Huawei PDU8000-0125DCV8-BXA006 User manual

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX BCB Box
User Manual
Issue
01
Date
2019-03-07
HUAWEI TECHNOLOGIES CO., LTD.

Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
i
Copyright © Huawei Technologies Co., Ltd. 2019. All rights reserved.
No part of this document may be reproduced or transmitted in any form or by any means without prior
written consent of Huawei Technologies Co., Ltd.
Trademarks and Permissions
and other Huawei trademarks are trademarks of Huawei Technologies Co., Ltd.
All other trademarks and trade names mentioned in this document are the property of their respective
holders.
Notice
The purchased products, services and features are stipulated by the contract made between Huawei and
the customer. All or part of the products, services and features described in this document may not be
within the purchase scope or the usage scope. Unless otherwise specified in the contract, all statements,
information, and recommendations in this document are provided "AS IS" without warranties, guarantees or
representations of any kind, either express or implied.
The information in this document is subject to change without notice. Every effort has been made in the
preparation of this document to ensure accuracy of the contents, but all statements, information, and
recommendations in this document do not constitute a warranty of any kind, express or implied.
Huawei Technologies Co., Ltd.
Address:
Huawei Industrial Base
Bantian, Longgang
Shenzhen 518129
People's Republic of China
Website:
http://e.huawei.com

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
About This Document
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
ii
About This Document
Purpose
A battery circuit breaker (BCB) box controls the connection and disconnection between
battery strings and a UPS and protects batteries. This document describes the BCB box in
terms of its structure, installation, troubleshooting, maintenance, and technical specifications.
Intended Audience
This document is intended for:
Sales engineer
Technical support engineer
System engineer
Hardware installation engineer
Commissioning engineer
Data configuration engineer
Maintenance engineer
Symbol Conventions
The symbols that may be found in this document are defined as follows.
Symbol
Description
Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
Indicates a potentially hazardous situation which, if
not avoided, could result in equipment damage, data
loss, performance deterioration, or unanticipated

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
About This Document
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
iii
Symbol
Description
results.
NOTICE is used to address practices not related to
personal injury.
Calls attention to important information, best
practices and tips.
NOTE is used to address information not related to
personal injury, equipment damage, and environment
deterioration.
Change History
Changes between document issues are cumulative. The latest document issue contains all the
changes made in earlier issues.
Issue 01 (2019-03-07)
This is the first release.

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
Contents
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
iv
Contents
About This Document.................................................................................................................... ii
1 Safety Precautions.........................................................................................................................1
2 Overview.........................................................................................................................................2
2.1 Exterior.........................................................................................................................................................................2
2.2 Interior..........................................................................................................................................................................3
2.2.1 Opened BCB Box ......................................................................................................................................................3
2.2.2 PDU8000-0125DCV8-BXA006 Interior...................................................................................................................5
2.2.3 PDU8000-0250DCV8-BXA005 Interior...................................................................................................................6
2.2.4 PDU8000-0400DCV8-BXA006 Interior...................................................................................................................7
2.2.5 PDU8000-0630DCV8-BXA006 Interior...................................................................................................................8
3 Installation......................................................................................................................................9
3.1 Unpacking and Checking..............................................................................................................................................9
3.2 Installation Preparations ...............................................................................................................................................9
3.2.1 Tools ..........................................................................................................................................................................9
3.2.2 Environment ............................................................................................................................................................10
3.2.3 Cables ......................................................................................................................................................................10
3.2.4 Cable Connection Precautions.................................................................................................................................13
3.3 Installing the BCB Box (One Battery String).............................................................................................................14
3.3.1 Mechanical Installation............................................................................................................................................14
3.3.2 Connecting Cables...................................................................................................................................................20
3.4 Installing BCB Boxes (Two Battery Strings)..............................................................................................................23
3.4.1 Installing One BCB Box..........................................................................................................................................24
3.4.2 Installing Two BCB Boxes ......................................................................................................................................24
3.5 Installing BCB Boxes (Three Battery Strings)............................................................................................................26
3.5.1 Mechanical Installation............................................................................................................................................26
3.5.2 Connecting Cables...................................................................................................................................................26
4 Check Before Power-On ............................................................................................................29
5 Powering On and Commissioning ..........................................................................................31
6 Routine Maintenance .................................................................................................................32
7 Troubleshooting..........................................................................................................................33

