • Page 40 Figure 10.11 DIP switch overview Table 10.1 DIP dial code The dial-code switch is DIP switch, which is effective when dialed to ON side, indicating that the switch is ON, The four ID dial code keys are independent, for 0/1 binary encoding, 4 ID dial code a total of 16 encoding definition address.
  • Page 41 ID：8 ID：9 ID：10 ID：11 ID：12 ID：13 ID：14 ID：15 In general, the dial code of the lithium battery system connected to GBMS is 1, and the addresses of other cabinets are increased successively according to the above table. The system of the last address should enable can-r / 485-r functions, as shown in the figure below Figure 10.12 CBMS parallels communication connection(For cabinet)
  • Page 42  ground connection Step 9 In a lithium-ion power system, all non-current-carrying metal components and equipment casings should be connected to the ground and nearby.In each device with protective connection, the main grounding terminal shall be configured. In the case of multi-system parallel operation, the main grounding terminal of each device shall be connected to the conductor.The grounding conductor shall be copper conductor, the minimum section of protective ground wire (PE) shall be no less than 6mm2, copper terminal must be installed,...
  • Page 43 Step 10： REVO series lithium battery system provides a variety of communication methods to meet the needs of users :CAN/RS485. The communication interface is unified and integrated on the integrated GBMS. GBMS is responsible for communicating with external equipment to realize information sharing.
  • Page 44 Step 11： In order to provide or accept quick response fault/danger protection actions, our REVO system provides 1 input dry contact I1 and 3 output dry contact D1 D2 D3.Its fault input and output dry contacts are shown in the figure below Figure 10.14 dry contact define...

  • Page 45: Test Run

    battery cabinets will be opened to cut off the output, usually used as an EPO signal The cross-sectional area of dry contact cable should be between 1mm2 and 1.5mm2 11 TEST RUNING 11.1 Starting up 11.1.1 Starting up checking  After installation or maintenance, the lithium battery system needs be started up. Before starting up, please check the following notes carefully to ensure that there is no error.

  • Page 46: Start Up

     If the battery is in the charging and discharging working state and the SOC does not change, please contact the manufacturer 11.1.3 Start up steps When lithium battery system is in normal operation, it is controlled by BMS intelligently without manual interference or control.When the lithium battery cabinet is in normal operation, the cabinet door should be locked tightly and the key of the cabinet door should be pulled out.
  • Page 47 2、Check the maximum setting voltage of battery terminal, and check the setting of protection parameters through LCD or VISION APP Check the minimum set voltage of the whole The system DC voltage is System under set of battery terminal, and check the...
  • Page 48 Low Temperature protection parameter setting through LCD or below the minimum Charging VISION APP. When the temperature rises to charging temperature the reasonable range , the battery is recharged. After setting, if repeated, such as the system completely power off, then the...
  • Page 49 The module temperature is check the protection parameter setting Discharge low below the minimum through LCD or VISION APP. When the temperature discharge temperature temperature rises to the reasonable range of lithium battery system, re-charge and discharge.
  • Page 50 LCD or temperature discharge temperature VISION APP. If reasonable, after the system is completely cut off, overhaul the module and overhaul the cooling fan Please check whether the network cable connected by CBMS is loose or correctly...
  • Page 51 1、Please Check whether the insulation impedance protection parameter setting is normal through LCD or VISION APP; 2、Please check the impedance of the module and the DC cable to the ground, and confirm whether there is voltage to the...

  • Page 52: Routine Maintenance

    A/B line is connected in reverse. If all above loose are normal, please replace the LCD display screen or contact with Vision 1、Determine the position of the defective Loose copper strip of battery cell module, unpack and inspect the welding...
  • Page 53 color change, if so, it must be replaced  Please check whether there is noisy, fan clog or fan Once blade physical defect during operation for fans. If yes, every replace the fan year Every  Please check whether the front and back door of the cabinet and modules are attached with dust.

  • Page 54: System Monitoring

    REVO series of systems. It can establish connection with REVO system through GPRS signal, and users can conduct information query, alarm protection status query, parameter setting and other operations on all running states of the system by using VISION APP . 12.1.2 Download and installation...

