BYD Battery-Box Premium LVL 15.4 Instruction Manual

BYD Battery-Box Premium LVL
Service Guideline and Checklist
Version 1.2
Valid for Premium LVL 15.4
LVL 15.4 (max. 64 per system) BMU (1 x per system)
Make sure to always use the latest version of this service document,
available at: www.bydbatterybox.com
Important: The installation and all other kinds of works or measurements in combination with the Battery-Box
Premium are only allowed by professional and qualified electricians.
This checklist is a shortened assistance for the Battery-Box and does not replace the original manual, which can
be found on www.bydbatterybox.com /www.eft-systems.de /www.alpspower.com.au. Subject to technical
modifications; no responsibility is accepted for the accuracy of this information. Attention: Improper handling can
cause danger and damage.

CONTENT
CONTENT 2
1. GENERAL STEPS 3
2. ERROR ANALYSIS 4
2.1 BMU does not turn on / BMU LED is off or flickering abnormally 4
2.2 Problem with the Firmware Update / App Configuration / Battery WiFi 5
2.3 Incorrect output voltage / No BMS Data / BMU EC102 6
2.4 Communication issue with Inverter / BMU EC106 7
2.5 SOC & charging logic 7
2.6 Unexpected shutdown 7
2.7 BMU/BMS LED event code (EC) 8
2.8 Be Connect Plus (BCP) 11
2.9 Voltage measurement and undervoltage 12
2.10 Unit Exclusion Method (only when at least 2 LVLs / parallel connection) 13
3. SERVICE TASKS 14
3.1 BMU Replacement 14
3.2 BMS Replacement 14
3.3 BIC Replacement 14
SERVICE CHECKLIST AND CONTACT INFORMATION 15
2

1. GENERAL STEPS
Make sure to always use the latest version of this service document, available at: www.bydbatterybox.com
Please proceed first with the installation steps by:
No.
Name
Description
1
Configuration
Check if the configuration is correct. Refer to latest “BYD Battery-Box Premium LVL
Minimum Configuration List” (V1.8 or above) available at: www.bydbatterybox.com
Make sure the inverter is configured correctly.
2
Correct internal
cabling
Please double check, referring to the manual
3
Correct external
cabling
1. Communication to inverter
a. Depending on the choice of inverter the cable between the BMU
port and the inverter must be specially made. Please check the
specifications in the installation manual.
b. Recommended CAT5 or higher;
c. Check the cables and replace them if necessary
2. Grounding
a. Battery-Box connected directly to the ground-bus of the house.
b. The battery must not be earthed via the inverter! Otherwise,
communication problems are possible.
3. Ethernet-Cable for Internet (strongly recommended!)
4. DC-Ports - Make sure that +and -are properly connected.
5. Correct parallel connection cabling if applicable
4
Latest Firmware
Always update the newest Firmware! (with using the latest App Version)
Note: If not stated otherwise, wifi password is BYDB-Box
5
App Configuration
To complete the commissioning, the configuration of the battery via “BYD Be
Connect” App or PC tool “Be Connect Plus” (BCP) is mandatory!
6
Restart
After app configuration, please perform a proper restart of the system by switching off
the battery correctly (press LED Button on BMU for 5 sec). Make sure all LEDs of the
battery are completely off. Then follow the correct switch on procedure (see step 7)
7
Switch on procedure
Correct switch on procedure is important for a correct operation!
1. Switch on the fuse between Inverter and Battery (if there is any)
2. Switch on the Battery-Box (button on LVL)
3. Activate the inverter after the battery
8
Checking the correct
operation
The system runs properly if:
- Inverter displays battery SOC correctly
- System charges / discharges
Note: If you can not complete the commissioning, then turn off the battery before
you leave the site and make sure all LEDs are off to avoid a discharge of the battery.
3

2. ERROR ANALYSIS
Please refer to the general steps before proceeding, see chapter 1.
2.1 BMU does not turn on / BMU LED is off or flickering abnormally
LEDs of BMU do not light up, although the battery is ON.
No.
Name
Description
9
Check correct cable port
Make sure that the correct data cable port has been used at the BMU (“BMS” port.
Do not mix with “inverter” or “Ethernet” port).
10
Replace Comm Cable
Try a completely new communication cable between battery and BMU.
Note: Sometimes it might be necessary to unplug the communication cable and
plug it again while batteries are switched on.
11
Voltage measurement on
pin 7&8
Measure the voltage of PIN 7 & 8 while the other side of the cable is connected to
the IN port of the Battery-Box and while the Battery-Box is powered on. Voltage
should be around 50V. If yes: try another BMU (if available). If no: check another
cable or try another LVL if multiple batteries are installed in the system.
12
Only LED faulty?
In some rare cases, the LED of the BMU is faulty. To check that: check if there is a
WIFI access point of the Battery-Box and check if there are internal LEDs inside the
BMU. If so, only the external LED is inactive and a commissioning could still work.
13
Voltage measurement
Check voltage of battery. See Section 2.9
14
BMU exchange
If problem remains:
Test another BMU, if available.
4