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
Contents
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v
8 Technical Specifications ............................................................................................................34
A Acronyms and Abbreviations..................................................................................................36

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
1 Safety Precautions
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
1
1 Safety Precautions
Only qualified and trained personnel are allowed to operate and maintain the BCB box.
To ensure human safety and normal BCB box operation, ground the BCB box before use.
The ground cable must be capable of bearing fault currents.
Components under the isolation board inside the BCB box are not operable. Do not open
the cover. Otherwise, electric shocks may occur, and the resulting faults are beyond the
warranty scope.
During battery installation, ensure that the positive and negative copper bars are not short
circuited. Short circuits can cause a fire and result in personal injury.
The operating and storage environments affect the BCB box service life and reliability.
Therefore, the environments must meet the requirements specified in this document.
Install the BCB box in compliance with the local laws and regulations.
Reserve sufficient space in front of the BCB box to facilitate maintenance.
Prevent liquid or other foreign matter from entering the BCB box. Do not place containers
with liquid near the BCB box.
Perform electrical connection to a specified torque.
To avoid damages, move the BCB box gently.
Before operating batteries, carefully read the safety precautions for battery handling and
connection.
The BCB box may cause electric shocks and high short-circuit currents. Therefore, before
operating the BCB box, get tools insulated, and take off metal articles such as watches and
rings.
In case of fire, use a dry power fire extinguisher to put out the fire. Using a fluid fire
extinguisher may cause electric shocks.
Do not install a switch and other disconnection devices on the ground cable.

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
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Copyright © Huawei Technologies Co., Ltd.
2
2 Overview
2.1 Exterior
A BCB box controls the connection and disconnection between a single battery string and a
UPS and protects batteries. It has the following models:
PDU8000-0125DCV8-BXA006
PDU8000-0250DCV8-BXA005
PDU8000-0400DCV8-BXA006
PDU8000-0630DCV8-BXA006
The four models of BCB boxes have the similar appearance. The
PDU8000-0250DCV8-BXA005 is used as an example, as shown in the following figure.

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
Issue 01 (2019-03-07)
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Figure 2-1 PDU8000-0250DCV8-BXA005
1 Silk screen
2 Lock
3 Handle
4 Cable outlet
2.2 Interior
2.2.1 Opened BCB Box
The following figure shows an open BCB box.

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
Issue 01 (2019-03-07)
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Figure 2-2 Opened BCB box
1 Wiring diagram
2 Certificate of
qualification
3 Bar code
4 Nameplate
5 Door support bar
6 Door ground terminal
7 Circuit breaker
8 Isolation board
handle
9 Warning label

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
5
2.2.2 PDU8000-0125DCV8-BXA006 Interior
Figure 2-3 PDU8000-0125DCV8-BXA006 interior
1 Positive wiring
terminals (connecting
to batteries)
2 Negative wiring
terminals (connecting
to batteries)
3 Ground
terminal
4 Circuit breaker
5 Negative wiring
terminals (connecting
to the UPS)
6 Positive wiring
terminals (connecting
to the UPS)

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
6
2.2.3 PDU8000-0250DCV8-BXA005 Interior
Figure 2-4 PDU8000-0250DCV8-BXA005 interior
1 Positive wiring
terminals (connecting
to batteries)
2 Negative wiring
terminals (connecting
to batteries)
3 Ground
terminals
4 Circuit breaker
5 Terminal block
6 Negative wiring
terminals (connecting
to the UPS)
7 Positive
wiring
terminals
(connecting to
the UPS)

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
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2.2.4 PDU8000-0400DCV8-BXA006 Interior
Figure 2-5 PDU8000-0400DCV8-BXA006 interior
1 Positive wiring
terminals (connecting
to batteries)
2 Negative wiring
terminals (connecting
to batteries)
3 Ground
terminals
4 Circuit breaker
5 Terminal block
6 Negative wiring
terminals (connecting
to the UPS)
7 Positive
wiring
terminals
(connecting to
the UPS)

