KEHUA TECH BCS-B-HM Series User manual

Power Conversion System
BCS-B-HM Series (75K-125K)
User Manual

All rights reserved © Kehua Data Co., Ltd.
i
Copyright © Kehua Data Co., Ltd. 2021.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 Kehua Data Co., Ltd.
Trademarks and Permissions
and other Kehua trademarks are trademarks of Kehua Data 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 Kehua 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 specification 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.
KEHUA DATA CO.,LTD.
Address:
No.457,MalongRoad,TorchHigh-TechIndustrialZone,Xiamen,Fujian,China
Website:
www.kehua.com
E-mail:
[email protected]
Customer Service Telephone:
400-808-9986
Tel:
0592-5160516
Fax:
0592-5162166

Foreword
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
ii
All rights reserved © Kehua Data Co., Ltd.
Foreword
Summaries
Thank you for choosing the Kehua's power conversion system (hereinafter referred to as PCS)!
This document gives a description of the PCS, including appearance, features, working principles,
installation, electrical connection, operation, maintenance and storage, etc.
Please save the manual after reading, in order to consult in the future.
The figures in this manual are just for reference, for details please see the actual product.
Applicable Model
BCS75K-B-HM
BCS100K-B-HM
BCS125K-B-HM
Symbol Conventions
The manual quotes the safety symbols, these symbols used to prompt users to comply with safety
matters during installation, operation and maintenance. Safety symbol meaning as follows.
Symbol
Description
Alerts you to a high risk hazard that will, if not avoided, result in
serious injury or death.
Alerts you to a medium low risk hazard that could, if not avoided,
result in moderate or minor injury.
Alerts you to a low risk hazard that could, if not avoided, result in
minor injury.
Anti-static prompting.

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
Foreword
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iii
Symbol
Description
Be care electric shock prompting.
Provides a tip that may help you solve a problem or save time.
Provides additional information to emphasize or supplement
important points in the main text.
Product standard: CE, IEC 62477, IEC 61000

Contents
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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All rights reserved © Kehua Data Co., Ltd.
Contents
1 Safety Description.........................................................................................................................1
1.1 Safety Announcements.....................................................................................................................................1
1.1.1 Use Announcements................................................................................................................................1
1.1.2 Energy Storage Battery Protection..........................................................................................................3
1.1.3 ESD Protection........................................................................................................................................3
1.1.4 Grounding Requirements........................................................................................................................3
1.1.5 Moistureproof Protection........................................................................................................................4
1.1.6 Warning Mark Setting.............................................................................................................................4
1.1.7 Electrical Connection..............................................................................................................................4
1.1.8 Live Line Measurement..........................................................................................................................5
1.2 Operator Requirements ....................................................................................................................................5
1.3 Announcements for Maintenance.....................................................................................................................5
1.4 Others...............................................................................................................................................................6
2 Overview.........................................................................................................................................7
2.1 Product Intro.....................................................................................................................................................7
2.1.1 Features...................................................................................................................................................8
2.1.2 Model Meaning.......................................................................................................................................8
2.2 Apperance and Structure ..................................................................................................................................9
2.2.1 Apperance ...............................................................................................................................................9
2.2.2 Dimensions ...........................................................................................................................................13
2.3 Working Principle...........................................................................................................................................13
2.4 Work Mode.....................................................................................................................................................14
2.5 Communication..............................................................................................................................................15
2.5.1 Communication to PCS.........................................................................................................................15

Power Conversion System BCS-B-HM Series
(75K-125K)
User Manual
Contents
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2.5.2 Communication to BMS .......................................................................................................................18
3 Installation....................................................................................................................................20
3.1 Installation Process.........................................................................................................................................20
3.2 Unpacking and Checking...............................................................................................................................21
3.3 Selection of Installation Site ..........................................................................................................................21
3.3.1 Installation Environment.......................................................................................................................21
3.3.2 Installation Clearance............................................................................................................................22
3.3.3 Requirements for Installation Carrier....................................................................................................24
3.3.4 Installation Method...............................................................................................................................24
3.4 Transportation ................................................................................................................................................25
3.4.1 Handle Transporting..............................................................................................................................25
3.4.2 Ring Transporting .................................................................................................................................26
3.5 Installation Tools............................................................................................................................................27
3.6 Mechanical Installation..................................................................................................................................28
3.6.1 Bracket Installation...............................................................................................................................28
3.6.2 Wall Mounting ......................................................................................................................................32
3.7 Electrical Connection.....................................................................................................................................36
3.7.1 Safety Announcements..........................................................................................................................36
3.7.2 Requirements for Wire..........................................................................................................................36
3.7.3 External Grounding Connection ...........................................................................................................37
3.7.4 AC Wiring.............................................................................................................................................39
3.7.5 Internal Grounding Connection.............................................................................................................43
3.7.6 DC Wiring.............................................................................................................................................44
3.7.7 WIFI Communication Connection (Optional) ......................................................................................46
3.7.8 Communication Connection .................................................................................................................47
3.8 Check the Installation.....................................................................................................................................47
4 Startup and Shutdown ...............................................................................................................48
4.1 Check Before Startup.....................................................................................................................................48
4.2 Start the PCS..................................................................................................................................................49