2.2 Problem with the Firmware Update / App Configuration / Battery WiFi
The Battery Management consists of two components: the BMU and the BMS. The Firmware Update from the App will update
the BMU, which will then update the BMS. The BMS update can take up to 30 Minutes.
No.
Name
Description
15
Correct App and
Firmware
Make sure to have the latest App version (>1.7.4) and Battery Firmware (download
inside the App) on your mobile device before connecting the app with battery WiFi.
If the App cannot be installed, or other general Problems occur with the App:
- Try with a different mobile device (For Android: min Android version
requirement is 4.4. )
- Try with PC Tool BCP (section 2.8)
-Note: If the WiFi connection is not stable you might remove the lan cable
during the configuration. Once the battery has been configured correctly
you can connect it again to the Internet.
16
WiFi cannot be found /
WiFi unstable
The Battery WiFi turns off 5 hours after the start of the Battery. To reactivate the WiFi,
press the LED button of the BMU about 1 second or restart the system.
To reset the WiFi, press the LED button of the BMU three times 1 second within 6
seconds.
If problem remains:
- remove the lan cable during the configuration. Once the Battery has been configured
correctly you can connect it again to the Internet.
- check whether other mobile devices are connected the same wifi
- try another mobile device
17
Proper restart
Note: Whenever the configuration via Be Connect app / Be Connect Plus tool is
changed, a restart of the battery is necessary to make sure that all changes come
into effect.
1. Switch off the Inverter
2. Switch off the battery (Press button on BMU for 5 seconds until all batteries switch
off. All LEDs should be off)
3. Wait for 2 Minutes
4. Turn on the Battery (button on battery connected to BMU) and then
5. Turn on inverter second
18
Close and restart the App
If the App does not react anymore after some minutes loading during the update
process, close (close the program completely) and restart the App. Or try with PC
Tool BCP (section 2.8)
19
BMS Version not updated
The App will only update the BMU. The BMU will update the BMS, which can take up
to 30 minutes.
If the BMS Version is not updated after 30min with stable inverter communication,
follow the below Process:
1. Update Firmware through the App again
2. Restart the system
a. Switch off the Inverter first, then switch off the battery second
(Press the LED of the BMU for 5 seconds)
b. Wait for 2 Minutes
c. Turn on the Battery first, then turn on the inverter second
3. Wait for 30 Minutes
4. Check BMS Firmware Version again with App. If Version is still wrong,
please do the update process again (if possible with another mobile
device).
5. Note: if Voltage of Battery is not shown in Be Connect, the update will not
be transferred to BMS. Make sure the BMU recognizes BMS properly.
5

2.3 Incorrect output voltage / No BMS Data / BMU EC102
Wrong PDU output voltage (e.g 16V) is normally an indicator for incorrect configuration or BMU<>BMS communication issue
No.
Name
Description
20
Battery correctly
configured?
Please check if the App configuration was successful and the Firmware is the
most recent one. If there are problems, please refer to Section 2.2
Note: It is important to select the correct system quantity. Else, the output
voltage might be wrong! The quantity you need to select refers to the overall
quantity of LVL15.4 units. If you have 2xLVL15.4 connected in parallel, you need to
select the system quantity of “2” in the Be Connect app / BCP tool.
Note: Don’t forget to properly restart system after changing configuration!
21
Proper restart
Note: Whenever the configuration via Be Connect app / Be Connect Plus tool is
changed, a restart of the battery is necessary to make sure that all changes come
into effect.
1. Switch off the Inverter
2. Switch off the battery (Press button on BMU for 5 seconds until all batteries
switch off. All LEDs should be off)
3. Wait for 2 Minutes
4. Turn on the Battery (button on battery connected to BMU) and then
5. Turn on inverter second
22
BMU<>BMS
communication
make sure that the comm cable is connected to the right port of BMU (the one
labeled as "BMS"). Replace comm cable between BMU and battery.
23
Check terminal resistor
Make sure that the terminal resistor is connected to the OUT port (Terminal
resistor properties: 120 Ω resistor between pin 5 and 6)
If it was connected already, then please remove it and try without it to rule out a
faulty terminal resistor. Don't forget to properly restart system afterwards.
24
No output voltage /
incorrect output voltage
When there is no output voltage, this typically means that the BMS relay is not
closed. This can have many reasons:
- Check if BMU properly detects BMS data (cell voltages, cell
temperatures). If not, see following step 25.
- Check LED codes (see section 2.7)
25
BMU<>BMS
communication / No BMS
data shown / BMS data is
0
make sure that the comm cable is connected to the right port of BMU (the one
labeled as "BMS"). Replace comm cable between BMU and battery.
Note: as long as there is a communication problem between BMU & BMS, you
won’t be able to see any BMS data / values will appear as zero and the relay will
remain open (no output voltage) In that case, redo app configuration (unit
quantity must be correct!) and don’t forget to properly restart system!
26
LVL Exclusion Method
(for parallel connected
systems)
- If multiple LVL batteries connected in parallel: Try the Exclusion Method (see
section 2.10): Check if the system works when removing the suspected LVL unit
Very important: don't forget to reconfigure and to restart always when changing
the configuration!
27
Further checking
If problem remains:
- Download all data with BCP (section 2.8)
- Check the inverter
- Try replacing the BMU, if available
6