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
2 Overview
Issue 01 (2019-03-07)
Copyright © Huawei Technologies Co., Ltd.
8
2.2.5 PDU8000-0630DCV8-BXA006 Interior
Figure 2-6 PDU8000-0630DCV8-BXA006 interior
1 Positive wiring
terminals (connecting
to batteries)
2 Negative wiring
terminals (connecting
to batteries)
3 Ground
terminals
4 Circuit breaker
5 Negative wiring
terminals (connecting
to the UPS)
6 Positive wiring
terminals (connecting
to the UPS)

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
3 Installation
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9
3 Installation
3.1 Unpacking and Checking
After the BCB box is delivered onsite, unpack the case and check as follows:
Visually inspect the BCB box for shipping damage. If it is damaged, notify the carrier
immediately.
Check that the device bar code is consistent with that in the order. Check that the fittings
comply with the packing list. The rodent-proof mesh and screws are bound to copper
bars. You can find them after you remove the baffle in the BCB box. If some fittings are
missing or do not comply with the packing list, record the information and contact your
local Huawei office immediately.
Screws are tied to copper bars in the BCB box. Therefore, remove the isolation board before taking out
the screws.
3.2 Installation Preparations
3.2.1 Tools
Tool Name, Specifications, and Appearance
Multimeter
Phillips screwdriver
Insulated adjustable wrench
Insulated torque wrench
Combination wrench
Hydraulic pliers

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
3 Installation
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Tool Name, Specifications, and Appearance
Diagonal pliers
Wire stripper
Rubber mallet
Hammer drill (with a Ф8
drill bit)
Hand-held electric drill
Hole saw
Polyvinyl chloride (PVC)
insulation tape
Brush
Electrician's knife
Protective gloves
Electrostatic discharge
(ESD) gloves
Insulation gloves
Protective shoes
Cable tie
N/A
3.2.2 Environment
The BCB box is installed in environments with proper ventilation and is far away from
water, heat sources, and flammable and explosive materials.
The BCB box should be far away from direct sunlight, dust, volatile gases, corrosive
materials, conductive metal dust, and salty air.
3.2.3 Cables
Prepare battery cables before installation as required. You can prepare cables based on the
recommended specifications in this section after the following requirements are met:
Cables are routed on the wall or on the floor, the ambient temperature is 30°C, the DC
voltage drop is less than 1%, and the length of DC cables does not exceed 40 m.

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
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When the installation environment (such as routing mode and ambient temperature)
changes, prepare cables according to IEC60364-5-52 or local standards.
Use double-insulated polyethylene copper cables. The current-carrying capacity is
calculated based on polyethylene copper cables.
If cables are provided by customers, the cables must be double-insulated and meet 1000
V DC voltage withstanding and current-carrying capacity requirements.
PDU8000-0125DCV8-BXA006 Cables
Table 3-1 Specifications for PDU8000-0125DCV8-BXA006 cables and terminals
Terminal
Number of
Terminals and
Hole Diameter
Recommende
d Cable
Specification
s
Recomme
nded
Wiring
Terminal
Bolt
Specificat
ions
Reco
mmen
ded
Cable
Color
UPS+
1 x M8
(through-hole)
1 x 35mm2
35-M8
M8 x 25
Red
UPS-
1 x M8
(through-hole)
1 x 35mm2
35-M8
M8 x 25
Black
BAT+
1 x M8
(through-hole)
1 x 35mm2
35-M8
M8 x 25
Red
BAT-
1 x M8
(through-hole)
1 x 35mm2
35-M8
M8 x 25
Black
PE
1 x M6 (rivet nut)
1 x 16mm2
16-M6
M6 x 16
Green-
and-yel
low
PDU8000-0250DCV8-BXA005 Cables
Table 3-2 Specifications for PDU8000-0250DCV8-BXA005 cables and terminals
Terminal
Number of
Terminals and
Hole Diameter
Recommende
d Cable
Specification
s
Recomme
nded
Wiring
Terminal
Bolt
Specificat
ions
Reco
mmen
ded
Cable
Color
UPS+
1 x M10
(through-hole)
1 x 95mm2
95-M10
M10 x 40
Red
UPS-
1 x M10
(through-hole)
1 x 95mm2
95-M10
M10 x 40
Black
BAT+
1 x M10
(through-hole)
1 x 95mm2
95-M10
M10 x 40
Red
BAT-
1 x M10
1 x 95mm2
95-M10
M10 x 40
Black