  • Page 55: Monitor Software

    Note:regarding the APP ,EMEA is not available now 12.2 Monitor software 12.2.1 monitor software connection The monitor software is a battery monitoring system running on the PC, please refer to the following steps , that means click here. Set the IP address of the laptop, set as follows: Step IP address...
  • Page 57 12.2.2 monitor software home page: BMS real-time monitoring...
  • Page 58 Table 12.1 monitor software overview item Designation Description Navigation area Display monitoring software different monitoring Settings functional area Overall monitoring area of Displays the current running state of the the system system Module information area Display the system module state, temperature voltage state Device information Display product model, software version, etc...
  • Page 59 Table 12.2 BMS parameter overview Item Designation description System parameter Used for setting system information, including rated capacity, number of modules, etc Battery module Used to set the overall protection value of the system, parameters charging and discharging current value Single cells It is used to set over voltage and under voltage protection parameters...
  • Page 60 temperature Used for setting the protection value of charging and parameter discharging at high temperature and low temperature Others Used for setting fan control parameters, parallel voltage parameters, etc When the product leaves the factory, the parameters are set by default to ensure the system safe operation of the system.
  • Page 61 Support IAP upgrade Support HMI display and parameter setting Dry contact output 3 output (0.5A@125VAC;1A@24VDC) Dry contact input 1 input ≤15 Number of CBMS supported for management powered by 24VDC(18~28V) Power consumption 15W MAX.4.8W Normal Dimensions 66*280*170mm 12.3.3 Homepage Figure 12.2 GBMS homepage preview After the HMI starts, the home page will be displayed, and the content of the home page is as follows:...
  • Page 62 Table 12.4 HMI interface overview Item Description check System self-check status, self-check failure is red cross, pass is green tick Status Display real-time charge and discharge status Power Display real-time power Current Display real-time system current Voltage Display real-time system voltage Click to display the system monitoring page Monitor Click to view the system cell data...
  • Page 63 Table 12.5 HMI homepage overview Item Description Voltage System voltage Current System current Cell_Max Maximum cell voltage Cell_Min Minimum cell voltage Temp_Max Maximum cell temperature Temp_Min Minimum cell temperature RACK CBMS number of Maximum value Module number of Maximum value 12.3.5 Cell data After clicking the icon on the home page, enter the cabinet selection page, you can...
  • Page 64 Figure 12.4 Cell data preview 12.3.6 Alarm/protection page Click the icon on the homepage to enter the alarm protection page. Figure 12.4 Alarm/protection preview...
  • Page 65 12.3.6 Parameter setting page After clicking the icon on the homepage, enter the password: 8888 in the pop-up login box to enter the parameter setting page. Currently, it only supports setting the parameters of GBMS itself,GBMS needs to set the rated capacity of the system, the number of modules in a single cabinet, the number of battery strings in the module, the number of temperatures in the module, and the number of CBMS that need to be managed Table 12.6 GBMS parameter setting overview...

  • Page 66: Firmware Upgrade

    13 Firmware upgrade 13.1 Prepare before upgrade Table 13.1 GBMS parameter setting overview Item Name Description Laptop or PC Windows 7 and above version system Upgrade software BMS_Upgrade_Tool.exe Ethernet cable connect BMS LAN port and computer/laptop 13.2 Upgrade Steps  Step 1 Close the anti-virus software of the security guard on the computer, close the firewall of the computer itself, and prevent the upgrade program from being intercepted by mistake...
  • Page 67  Step 3 The IP address of the Laptop/computer's wired network card is set as follows: Table 13.2 IP address of the Laptop setting 192.168. IP address 0.110 255.255. Subnet mask 255.0 192.168. Default gateway Preferred DNS 192.168. server  Step 4 Disable the computer's wireless network card (if it's a laptop).

  • Page 68: Trouble Shooting

     Step 5 When the device is connected, it will be displayed in the list of online devices on the left. At this time,check the device,then click the "Start Upgrade" button to start the upgrade. Figure 13.1 upgrade firmware steps 2 upgrade 1 Select IP ...

  • Page 69: Spare Part

    BMS can be connected, 1．Is the ethernet cable loose during upgrade? but the upgrade display 2．Is the equiment shutdown during upgrade? failed 14 Spare part 14.1 Spare part list Spare parts are the main material basis for system repair, and timely supply of spare parts can shorten repair time, reduce system losses, and improve equipment reliability Table 14.1 spare part overview No.

