BYD Battery-Box C130 Installation Manual

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Battery-Box C130

Installation Manual

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Version1.1

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Page 1 Battery-Box C130 Installation Manual English Version1.1...
Page 2: Table Of Contents
CONTENT Information of this Manual ................3 Purpose ........................3 Validity ........................3 Target Group ......................3 Version History......................3 Compatible Inverter Lists ..................3 Acronyms and Abbreviations .................. 3 Safety ........................ 4 Symbols in Document/Product： ................4 Safety Instructions ....................5 2.2.1 Intended Use ....................
Page 3 7.2.2 Testing Modules Voltages................. 36 7.2.3 Installing Modules to Cabinets..............37 7.2.4 Fixing Modules..................39 Modules’ Number in system ..............39 7.2.5 Cables between Modules ..................40 7.3.1 Communication Cables between Modules..........40 7.3.2 Power cables between Modules............... 41 Insolation Resistance &...
Page 4 BYD shall not be liable for any personal injury, property damage, 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.
Page 5 CAUTION Improper operating may result in a hazardous situation with minor or moderate injury. NOTICE The information is considered important and need to be paid attention. The information relates to property damage. Copyright© BYD Europe B.V. all rights reserved.
Page 6: Information Of This Manual
The product must only be operated in connection with a compatible inverter. Manufacture Type REFU REFUStore 88K Acronyms and Abbreviations Abbreviations Full Name Energy Management System Battery Management System Power Distribution Unit (part of BMS) Copyright© BYD Europe B.V. all rights reserved.
Page 7: Safety
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 sources. Beware of electrical voltage. The product operates at high voltages. Beware of flashover voltage Copyright© BYD Europe B.V. all rights reserved.
Page 8: Safety Instructions
The 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.
Page 9: General Instructions
4. Knowledge of and adherence to this document and other documents associated with the product including all safety instructions 5. Training in the installation and commissioning of electrical devices 6. Trained by BYD or organization authorized by BYD. 7. Electrical and installation qualification certificates issued with local permission. 2.2.3 General Instructions To prevent personal injury and property damage.
Page 10: Handling Modules
Please avoid the following mistakes. • Do not dissemble the module; • Do not charge this product or the module with a charger that is not approved by BYD; • If electrolyte leakage is identified, stop using the product and contact a BYD Authorized Service Partner immediately;...
Page 11 • Ensure that all pole connectors are connected with the connecting 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.
Page 12: Surge Protection
Observe the following precautions when the module has electrolyte leakage. Stop using the battery immediately. Isolate the battery and make sure that it cannot be used any longer. Contact BYD and wait for further handling. The electrolyte is slightly corrosive to the human body. Please avoid contact with it as much as possible.
Page 13: Location Of Installation
10. Assembling the Storage System must be done in the final desired destination, afterwards moving the battery is no longer possible. Space for installation. The available space reserved for this product should at least meet the requirement shown as following. (See figure 1) Copyright© BYD Europe B.V. all rights reserved.
Page 15: List Of Needed Tools
Remarks Reference picture HW3, PD1, TX25, TX35 and Combination tool MX8 screwdriver tips and 10 mm and 13mm sockets should be included at least. Electric screwdriver For use in conjunction with screwdriver tips Copyright© BYD Europe B.V. all rights reserved.
Page 16 For checking the battery computer status. For connecting the product and the commissioning CAN box computer CAN box For connecting the CAN box connecting cable Upper computer Software installed in the software commissioning computer. Copyright© BYD Europe B.V. all rights reserved.
Page 17: Scope Of Delivery
5. Scope of Delivery Checking the completeness of delivered parts and check if there’s a visible damage. Please contact BYD authorized service partner if any missing or damage is founded. 205x Main Parts Designation Qty. Packing condition Reference picture Battery cabinet...
Page 18: Accessories