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
3 Installation
Issue 01 (2019-03-07)
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Terminal
Number of
Terminals and
Hole Diameter
Recommende
d Cable
Specification
s
Recomme
nded
Wiring
Terminal
Bolt
Specificat
ions
Reco
mmen
ded
Cable
Color
(through-hole)
PE
1 x M8 (rivet nut)
1 x 35mm2
35-M8
M8 x 25
Green-
and-yel
low
PDU8000-0400DCV8-BXA006 Cables
Table 3-3 Specifications for PDU8000-0400DCV8-BXA006 cables and terminals
Terminal
Number of
Terminals and
Hole Diameter
Recommende
d Cable
Specification
s
Recomm
ended
Wiring
Terminal
Recomme
nded Bolt
Specificati
ons
Reco
mmen
ded
Cable
Color
UPS+
1 x M12
(through-hole)
1 x 150mm2
150-M12
M12 x 45
Red
UPS-
1 x M12
(through-hole)
1 x 150mm2
150-M12
M12 x 45
Black
BAT+
1 x M12
(through-hole)
1 x 150mm2
150-M12
M12 x 45
Red
BAT-
1 x M12
(through-hole)
1 x 150mm2
150-M12
M12 x 45
Black
PE
1 x M10 (rivet nut)
1 x 70mm2
70-M10
M10 x 25
Green-
and-yel
low
PDU8000-0630DCV8-BXA006 Cables
Table 3-4 Specifications for PDU8000-0630DCV8-BXA006 cables and terminals
Terminal
Number of
Terminals and
Hole Diameter
Recommended
Cable
Specifications
Recomm
ended
Wiring
Terminal
Recommend
ed Bolt
Specificatio
ns
Reco
mmen
ded
Cable
Color
UPS+
2 x M12
(through-hole)
1 x (2 x
150mm2)
150-M12
2 x (M12 x
45)
Red

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
3 Installation
Issue 01 (2019-03-07)
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Terminal
Number of
Terminals and
Hole Diameter
Recommended
Cable
Specifications
Recomm
ended
Wiring
Terminal
Recommend
ed Bolt
Specificatio
ns
Reco
mmen
ded
Cable
Color
UPS-
2 x M12
(through-hole)
1 x (2 x
150mm2)
150-M12
2 x (M12 x
45)
Black
BAT+
2 x M12
(through-hole)
1 x (2 x
150mm2)
150-M12
2 x (M12 x
45)
Red
BAT-
2 x M12
(through-hole)
1 x (2 x
150mm2)
150-M12
2 x (M12 x
45)
Black
PE
1 x M12
(through-hole)
1 x 150mm2
150-M12
M12 x 45
Green-
and-yel
low
The recommended cable specifications are for reference only. Prepare cables based on site requirements.
The following table lists the torque for securing bolts in the BCB box.
Table 3-5 Torque for securing bolts
Bolt Specifications
Torque (N.m)
M6
5
M8
13
M10
27
M12
47
M16
120
3.2.4 Cable Connection Precautions

PDU8000-(0125, 0250, 0400, 0630) DCV8-BXAXXX
BCB Box
User Manual
3 Installation
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Before connecting cables, check that the BCB box has been installed properly and that the
circuit breaker on the BCB box is OFF.
Take protective measures, wear insulated gloves and shoes, and stand on the insulated pad
when connecting cables.
Do not simultaneously touch positive and negative terminals to avoid electric shocks when
connecting battery cables.
Install power cables for the four BCB boxes based on their input and output currents.
The BCB box is wall-mounted or rack-mounted. Cables are routed in from the bottom and
out from the top. Reserve sufficient space on the top and bottom of the BCB box.
Each terminal (+, –) must be crimped with two power cables on both sides. That is, when
two cables are routed from batteries or the UPS to the same wiring terminal on the BCB
box, crimp the cable on both sides of the terminal.
Connect cables according to terminal silk screen and wiring diagrams in this document.
Secure cables to the specified torques. Do not short-circuit or reversely connect battery
terminals.
When connecting cables, use an insulated wrench or insulated socket wrench.
3.3 Installing the BCB Box (One Battery String)
This section describes how to install the BCB box for a UPS with a single battery string.
3.3.1 Mechanical Installation
Wall-mounting the BCB Box
Step 1 Install four mounting brackets on the BCB box using 16 M4 screws, as shown in the
following figure.