2.4 Communication issue with Inverter / BMU EC106
Output voltage is normal and you can see BMS (cell) data in BCP, but inverter does not detect battery.
Note: if output voltage is incorrect or BMS (cell) data cannot be seen in BCP, then go though section 2.3 first
No.
Name
Description
28
Configuration
Check if the configuration is correct. Refer to latest “BYD Battery-Box Premium LVL
Minimum Configuration List” (V1.8 or above) available at: ww.bydbatterybox.com
Make sure the inverter is configured and working correctly.
29
Output voltage incorrect?
No BMS Data?
Check according to section 2.3. Especially make sure to configure battery via app
and to properly restart afterwards.
30
Inverter settings
Make sure to configure the battery correctly on the inverter interface. Refer to
inverter manual for details.
31
Replace comm cable
Replace the communication cable (min. CAT5!). Confirm PIN cable configuration
for the specific inverter model (see manual)
32
Further checking
If problem remains: Test another BMU, if available
2.5 SOC & charging logic
No
Name
Description
33
SOC jumps
The SOC of an LFP battery cannot be measured. It is a calculated value. In general, the
state of charge (SOC) of a battery is calculated using the voltage, but other factors such
as temperature, current flow and charging behavior also play a role. The calculation of the
state of charge is generally more precise if the battery regularly sees full cycles. Every now
and then an SOC correction / calibration might occur. That is normal.
2.6 Unexpected shutdown
System has been successfully commissioned in the past and did run for some time. Later on an unexpected shutdown occured.
No
Name
Description
34
Minimum Configuration
fulfilled?
Check if the configuration is correct. Refer to latest “BYD Battery-Box Premium LVL
Minimum Configuration List” (V1.8 or above) available at: www.bydbatterybox.com
Make sure the inverter is configured and working correctly.
Note:
- if the minimum configuration list is not met, unexpected shutdown(e.g during
backup) might occur.
- peak power devices can cause shutdowns. Check the peak power of your loads
35
Inverter
Communication
The battery only works with an compatible external inverter. If for whatever reason the
communication between battery and inverter is lost, the battery will shut down itself within
30minutes. Therefore, check which one did shut down first ( battery or inverter) and check
if inverter is properly detecting battery (e.g showing correct SOC or temperature). If
problem remains, check according to section 2.4.
36
Battery Logs / History
Data
Sporadic alarms are hard to detect as they only occur sometimes. Therefore, it is very
important to download and provide all the historic battery log files in order to identify the
root cause. See section 2.8 for details.
37
Inverter Warning &
Monitoring
Unexpected Shutdown can be caused by overall system settings. Therefore, it is necessary
to evaluate inverter data as well.
- Which error message are shown in inverter (portal?
- Please provide access to Inverter portal (add [email protected] and tell us
the name of the system in the portal)
7

