BYD Battery-Box Premium HV Combiner Box Installation Manual

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All information in this document is the property of BYD Europe B.V. No part may be reproduced for business use. Internal use is allowed.

BYD Europe B.V. makes no representations or warranties, express or implied, regarding this document. All implied warranties of utility, merchantability, or fitness for any particular purpose are expressly disclaimed. BYD Europe B.V. or its distributors/dealers shall not be liable for any indirect, incidental, or consequential damages.

The exclusion of implied warranties may not apply in all cases under some statutes.

This document does not replace or intend to replace any local, state, provincial, federal, or national laws, regulations, or codes applicable to the installation, electrical safety, and use of the battery system. BYD Europe B.V. assumes no responsibility for compliance or noncompliance with such laws or codes.

Specifications are subject to change without notice. While efforts have been made to ensure completeness and accuracy, BYD Europe B.V. may make improvements without advance notice. BYD Europe B.V. shall not be responsible for any loss caused by omissions, errors, typographical errors, arithmetical errors, or listing errors in this document.

All trademarks are recognized.

BYD Europe B.V.
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1. Information on this Document

1.1. Validity

This document is valid for the Battery-Box Premium HV Combiner Box CBH-40A.

1.2. Target Group

Instructions in this document may only be performed by qualified persons with the following skills:

• Knowledge of how batteries work and are operated.
• Knowledge of how an inverter works and is operated.
• Knowledge of, and adherence to, locally applicable connection requirements, standards, and directives.
• Knowledge of, and adherence to, this document and associated system documentation, including all safety instructions.
• Training in dealing with hazards associated with the installation and operation of electrical equipment and batteries.
• Training in the installation and commissioning of electrical equipment.

Failure to comply may nullify the manufacturer's warranty, guarantee, or liability, unless it can be proven that damage was not due to non-compliance.

1.3. Symbols

2. Safety

2.1. Intended Use

This product must only be used for its designed purpose. Any other use is considered improper and dangerous. BYD Europe B.V. is not liable for damage caused by improper, incorrect, or unreasonable use.

BYD is only responsible for the product in its original configuration. BYD declines responsibility for consequences arising from non-original spare parts. Any intervention altering the structure or operating cycle must be carried out or authorized by BYD Europe B.V.

2.2. Instructions and Warnings

Failure to follow these instructions may have serious consequences, including device destruction, personal injury, or death due to electric shock. Read and understand the following safety instructions before installation and use.

2.3. Position and securing

2.4. Safety Precautions

This section contains safety precautions that must be observed at all times when working on or with the product. To prevent personal injury and property damage and to ensure long-term operation, read this section carefully and follow all safety precautions.

DANGER: Danger to life from electric shock due to live voltage. High voltages are present in the live components. Touching live components results in death or serious injury.

• Wear personal protective equipment when working on the Combiner Box.
• Do not touch live components.
• Before performing any work, always disconnect the Combiner Box from voltage sources unless supply voltage is absolutely necessary.
• Ensure the device cannot be reconnected.
• Ensure that no voltage is present.
• Ground and short-circuit.
• Cover or isolate any adjacent live components. Protective covers must always be mounted.

DANGER: Danger to life from electric shock due to live DC cables. Touching live DC cables from batteries or an inverter results in death or serious injury.

• Prior to connecting DC cables, ensure they are voltage-free.
• Wear suitable personal protective equipment when working on the Combiner Box.

DANGER: Danger to life from electric shock if the Combiner Box is damaged. If damaged, dangerous situations may arise during operation.

• Only use the Combiner Box when it is in a technically faultless and safe operating condition.
• Regularly check the Combiner Box for visual damage.
• Ensure all external safety equipment is freely accessible at all times.
• Ensure all safety equipment is in good working order.

3. Scope of delivery

Check the scope of delivery for completeness and any externally visible damage. Contact your distributor if the scope of delivery is incomplete or damaged.

Figure 1 Component included in the scope of delivery

A: Battery-Box Premium HV Combiner Box CBH-40A

B: Installation Manual

4. Product Description

4.1. Circuit Diagram

The CBH-40A Combiner Box is a BYD battery system junction box to an inverter. Up to three battery towers can be connected in parallel with this Combiner Box.

Figure 2 Block circuit diagram of the CBH-40A Combiner Box

"1-B+", "1-B-" and "PE 1" in the diagram mean the positive power cable, negative power cable, and grounding cable from battery tower Number 1.

