BYD Battery-Box C130 Installation Manual Download Page 48

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The specific test information is as followings:

1. Insulation resistance test:

@500v, 10 sec

—

Resistance

＞

10MΩ

2. Puncture test

：

@2,5kV AC, 60 sec---Current

＜

20mA

LOW

HIGH

TEST

Grounding Point

OUT+

Insulation Resistance Test, Puncture Test

Grounding Point

OUT-

Grounding Point

BAT+

Grounding Point

QLI-3

Grounding Point

QLI-2

Grounding Point

BATT-

OUT+

OUT-

Puncture Test

BAT+

QLI-2

BAT-

QLI-3

3. Each cabinet Grounding Impedance

＜

0.2

LOW

HIGH

Grounding Rail

PDU cover

Grounding Rail

Metal frame cabinet 1

Grounding Rail

Metal frame cabinet 2

Grounding Rail

Metal frame cabinet 3

Grounding Rail

Metal frame cabinet 4

Grounding Rail

Metal frame inverter cabinet

7.4.2

Connect the rest modules

•

Screwing the connectors/bus bar with same methods. Apply the torque of 18 N·m, and draw

a red mark. (See Figure55)

•

Put on the terminal cover. (See Figure56)

Figure55

Figure56

Summary of Contents for Battery-Box C130

Page 1: ...English Version1 1 Battery Box C130 Installation Manual ...

Page 2: ...n of Installation 10 Requirements 10 Space for installation 10 4 List of Needed Tools 12 Safety Gears 12 Needed Tools 12 5 Scope of Delivery 14 Main Parts 14 Accessories 15 6 Product Overview 17 Technical Data 17 System Structure 17 Battery Modules 19 Power Distribution Unit PDU 19 7 Installation 21 Unpacking and Placement of Cabinets 21 7 1 1 Unpacking 21 7 1 2 Checking the Accessories and Cabine...

Page 3: ...of Battery Installation 47 7 5 1 Checking all Wirings and connections 47 7 5 2 Check the torque has been applied on all points the power cable points 48 7 5 3 Install the PDU front cover 48 7 5 4 Install White Baffles 48 7 5 5 Reinstall the 3 white doors 49 7 5 6 Inverter EMS Grid Installation Connection 49 8 Installation Check list 50 9 Trouble Shooting 51 Commissioning 51 Errors of System 51 Err...

Page 4: ...or any damage caused by non compliance with this manual from improper use of the product repairing opening of the modules or any other action taken by anyone other than qualified personnel BYD shall not be liable for any damages including indirect incidental or consequential damages resulting from the reliance on the material presented including but not limited to omissions in the content typograp...

Page 5: ...ocument for proper installation DANGER Improper operating will result in a hazardous situation with serious accident causing death or a severe injury WARNING Improper operating may result in a hazardous situation with serious accident causing death or a severe injury CAUTION Improper operating may result in a hazardous situation with minor or moderate injury NOTICE The information is considered im...

Page 6: ...formation and instructions contained in this document may only be performed or operated by qualified personnel This document is intended exclusively for authorized and trained party Version History Version Date Responsible Changing V1 0 2019 07 28 BYD First edition issued V1 1 2019 09 20 BYD C130 version Added V1 11 2019 02 11 BYD Checking Protocol added Compatible Inverter Lists CAUTION The produ...

Page 7: ...pose of the product together with the household waste but in accordance with the disposal regulations for electronic waste applicable at the installation site CE marking The product complies with the requirements of the applicable EU Directives Place it straight up without inclination or upside down Handle with care Keep it dry Recycle Keep the battery modules away from open flame or ignition sour...

Page 8: ...e system is not suitable for supplying life sustaining medical devices Please ensure that no personal injury would lead due to the power outage of the system Alterations to the BYD system e g changes or modifications are not allowed unless the written permission of BYD Europe B V is achieved The enclosed document is an integral part of this system Keep the documentation in a convenient dry place f...

Page 9: ...tective equipment for all work on the product Please perform all the work in accordance with the warning signs attached and the safety instructions in the manual Do not contact any module terminal or power cable directly or non insulated parts with the hand or any other part of the human body Disconnect the product from voltage sources and make sure it cannot be reconnected before working on the d...