Grounding between cabinets wire Terminal Plastic Short Circuit Prevention on Modules strap Cabinets Keys. Open Cabinets Modules Connecter Bolt M6*16 and Hangers Self-tapping Case #2 Module BMS Installing. Screws M5*10 Hexagonal nut Cabinets Combination Copyright© BYD Europe B.V. all rights reserved.
Page 19 Cabinets Combination Bolt: M10*55 Cabinets Combination Case Nut: M10 Cabinets Combination Modules Module BMS Communication connection Cords Module Copper Modules Power Connection Connectors Modules Hangers Modules Installing Module BMS Modules Controllers Cases Straps Copyright© BYD Europe B.V. all rights reserved.
Page 20: Product Overview
Peak Shaving/ Self Consumption/ Standard EV Charging/ Intelligent EV Charging Application (Optional)/ Frequency Regulation (Optional) / Backup System Structure This system consists of 4 cabinets, including 3 battery cabinets and 1 inverter cabinet. The 3 Copyright© BYD Europe B.V. all rights reserved.
Page 22: Battery Modules
Fan power cord connector J2 interface J3 interface J1 interface Power Distribution Unit（PDU）. The PDU is mainly functioning on distribution and controlling of the power supply Cover mounting hole Power button and indicator Switch Copyright© BYD Europe B.V. all rights reserved.
Page 23 When the PDU is not powered, the indicator will not illuminate. • 右侧盖板 Cable entry hole 1 Cable entry hole 3 Cable entry hole 2 Cable entry hole 4 Copyright© BYD Europe B.V. all rights reserved.
Page 24: Installation
• There should be 2 persons to remove the wooden cases. (See Figure3) • Taking out the parts and keep them properly • Taking out the cabinet from the wooden cases (See Figure4) Figure2 Copyright© BYD Europe B.V. all rights reserved.
Page 25: Checking The Accessories And Cabinets
• Check the cabinets for damage: structural damage/ paint peeling/ damaged or protruding screws. Figure5 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.
Page 26: Remove All Front Doors
• Install the cabinet combiners in an order from top to down(See Figure14), with 9 combiners. • Install all combiner with M6x10 screws. Applying a torque of 6.5 N·m. The process showed below. (See Figure10-13) Copyright© BYD Europe B.V. all rights reserved.
Page 28: Grounding Of Cabinets
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 Copyright© BYD Europe B.V. all rights reserved.
Page 29: Removing The Pdu
TXY06/07/08 TO PDU CN 5-1/2/3 Fan power cables PDUs power cord PDUs power supply  Connecting the communication cable Cable port port J2 at modules BMU J1 at below modules BMU Fan control Copyright© BYD Europe B.V. all rights reserved.
Page 30 (1) Place the “OUT+” cable, “OUT-“ cable, “RJ45 network” cable and “PDU power cord” to near the installation point in PDU. According to Figure19. OUT+ OUT- Figure19 Line Arranging-1 Copyright© BYD Europe B.V. all rights reserved.
Page 31 See Figure21. Plug the “RJ45 network” Cable to CN3 port. • PDU power cord” to CN1 port. Plug in the “ • • Screw the Power cable with original Screws in the PDU, Figure20 Copyright© BYD Europe B.V. all rights reserved.
Page 33 S2P TO QL1-3 Figure23 Line Arranging-2 • 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 Copyright© BYD Europe B.V. all rights reserved.
Page 34 • Screw and torque with 18Nm and draw a mark with marker. • Lay the power cable from cabinet2, to the installation points. According to Figure26 Figure26 LIne Arranging-3 • Lay the 2 power cables from cabinet3, to the installation points. According to Figure27. Copyright© BYD Europe B.V. all rights reserved.
Page 35 • 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 Copyright© BYD Europe B.V. all rights reserved.
Page 36 (3) Lay the fans power cord from each cabinet to the PDU according to Figure28. Figure28 Line Arranging-5 • Plug in the 3 fan power Cables to CN5-1/CN5-2/CN5-3 ports in PDU separately. Copyright© BYD Europe B.V. all rights reserved.
Page 37 (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 Copyright© BYD Europe B.V. all rights reserved.
Page 38: Assembling Modules
• 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 Figure33 Figure34 Figure32 Copyright© BYD Europe B.V. all rights reserved.
Page 39: Testing Modules Voltages
• 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 authorized service partner. • Record every modules’ voltage and serial number in checking protocol list.
Page 40: Installing Modules To Cabinets
This is the right direction of installing two cabinets. (See Figure41) Figure41 Figure40 • Use a stacker to place modules into cabinet from top to down, and from left to right. Be sure not to knock the cabinet in this step. (See Figure42) Copyright© BYD Europe B.V. all rights reserved.
Page 42: Fixing Modules
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. Copyright© BYD Europe B.V. all rights reserved. Figure45 Modules Sequence Number...