4.2. Type Label

A type label is attached to the Combiner Box, located on the left upside. It provides the following information:

• Manufacturer
• Device type
• Serial number
• Device-specific characteristics
• Production date

Type: Battery-Box Premium HV Combiner Box
Model: CBH-40A
Rated Voltage: DC 1000V
Rated Current: 40A
Manufacturer: Shenzhen BYD Electronics Co.,LTD.

P030 T 030 Z 201207 0001

IEC 61439-2
Made in China

Production date: Year Month Day

The information on the type label is required for safe product use and customer support. The type label must remain permanently attached to the product.

4.3. Symbols on the Type Label

5. Assembly

5.1. Wall Mounting

5.1.1. Selecting the Mounting Location

WARNING: Fire hazard due to wrong choice of mounting location. Under fault conditions, electric arcs may occur, causing fires if the Combiner Box is mounted on flammable materials.

• Do not mount on flammable construction materials.
• Do not mount near highly flammable materials.
• Do not mount in potentially explosive atmospheres.

Requirements for the mounting location:

• Not in a living or office area.
• Must not block any escape routes.
• Must be freely and safely accessible at all times without auxiliary equipment.
• Must be suitable for the weight and dimensions of the Combiner Box.
• Must not be exposed to direct solar irradiation.
• Recommended height: higher than 1.6 meters from the ground.
• Ensure the enclosure is not in the path of rainwater.

Requirements for mounting:

• Mount with the connection area facing downwards.
• Recommended height of the wall box [height not specified].
• Do not mount in an inclined position.

5.1.2. Mounting the Combiner Box

CAUTION: Danger of crushing if the Combiner Box is dropped.

• When mounting, consider the weight of up to 9.7 kg.
• Installer should use personal protective equipment.

NOTICE: Damage to cable glands and plug connections due to improper transport and installation. The cable glands and plug connections protrude from the enclosure.

Additionally required mounting material (not included):

• Four M5 screws (choose type based on wall properties).
• Four washers.
• If necessary, four screw anchors (choose type based on wall properties).

Figure 3 Dimensions of the Combiner Box

Procedure:

1. Mark the position of the drill holes on the wall or stand.
2. Drill holes at the marked positions.
3. If necessary, insert the screw anchors.
4. Fasten the Combiner Box to the wall or stand using suitable screws and washers.
5. Ensure that the Combiner Box is securely fixed.

6. Electrical Connection

6.1. Connection Instructions

6.1.1. Preliminary Checks

DANGER: Before connecting the Combiner Box to the battery and inverter, ensure:

• The Combiner Box is in good condition with no transport damage.
• The Combiner Box is firmly anchored to walls and stable supports.
• There are no remaining metallic parts, chips, or derivatives from installation activities.

DANGER: After performing checks, proceed to wire cables according to the wiring diagram, using suitable sizes and colors.

CAUTION: Ensure DC connections are properly secured inside terminals to prevent overheating.

6.1.2. Safety during Electrical Connection

DANGER: Danger to life due to electric shock. High voltages are present. Work is allowed only if power is disconnected and guidelines are strictly followed.

• Disconnect from voltage sources.
• Ensure the device cannot be reconnected.
• Ensure no voltage is present.
• Ground and short-circuit.
• Cover or isolate any adjacent live components. Protective covers must always be mounted.

6.2. Inserting the Cables into the Switch Cabinet

6.2.1. Bottom view of Combiner Box with cable glands

Figure 4 Bottom view of Combiner Box with cable glands

6.2.2. Overview of the Connection Area

Figure 5 Overview of the connection area

6.3. Leading the Cables through the Cable Glands with sealing Gasket

Procedure:

1. Release the cable gland.
2. Lead the cable through the swivel nut of the cable gland, ensuring the thread faces upwards.
3. Lead the cable through the seal insert.
4. Insert the seal insert into the cable gland together with the cable.

6.4. Connecting the DC Cables

NOTICE: Damage to the Combiner Box due to moisture penetration. Moisture can penetrate through unsealed cable glands.

BYD recommends using bootlace ferrules for connecting DC cables.

Cable requirements:

• Diameter of DC cables: 5 mm to 12.5 mm.
• Cross section: 6 mm² to 50 mm².