Page 10: ...personal injury and property damage Read this section carefully and observe all safety information at all times The information contained in this part need to be observed all time during installation DANGER Improper handling of module will cause the damage of product and the personal injury Please avoid the following mistakes Do not dissemble the module Do not charge this product or the module wit...

Page 11: ...ting torque specified in the document Ensure that the inverters are approved for use by BYD Set the correct battery values for in Inverter and EMS when configuring WARNING Chemical burns due to battery electrolyte If handled inappropriately battery electrolyte can leak from the battery and cause irritation to the eyes respiratory system and skin Whenever working on the battery wear suitable person...

Page 12: ...d wait for further handling c The electrolyte is slightly corrosive to the human body Please avoid contact with it as much as possible d Clear the electrolyte with gauze or similar material e If it accidentally comes into contact with the human body rinsing it immediately with water If it splashes into the eye wash it immediately with 2 4 boric acid and seek medical attention in hospital f If you ...

Page 13: ...xposure to harsh temperatures may impact battery performance and life 4 This product should not be placed in an environment with corrosive atmospheres 5 If this product is installed in a coastal area or a farm the room should be additionally reinforced to ensure that the product would not be damaged during operation If the installation location is vulnerable to flooding be sure to install the prod...

Page 15: ...voltage Insulating Gloves For insulation against voltage up to 1000V 3 Safety Helmet Protection from falling from cabinets or heavy objects Safety Shoes For feet protection against injury by falling object Ground insulation Needed Tools Name Remarks Reference picture 1 Combination tool kit HW3 PD1 TX25 TX35 and MX8 screwdriver tips and 10 mm and 13mm sockets should be included at least 2 Electric ...

Page 16: ...Puncture Tester Insolation resistance test Grounding Impedance test Dielectric withstand test 8 Straight screwdriver 3 mm wide For inserting wires into the connector 9 Stacker For lifting the battery modules and PDU 10 Commissioning computer For checking the battery status 11 CAN box For connecting the product and the commissioning computer 12 CAN box connecting cable For connecting the CAN box 13...

Page 17: ...ease contact BYD authorized service partner if any missing or damage is founded Main Parts No Designation Qty Packing condition Reference picture Main Parts Battery cabinet 2 In 3 wooden cases Battery cabinet With PDU 1 Inverter cabinet 1 In 1 wooden case Battery module 19 In 10 Boxes 54x 2x 40x 15x 16x 1x 19x 19x 38x 3x 4x 7x 5x 205x 18x 36x 9x 12x 1x ...

Page 18: ...0 30 3 Cabinets Combination Bolt M10 55 1 Cabinets Combination Nut M10 4 Cabinets Combination Modules Communication Cords 6 Module BMS connection Module Copper Connectors 6 Modules Power Connection Modules Hangers 14 Modules Installing Modules Terminal Cover 40 Protection of Terminals Cabinet Ground wire 3 Grounding between cabinets Terminal Plastic Cap 7 Short Circuit Prevention on Modules strap ...

Page 19: ...s Installing Cabinets Baffle 5 Covering Cables Case 3 Bolt M6 16 60 Modules Connecter and Hangers Self tapping Screws M5 10 16 MODULE BMSs Installing Hexagonal nut 6 Cabinets Combination Hexagon socket head cap screw M6X10 12 Cabinets Combination Bolt M10 30 3 Cabinets Combination Bolt M10 55 1 Cabinets Combination Nut M10 4 Cabinets Combination Modules Communication Cords 6 Module BMS connection ...

Page 20: ... on the terminals between modules M6 16 18 N m 6 Product Overview Technical Data Technical Specifications Usable Energy 131 kWh Max Output Current 150A Nominal Voltage 729 6 V Operating Voltage Range 638 4 820 8 V Operating Temperature 10 C to 50 C Communication RS485 CAN Dimensions W H D 2200 x 2600 600 mm Weight Per System 1751 kg Weight Per Module 64 kg Cells Lithium Iron Phosphate Enclosure Pr...

Page 21: ...18 Copyright BYD Europe B V all rights reserved battery cabinets contain 19 battery modules and 1 PDU in total Inverter Cabinet Battery Cabinet 1 Battery Cabinet 2 Battery Cabinet 3 PDU Modules ...