2.7 BMU/BMS LED event code (EC)
A constant white LED refers to standby mode. White blinking means charge or discharge.
When the battery is initiating, the LED will flash white and blue with an interval time of 0.5 seconds (normal during startup).
When the LED flashes blue with an interval time of 1 second it indicates an event code. Please start to count when the white
LED begins to flash, then count how many times the white and blue LED flashes. (also refer to the manual!)
Example: 1xwhite, 6xblue → EC 106 / 1xwhite, 11xblue → EC 111 / 3xwhite, 3xblue → EC 303
Note: every LVL has its own BMS. The Event Code of the BMS will therefore be shown in the LED of the individual LVL.
Most errors are caused by a faulty communication line, an incorrect app configuration or the missing restart after the
app-configuration. Please go in detail through: Section 2.2 & 2.3
Note: if the system is not correctly configured with the app, the event code (EC) might be misleading.
EC
BMU
EC
BMS
Measure
EC 101
/
Initialisation Failure.
- Make sure the app-configuration has been completed correctly (especially quantity!).
- Restart the system according properly (see step 17, section 2.2)
If problem remains:
- Download all data with BCP (especially the historical data) (section 2.8)
- replace BMU, if available
EC 102
EC 105
/
Incorrect module quantity / Module not detected.
- Make sure the app-configuration has been completed correctly (especially quantity!).
- Check the terminal resistor. The terminal resistor (120 Ω at pin 5+6) is responsible for a
clean communication between BMS and BMU. In rare cases it can be damaged and can
disturb the signal. In these rare cases it is recommended to remove the terminal resistor.
- replace communication cable between Battery and BMU
- Restart the system according properly (see step 17, section 2.2)
- If multiple LVL batteries connected in parallel: Unit Exclusion Method (see section 2.10):
Check if the system works when removing the suspected LVL unit
If problem remains:
- Download all data with BCP (especially the historical data) (section 2.8)
- replace BMU, if available
8

EC 103
EC 108
PreCharge Fault.
- Check the DC cabling and make sure that the Minimum Configuration is met.
- Restart the system according properly (see step 17, section 2.2)
- If multiple LVL batteries connected in parallel: Exclusion Method (see section 2.10):
Check if the system works when removing the suspected LVL unit
If problem remains:
- Download all data with BCP (especially the historical and the cell data) (section
2.8)
- provide the SN and voltage of the suspected LVL unit (see checklist on last
page)
EC 104
EC 101
Short circuit / DC reverse connection.
- Check DC cabling (is there any short circuit? Is the fuse between battery and inverter
closed?)
- Disconnect the battery system from the inverter and restart the battery system alone
(battery isolated), to evaluate if the error is being caused externally (i.e. short circuit in
inverter or MPPT). If the Event Code remains, the error might be in the battery. If the Event
Code has changed, there might be an error in the inverter side.
- If multiple LVL batteries connected in parallel: Exclusion Method (see section 2.10):
Check if the system works when removing the suspected LVL unit
If problem remains:
- Download all data with BCP (especially the historical and the cell data) (section
2.8)
- provide the SN and voltage of the suspected LVL unit (see checklist on last
page)
EC 104
EC 103
BIC Communication Failure.
Turn on battery and check whether the blueLED lights on the two BIC boards are on (BIC =
circuit boards directly on the two battery modules inside LVL - see section 3.3).
- If blue LED on BIC boards are on:
- try to exchange the upper BIC with the lower one.
- if problem remains: BIC replacement might be necessary
- If blue LED on BIC boards are off:
- Check if there is any sign of short circuit in the BICs (e.g. component damage).
- Check the sampling cables connection: B2+ up left / B1+ bottom left / B2- up
right / B1- bottom right
- if problem remains: BIC replacement might be necessary
- If multiple LVL batteries connected in parallel: Exclusion Method (see section 2.10):
Check if the system works when removing the suspected LVL unit. Try swapping the BIC
boards of two different LVL units.
If problem remains:
- Download all data with BCP (especially the historical and the cell data) (section
2.8)
- Measure the cell voltage according to section 2.9
- provide the SN and voltage of the LVL with the EC (see checklist on last page)
EC 104
EC 107
EC 113
Undervoltage.
- Shut down the system quickly to avoid further discharge. Check whether the system can
shut down normally (by pressing the LED button in BMU for 5s).
- Follow section 2.9 (Voltage measurement of cells)
9

EC 104
EC 102
up to
EC112
(All other than
101, 103, 107,
113)
One of the BMS (LVL units) reports an event message.
- If multiple LVL batteries connected in parallel: Exclusion Method (see section 2.10):
Check if the system works when removing the suspected LVL unit
If problem remains:
- Check the voltage of the batteries according to section 2.89Download all data
with BCP (especially the historical and the cell data) (section 2.8)
- provide the SN and voltage of the suspected LVL (see checklist on last page)
EC 106
/
No communication with Inverter.
- Make sure the inverter is on, configured and working correctly.
- Check according to section 2.4
10