Contents
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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All rights reserved © Kehua Data Co., Ltd.
4.3 Shut Down the PCS........................................................................................................................................49
5 Maintenance and Troubleshooting .........................................................................................50
5.1 Maintenance...................................................................................................................................................50
5.1.1 Maintenance Details and Period............................................................................................................50
5.1.2 Maintenance Guide...............................................................................................................................51
5.2 Troubleshooting..............................................................................................................................................53
6 Stop Running, Dismantle, Discard..........................................................................................59
6.1 Stop Running..................................................................................................................................................59
6.2 Dismantle the PCS .........................................................................................................................................60
6.3 Discard the PCS .............................................................................................................................................60
7 Package, Transportation, Storage.............................................................................................61
7.1 Package ..........................................................................................................................................................61
7.2 Transportation ................................................................................................................................................61
7.3 Storage ...........................................................................................................................................................61
A Technical Specifications...........................................................................................................62
B Fasten Torque List......................................................................................................................71
C Quality Assurance......................................................................................................................72
D Acronyms and Abbreviations..................................................................................................74

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
1 Safety Description
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1
1 Safety Description
This chapter mainly describes the safety announcements. Prior to performing any work on the device,
please read the user manual carefully, follow the operation and installation instructions and observe
all danger, warning and safety information.
1.1 Safety Announcements
This section mainly describes the safety announcements when operating and maintaining. For details,
please refer to safety description in relevant chapters.
Before operation, please read the announcements and operation instructions in this section carefully
to avoid accident.
The promptings in the user manual, such as "Danger", "Warning", "Caution", etc. don't include all
safety announcements. They are just only the supplement of safety announcements when operation.
Any device damage caused by violating the general safety operation requirements or safety standards
of design, production, and usage will be out of Kehua's guarantee range.
1.1.1 Use Announcements
Don't touch terminals or conductors that connected with grid to avoid lethal risk！

1 Safety Description
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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All rights reserved © Kehua Data Co., Ltd.
There is no operational part inside the device. Please do not open the crust by yourself, or it may
cause electric shock. The device damage caused by illegal operation is out of the guarantee range.
After disconnect the input and output of the PCS, there still has residual energy in the storage
capacitor, which may cause electric shock. Do not perform the maintenance until all power sources
are switched off for 10 minutes.
Please do not put fingers or tools into the rotating fans to avoid human injury or device damage.
The surface temperature of the PCS may reach to 75℃. During running, please don't touch the
surface to avoid scald.
In case of fire, please use dry power fire extinguisher. If using liquid fire extinguisher, it may cause
electric shock.
No liquid or other objects are allowed to enter the PCS, or, it may cause device damage.

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
1 Safety Description
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1.1.2 Energy Storage Battery Protection
There exists dangerous high voltage between the positive and negative of energy storage battery! If
touching by accident, it may cause electric shock or human injury!
When maintaining the device, make sure that the connection between the PCS and energy storage
battery has been disconnected completely. And set warning mark in the disconnected position to
avoid reconnecting by accident.
1.1.3 ESD Protection
To prevent human electrostatic damaging sensitive components (such as circuit board), make sure
that you wear an anti-static wrist strap before touching sensitive components, and the other end is
well grounded.
1.1.4 Grounding Requirements
High leakage risk! The PCS must be grounded before wiring. The grounding terminal must be
connected to ground, or, there will be the risk of electric shock when touching the PCS.
When installing, the PCS must be grounded first. When dismantling, the grounding wire must be
removed at last.
Don't damage the grounding conductor.
The PCS must be connected to protection grounding permanently.
Before operation, check the electrical connection to ensure the PCS is grounded reliably.