Page 22: ...l unit The positive and negative terminal housings should always cover the terminals until connection of the terminals and should be fitted immediately after connection of the terminals Power Distribution Unit PDU The PDU is mainly functioning on distribution and controlling of the power supply Terminal housing Fan Module BMS Fan power cord connector Fan control cord connector J2 interface J3 inte...

Page 23: ...he switch ON After the power button is pressed the PDU is powered and the indicator light turns green To turn on the system close the switch and then press the power button To turn off the system press the power button and then turn off the switch If the product is not intended to use for a long time the system should be turned off at the time it is not being used The state indicator illuminates i...

Page 24: ...les can only be lifted to cabinets by lifter stacker Lifting the battery modules manually will cause muscles strains personal injury Be sure to wear protective equipment such as safety shoes safety helmets protective gloves etc Do not stack the cabinet packages with more than 2 layers The wooden cases will be damaged by the heavy weights Unpacking and Placement of Cabinets 7 1 1 Unpacking CAUTION ...

Page 25: ...peratively See Figure4 5 Check the cabinets for damage structural damage paint peeling damaged or protruding screws CAUTION Please contact BYD authorized service partner if any missing or damage is founded 7 1 3 Cabinet Placement Following the labeled number of cabinets place the cabinets side by side The numbers are showed on the packing cases as well as inside of cabinets See Figure6 The finishe...

Page 26: ...the 3 battery cabinets and the inverter cabinet Use diagonal pliers to pull up the upper sheath at the cabinet door connection and pull down the lower sheath to separate each door from cabinet See Figure8 Keep the doors properly See Figure9 7 1 5 Combining the cabinets Install the cabinet combiners in an order from top to down See Figure14 with 9 combiners Install all combiner with M6x10 screws Ap...

Page 28: ... BYD Europe B V all rights reserved 7 1 6 Grounding of Cabinets Grounding the 2 PE cables in the 2 cabinet See Figure15 16 17 Using original screws to screw the cables with 10 N m torques Figure15 Figure16 Figure17 ...

Page 29: ...nt on PDU DC line Cable Port of PDU OUT OUT OUT OUT S1P TO BATT BAT S2P TO QL1 3 QLI 3 S1N TO QL1 2 QLI 2 S2N TO BATT BATT Communication line Cable Port of PDU Function RJ45 Network CN 3 Network connection TXY02 TO PDU CN8 CN 8 CAN Bus of modules TXY06 07 08 TO PDU CN5 CN 5 1 2 3 Fan power cables PDUs power cord CN1 PDUs power supply Connecting the communication cable Cable port port A J2 at modul...

Page 30: ...uld be laid Observe every labels to make sure it s connected to the right place Battery modules are not installed at this stage In order to make it understandable where to lay the cables and wires we put them in the figures 1 Place the OUT cable OUT cable RJ45 network cable and PDU power cord to near the installation point in PDU According to Figure19 Figure19 Line Arranging 1 OUT OUT ...

Page 31: ...o OUT port in PDU See Figure20 Connecting the OUT Cable to OUT port See Figure21 Plug the RJ45 network Cable to CN3 port Plug in the PDU power cord to CN1 port Screw the Power cable with original Screws in the PDU Figure20 RJ45 Network PDU Power cord Figure19 Line Arranging 1 ...

Page 32: ...29 Copyright BYD Europe B V all rights reserved Then torque all Power Cable with 18N m And draw a mark across the bolt nut spring washer and lug with a marker Figure22 Figure21 Figure22 ...

Page 33: ...om cabinets and PDU Lay the 3 power cables from cabinet1 to the installation points According to Figure23 Connecting the S1P TO BATT Cable to Batt port in PDU Screw and torque with 18Nm and draw a mark with marker See Figure25 Figure24 Figure25 Figure23 Line Arranging 2 S1P TO BATT S2P TO QL1 3 ...

Page 34: ...le to QLI3 port Screw it in PDU Screw and torque with 18Nm and draw a mark with marker Lay the power cable from cabinet2 to the installation points According to Figure26 Lay the 2 power cables from cabinet3 to the installation points According to Figure27 Figure26 LIne Arranging 3 ...