  • Page 70: Spare Part Replacement

    Module LFP51.2V module,442mm width GBMS Display GBMS integrated 14.2 spare part replacement 14.2.1 Module replacement When the battery module has a cell failure or abnormal voltage/temperature/communication collection, we need to repair or replace the module. When replacing a new module, we must pay special attention to the SOC of the new module. Generally speaking, it is necessary to recharge the new module to make the same SOC level with the older modules.
  • Page 71 Recommend: start the charger (CC/CV mode), charge voltage: 54.4V (3.4V/cell), charge current 0.2C, cut-off current 0.1C  Step 3 Disconnect the MCB of the cabinet CBMS where the abnormal module is located to ensure that we can remove the faulty module in the case of power off. Figure 14.2 MCB OFF ...
  • Page 72 Disconnect the power cable and fixing screws of the faulty module, remove the faulty module, pay attention to the weight of the module, it is recommended to use a lift truck to unload and transport the module. Figure 14.3 module replacement...

  • Page 73: Fan Replacement

     Step 5 Reconnect the power and communication cable, power-on CBMS to self-check, check whether the system has returned to normal after replacement Noted: Check whether all the states of the new module are restored to normal, including battery cell voltage, temperature, and communication status, which can be viewed through LCD or monitoring software 14.2.2 Fan replacement The battery module is cooled by air, and the cooling fan is located behind the module, which is...
  • Page 74  Step 2 Take out the fan module and disconnect the fan power plug  Step 3 Loosen the fan fixing screws Figure 14.5 remove FAN fixing screws  Step 4 Replace the FAN and fix it back again on the module plate Figure 14.6 replace the FAN...

  • Page 75: Gbms Replacement

    14.2.3 GBMS replacement During system running, GBMS needs to be replaced when it cannot communicate or the display cannot work or other hardware problems. GBMS replacement is easy and will not affect the battery to supply power to the load online.Please check the following steps ...
  • Page 76  Step 2 disconnect the GBMS 24Vdc plug Figure 14.7 disconnect GBMS power plug...

  • Page 77: Cbms Replacement

     Step 3 Loosen the GBMS fixing screw and remove it to replace. Figure 14.8 replace GBMS 14.2.4 CBMS replacement...
  • Page 78 When the CBMS has a communication failure, the contactor cannot be closed due to the failure of the self-check, and the circuit breaker fails to close, etc., check if it is a hardware problem, consider replacing the CBMS.  Step 1 All the MCB of the CBMS must be disconnected, CBMS DC bus voltage must be cut off for safety operation.
  • Page 79 If there is no junction cabinet between the UPS and the battery cabinet, you need to turn the UPS to the bypass mode to make sure that no high DC Voltage output from the UPS DC side.  Step 3 Disconnect the battery output DC cable.At the same time, pay attention to the insulation of the exposed output wire terminals Figure 14.11 disconnect all the CBMS cable...
  • Page 80  Step 4 Figure 14.12 Remove all fixing screws of CBMS  Step 5...
  • Page 81 Move out of CBMS, pay attention to the weight of CBMS. Figure 14.13 move out of CBMS Noted: 1)The tools used by installation and commissioning personnel must have insulation protection. 2) During installation, debugging and maintenance, you must wear insulated rubber gloves, goggles and insulated rubber boots as appropriate to avoid safety accidents as much as possible.

  • Page 82: Appendix

    15 Appendix 15.1 Factory Warranty Our company promises that during the warranty period, any defective products of REVO system will be replaced with free of charge which customers must provide the purchase invoice and relevant warranty information of the products. Otherwise, our company has the right not to guarantee the quality.

  • Page 83: About Vision

    15.3 About VISION If you have any questions in the process of using or installing the product, please contact the relevant personnel of Vision in time. Our company will arrange relevant after-sales service in time. Contact information is as follows...

  • Page 84: Related Annex

    16 Related annex 16.1 About storage a. Short-term lithium storage：When the lithium battery is not used for a short period of time(≤6 months), the battery shall be store in a cool and dry environment. b. the storage temperature range: 20℃~35℃, the relative humidity range is 35%~85%. c.
  • Page 85 Step 3、 Turn on the charger Start charging until charging is stopped automatically, it can be regarded as charging completed, and turn off charger equipment.

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