Procedure:

1. Attach cables to an external cable support rail.
2. Cut cables to length and strip 25 mm of insulation.
3. If using bootlace ferrules, mount and crimp them gas-tight.
4. Lead the cables to the blocks.
5. Insert a flat-head screwdriver into the switch of the connector (recommended type: S3.5×100).
6. Hold the cables and push the screwdriver to move the switch to the end.
7. Ensure the switch is well fixed at the end.
8. Remove the screwdriver from the connector. [Checkmark emoji]

6.5. Connecting the Grounding Cable

Cable requirement:

• Conductor cross-section: equal to or higher than 10 mm².
• Outer diameter: 5 mm to 12.5 mm.
• With a ring terminal.

Procedure:

1. Loosen the original nut and washer on the ground post.
2. Place the grounding cable in the ground post.
3. Tighten the nut and washer (torque: 5.5 Nm).
4. Ensure the grounding cable is securely fixed.

7. Maintenance

7.1. Periodic Maintenance

It is recommended to periodically inspect the panel and check the following points:

• No evident signs of rust or corrosion. (Yearly - Visual inspection)
• No water infiltrations and excessive dust infiltration. (Yearly - Visual inspection)
• Efficient mass grounding and drains. (Yearly - Visual inspection)
• Insulation between electrical circuits and masses. (5 Year - Insulation test)
• All DC connections are correctly tightened. (Yearly - Dynamometric torque tool)
• No burn marks on the terminals. (Yearly - Visual inspection)
• The door panel of the enclosure is firmly closed. (Yearly - Visual inspection)

7.2. Extraordinary Maintenance

If damaged components need replacement, use only materials identical to the original ones. If electrical connections are damaged due to mechanical or electrical causes or rodents, immediately disconnect the system or the damaged part. After verifying no failures were caused to the equipment, proceed with wire replacement using similar materials.

CAUTION: All maintenance operations must be performed considering all safety instructions. Check beforehand that components are not powered.

8. Decommissioning

8.1. Disassembling the Combiner Box

DANGER: Danger to life due to electric shock when touching live components.

• Observe safety rules when disconnecting:
• Disconnect from voltage sources.
• Ensure the device cannot be reconnected.
• Check that no voltage or current is present.
• Ground and short-circuit.
• Cover or isolate any adjacent live components.

CAUTION: Risk of burns from touching hot components.

Requirement: The Combiner Box must be disconnected from voltage sources.

Procedure:

1. Open the doors of the Combiner Box.
2. Disconnect the input cables from the blocks.
3. Disconnect the output cables.
4. Disconnect the grounding cables.
5. Release the cable glands.
6. Pull all cables out of cable glands and isolate them.
7. Disassemble the Combiner Box.

8.2. Disposing of the Combiner Box

Dispose of the Combiner Box in accordance with applicable disposal regulations for electronic waste.

9. Technical Data

General Data

MECHANICAL DATA

ENVIRONMENT DATA

DC INPUT DATA

DC OUTPUT DATA

(Note 1): Derating of 0.5%/K of max. current from 40°C to 50°C.

(Note 2): Derating of maximum voltage versus altitude. 1.5 % per 100 m from 2,001 m to 3,000 m. 1.0% per 100 m from 3,001 m to 4,000m.

10. Contact Information

BYD Global Service

Email: bboxservice@byd.com

Telephone: +86 755 89888888-47175

Address: No.3009, BYD Road, Pingshan, Shenzhen, 518118, P.R.China

Website: www.bydbatterybox.com

Social media:

• Facebook
• Twitter
• LinkedIn

Australia

Alps Power Pty Ltd

Email: service@alpspower.com.au

Telephone: +61 2 8005 6688

Address: 14/47-51 Lorraine St Peakhurst NSW 221

Website: www.alpspower.com.au

Europe

EFT-Systems GmbH

Email: service@eft-systems.de

Telephone: +49 9352 8523999, +44 (0) 2037695998(UK), +34 91 060 22 67(ES), +39 02 873683(IT)

Address: Bruchtannenstraße 28, 63801 Kleinostheim, Germany

Website: www.eft-systems.de

South Africa

AFRIPLUS ENERGY GROUP (PTY) LTD

Email: Support@afriplusenergy.co.za

Telephone: +27 21 140 3594

Address: The Pavilion, Corner of Dock & Portswood Road, V&A WATERFRONT, 8001, CAPE TOWN

USA

BYD US service

Email: bboxusservice@byd.com

Telephone: +1(833) 338-8721