Page 35: ...ved Connecting the S1N TO QL1 2 Cable to QLI2 port Screw and torque with 18Nm and draw a mark with marker Connecting the S2N TO BATT Cable to Batt port Screw and torque with 18Nm and draw a mark Figure27 Line Arranging 4 S1N TO QL1 2 S2N TO BATT ...

Page 36: ... BYD Europe B V all rights reserved 3 Lay the fans power cord from each cabinet to the PDU according to Figure28 Plug in the 3 fan power Cables to CN5 1 CN5 2 CN5 3 ports in PDU separately Figure28 Line Arranging 5 ...

Page 37: ...34 Copyright BYD Europe B V all rights reserved 4 Lay the communication cables between the cabinets according to Figure29 Plug in the communication cable into CN8 port in PDU Figure29 Line Arranging 6 ...

Page 38: ...The power terminals on modules are protected with covers to prevent short circuit Please make sure the covers are always on the modules except testing or connecting the power connectors 7 2 1 Unpacking the Modules Unpack each hazardous chemical packing box take out the module and check whether the battery module is damaged Figure31 Figure34 Figure33 Figure32 ...

Page 39: ...ger with a tightening torque of 6 5 N m See Figure37 7 2 2 Testing Modules Voltages NOTICE The positive and negative terminals of the module are protected by a cover to prevent the risk of short circuit Put on the new cover to each terminal after voltage testing The original cover is only for protection during shipping If any failure or abnormal voltage on module was founded please contact BYD aut...

Page 40: ...ee Figure39 7 2 3 Installing Modules to Cabinets Move the stacker close to the modules packages See Figure40 2 persons move the modules from the package to the stacker The front of modules is facing to the stackers This is the right direction of installing two cabinets See Figure41 Use a stacker to place modules into cabinet from top to down and from left to right Be sure not to knock the cabinet ...

Page 42: ...ing torque of 6 5 N m See Figure44 7 2 5 Modules Number in system NOTICE Numbering the modules will help to calibrate and identify the abnormal modules in troubleshooting It also makes it easier to find the right points for power cables connections Figure44 Figure45 Modules Sequence Number 1 2 3 10 11 12 19 18 17 16 15 14 13 9 8 7 6 5 4 ...

Page 43: ...es between Modules Connect the communication cords between the two modules in a cabinet See figure 46 Connect port A to the J2 interface shown connect port B to the J1 interface of the module below and connect port C to the fan control line interface See figure 46 47 Figure47 A B C Figure46 A B C ...

Page 44: ...ction cover the terminals to prevent the accidently contact CAUTION Before operating high voltage wiring harnesses connection be sure to wear insulating gloves and safety shoes Before connecting the power output cable and performing subsequent power cable operations make sure that the PDU switch is off The positive and negative poles of each module are marked Exercise extreme caution to prevent th...

Page 45: ...nt Leave it open until the tests were finished 2 Connecting modules to modules NOTICE Always plug in the Plastic Caps before connecting modules Plastic Caps were designed for danger prevention In case of short circuit within module caused by wrong operation plug in the plastic caps in every module within 1 cabinet See Figure50 Take out the terminal cover cabinet Figure 1 Modules Power Connection F...

Page 46: ...g the connectors bus bar with M6 16 screws on the terminals between 2 different modules Apply a torque of 18 N m and draw a red mark See figure 52 53 54 Put on the terminal cover and keep the cover open all time Figure50 Figure51 Figure52 Figure53 Figure54 ...

Page 47: ...ct the master positive terminal and negative terminal of the battery before performing the test 2 Test grounding to all power points If the tester has no alarming the test passed Otherwise test failed Puncture Test Power the testing point with 2500VAC 3110VDC Voltage With duration time 60s No flashover or breakdown is allowed The leakage current should be 20mA Puncture tester 1 Disconnect the mast...

Page 48: ...ng Point QLI 2 Grounding Point BATT OUT OUT Puncture Test BAT QLI 2 BAT QLI 3 3 Each cabinet Grounding Impedance 0 2 Ω LOW HIGH Grounding Rail PDU cover Grounding Rail Metal frame cabinet 1 Grounding Rail Metal frame cabinet 2 Grounding Rail Metal frame cabinet 3 Grounding Rail Metal frame cabinet 4 Grounding Rail Metal frame inverter cabinet 7 4 2 Connect the rest modules Screwing the connectors ...