Page 43: Cables Between Modules
• 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 Copyright© BYD Europe B.V. all rights reserved.
Page 44: Power Cables Between Modules
• The positive and negative poles of each module are marked, Exercise extreme caution to prevent the wrong connecting. • Be aware of avoiding touching the modules positive and negative terminals with the Copyright© BYD Europe B.V. all rights reserved.
Page 45 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. Copyright© BYD Europe B.V. all rights reserved.
Page 46 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 Copyright© BYD Europe B.V. all rights reserved.
Page 47: Insolation Resistance & Puncture Test
Test the electrical impedance between Grounding each key component grounding each cabinets frames/ PDU housing Multi-meter Impedance point to the housing should be grounding point to the grounding less than 0.2Ω copper rail Copyright© BYD Europe B.V. all rights reserved.
Page 48: Connect The Rest Modules
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) Figure56 Figure55 Copyright© BYD Europe B.V. all rights reserved.
Page 49: System Voltage Tests When The Switch Is Open
• 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) Figure57 Figure58 HIGH VOLTAGE BATT- QLI3 345V-358V QLI2 BATT+ 384V-398V ＜1V BATT- BATT+ Copyright© BYD Europe B.V. all rights reserved.
Page 50: Close Out Of Battery Installation
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 Copyright© BYD Europe B.V. all rights reserved.
Page 51: Check The Torque Has Been Applied On All Points The Power Cable Points
• Screw the cover with S3 hexagon head bolt. (See Figure61) 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) Figure63 Figure62 Copyright© BYD Europe B.V. all rights reserved.
Page 52: Reinstall The 3 White Doors
• Plug in the power cable of PDU indicator on the #2 cabinet door. (See Figure64) Figure64 Figure65 7.5.6 Inverter + EMS + Grid Installation/Connection Refer to the instruction or Installation Manual of inverter manufacture. Copyright© BYD Europe B.V. all rights reserved.
Page 54: Trouble Shooting
The Battery/BMS keep sends status messages to Inverter/EMS. The system will be adjusted or stopped immediately when errors was detected. Always follow the procedures showed in below table to handle errors or event messages. If errors persist, please contact the BYD service line. Copyright© BYD Europe B.V. all rights reserved.
Page 55 ACTION: Turn off the system Check if the fans communication cables connected correctly. If not, correct or replace the cables. If errors persist. Replace the BMU. If failure persist, Please replace the module Copyright© BYD Europe B.V. all rights reserved.
Page 56: Shut Down/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 Figure68 Figure69 Copyright© BYD Europe B.V. all rights reserved.
Page 57: Exception Clause For Warranty
If the product was not operated with a BYD certified inverter, according to BYD Compatible Inverter List (Appendix 1); If the Product has been modified or repaired without the approval of BYD or BYD Partner; If the Product was damaged by force majeure (e.g. natural catastrophes, such as flooding, fires, earthquakes, lightning or other abnormal environmental conditions, war, etc.);...
Page 58: Disposal Of Products And Batteries
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(DE) Website: www.eft-systems.de Copyright© BYD Europe B.V. all rights reserved.
Page 59: Checking Protocol
13.1.1 System Records Product Serial Number Product Version C130 C230 Inverter Type 13.1.2 Modules Records Serial Number Voltage Serial Number Voltage Testing Records TESTS HIGH Insulation Grounding Point OUT+ Resistance Grounding Point OUT- Copyright© BYD Europe B.V. all rights reserved.
Page 60 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. The PDU indicator is on GREEN Light, No RED light The meter is connected. The inverter is on non-error status. Check battery Info via BMS software Copyright© BYD Europe B.V. all rights reserved.
Page 61 Dangerous warnings, safety restrictions; emergency instructions, etc… Educated the user on system functions, included but not limited on: System components; functions; Parameters, etc… Supplied user with sufficient documents. Company: Position: Name/ signature: Date/location: Copyright© BYD Europe B.V. all rights reserved.

BYD Battery-Box C130 Installation Manual

1 Information of this Manual

2 Safety

3 Location of Installation

4 List of Needed Tools

5 Scope of Delivery

6 Product Overview

7 Installation

8 Installation Check List

9 Trouble Shooting

10 Shut Down/Turn on the System

11 Exception Clause for Warranty

12 Disposal of Products and Batteries

13 Service Contact

Checking Protocol

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