Page 49: ...he voltage between BATT and QLI 2 and between QL1 3 and BATT If the voltages are between 345 398V the installation could continue Otherwise the connection of the power cables should be checked again See figure Figure57 58 LOW HIGH VOLTAGE BATT QLI3 345V 358V QLI2 BATT 384V 398V BATT BATT 1V Figure58 Figure57 ...

Page 50: ...and connections Check the PDU power input cable output cable PDU power cord network cable grounding wire communication cables between modules and fan wirings are connected properly Follow the 2 diagrams in showed below See Figure59 60 Figure59 High voltage Wiring Diagram A Figure60 Low Voltage Wiring Diagram B ...

Page 51: ...ints the power cable points 7 5 3 Install the PDU front cover Screw the cover with S3 hexagon head bolt See Figure61 7 5 4 Install White Baffles Screw white panels in the cabinets See Figure62 White panels are designed for covering the cables in the cabinets See Figure63 Figure61 Figure63 Figure62 ...

Page 52: ... 7 5 5 Reinstall the 3 white doors Plug in the power cable of PDU indicator on the 2 cabinet door See Figure64 7 5 6 Inverter EMS Grid Installation Connection Refer to the instruction or Installation Manual of inverter manufacture Figure64 Figure65 ...

Page 54: ...facture s instruction Errors of Battery Check the indicators on the front PDU to determine the state of the battery DC side An error state of battery is displayed on the LED indicator Which will be showed as RED light The Warning is triggered when the voltage temperature current etc is detected beyond designed limitations The Battery BMS keep sends status messages to Inverter EMS The system will b...

Page 55: ...upper computer Via CAN box to PDU port 5 Checking all status messages warnings of battery showed on BMS interface 6 Perform corresponding methods to the errors See Instruction of BMS software 3 N A 1 or few Modules voltage or temp value is abnormal Over voltage or under voltage Over temp or under temp CAUSES Failed BMU Failed modules Modules internal failure ACTION 1 Checking all the of communicat...

Page 56: ...een lit on off on the PDU then switch off the PDU handles Shut Down the Inverter Please see documentation of the Inverter manufacturer Turn on the System Make sure the PDU external power supply is available 1 Turn the switch to the vertical position Then press the green lit on off switch on the PDU 2 The green LED indicator illuminates in green when the battery is on Figure66 Figure67 Figure68 Fig...

Page 57: ...nal testing institute such as PI Berlin or TÜV SUD for the remaining usable energy claim g If the product was not installed within one 1 month from Warranty Start Date h If the product was not operated with a BYD certified inverter according to BYD Compatible Inverter List Appendix 1 i If the Product has been modified or repaired without the approval of BYD or BYD Partner j If the Product was dama...

Page 58: ...the product with your household waste 3 Avoid expose the batteries to high temperature or direct sunlight 4 Avoid expose the batteries to high humidity or corrosive atmospheres 5 For more information please contact BYD 13 Service Contact BYD Authorized Service Partner EFT Systems GmbH Address Buchenstr 37 97816 Lohr a Main Customer Service Mailbox service eft systems de Telephone 49 9352 8523999 D...

Page 59: ...ds Product Serial Number Product Version C60 C130 C230 Inverter Type 13 1 2 Modules Records NO Serial Number Voltage NO Serial Number Voltage 1 15 2 16 3 17 4 18 5 19 6 20 7 21 8 22 9 23 10 24 11 25 12 26 13 27 14 Testing Records TESTS LOW HIGH YES NO Insulation Resistance Grounding Point OUT Grounding Point OUT ...

Page 60: ... each labels See figure 7 1 9 Checked every torque and marks on every connection points 10 All components are in connection box is installed and connected Post turning on the system If any of these items is checked as NO Turn off the PDU switch first Then press the power button on PDU If needed turn off the AC power 11 The PDU indicator is on GREEN Light No RED light 12 The meter is connected 13 T...

Page 61: ...17 Error simulation Turn off EMS during charging and discharging The system can be shut down automatically POST Installation 18 Educated the user on safety knowledge included but not limited on Dangerous warnings safety restrictions emergency instructions etc 19 Educated the user on system functions included but not limited on System components functions Parameters etc 20 Supplied user with suffic...

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