1 Safety Description
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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1.1.5 Moistureproof Protection
Moisture invasion may cause the device damage!
Observe the following items to ensure the PCS works normally.
When the air humidity is more than 95%, don't open the cover of the PCS.
In the wet or damp weather, don't open the cover of the PCS to maintain or repair.
1.1.6 Warning Mark Setting
In order to avoid accident for unwanted person gets close to the PCS or makes improper operation,
observe the following requirements while installing, maintaining or repairing.
Set warning marks where the switches are to avoid closing them improperly.
Set warning signs or safety warning belt in the operation area, which is to avoid human injury or
device damage.
1.1.7 Electrical Connection
Electrical connection must be performed according to the description and the electrical circuit
schematic in the user manual.
The configuration of battery, grid level, grid frequency, etc. must meet the technical requirements of
the PCS.
Grid-tied operation should be allowed by the local power supply department and the related operation
should be performed by professionals.
All electrical connection must meet the electrical standards of the country or local region where the
project located..

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
1 Safety Description
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1.1.8 Live Line Measurement
There exists high voltage in the device. If touching the device accidently, it may cause electric shock.
So, when perform measurement under operation, it must take protection measure (such as wear
insulated gloves, etc.)
The measuring device must meet the following requirements:
The range and operation requirements of measuring device meets the site requirements;
The connections for measuring device should be correct and standard to avoid arcing.
1.2 Operator Requirements
The operation and wiring for the PCS should be performed by qualified professional technicist,
which is to ensure that the electrical connection meets the related standards.
The professional technicist must meet the following requirements:
Be trained strictly and understand all safety announcements and master correct operations.
Fully familiar with the structure and working principle of the whole energy storage system.
Know well about the related standards of local country and district.
1.3 Announcements for Maintenance
After the connection at AC side and DC side of the PCS disconnected, it is necessary to wait at least
10 minutes, and then the maintenance can be done.
After the PCS power off and stop running, while maintenance, pay attention to following items.

1 Safety Description
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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All rights reserved © Kehua Data Co., Ltd.
Ensure that the PCS cannot reconnected by accident.
Ensure that the inner PCS has no electricity by multimeter.
Perform necessary grounding connection.
Cover the part that may with electricity by insulation material.
During maintenance, keep the escape way unblocked.
1.4 Others
All operation for the PCS must meet the relevant standards of the country or local region where the
project located.
When the PCS is electrified, it is strictly prohibited to carry out the maintenance.
It is necessary to keep at least two people be present while maintenance.
After the PCS power off and completely discharged, the maintenance operation can be done.
Besides, it is necessary to take following safeguard or emergency according to the actual situation.
The operator should take proper safeguard procedures according to needs, such as wear
noise-proof earplugs, insulated shoes, etc.
Generally, the PCS is installed far away from downtown, so, it is necessary to prepare relevant
emergency rescue facility to use in emergency.
Take any necessary auxiliary measures to ensure the safety of human and device.

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
2 Overview
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2 Overview
This chapter mainly describes the appearance, structure, working principle and communication
method, etc of the PCS.
2.1 Product Intro
BCS-B-HM series power conversion system is independently researched and developed by Kehua
Company. It can be used in energy storage link. The basic characteristic is bidirection (rectification,
inverter), and also, it has a series of special performance. It can be used in condition of grid-tied and
off-grid. The energy storage link in smart grid can effectively regulate the electric resources and well
balance the power consumption differences between day and night and different seasons, adjust the
surplus and shortage and guarantee the grid security. It is an important premise for renewable energy
application and an effective means to realize intelligent management. The PCS is a necessary link to
realize smart grid. The energy storage system is made up of energy storage batteries, PCS,
transformer, grid and load, as shown Figure2-1.
Figure2-1 Constitution of energy storage system

2 Overview
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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All rights reserved © Kehua Data Co., Ltd.
Grid-tied operation of the PCS needs to obtain the permission of local power supply department and
performed by professionals.
The grid form supported by the PCS is shown in Figure2-2.
Transformer
IT
PE
U
V
W
PCS
Figure2-2 Grid form
2.1.1 Features
Integrated system
Modular design: can be matched and integrated with battery system conveniently and flexibly.
With built-in DC pre-charge function, for user's battery, it no needs to configure independent
buffer circuit, and can be used immediately after inserting, which is safe and reliable.
Efficient and smart
Efficient three level design, the max. efficiency ＞98.8%.
Advanced midpoint potential balance control technology, effectively reduce the ripple voltage
and improve the service life of bus capacitors.
With the function of fault wave capture / remote online update.

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
2 Overview
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Flexible and conveniently
Convenient modular design, which makes the installation more easily, and decrease the
maintenance costing.
Support the AC parallel operation of several PCS. The system scheme configuration is flexible.
With independent design of fan module to realize the quick installation and maintenance.
With IP65 design, can adapt various wicked environment.
2.1.2 Model Meaning
BCS □□□K-B-H M
Product series mark
BCS series power conversion system.
Rated output power mark
When it is 75, it means the rated power is 75kVA;
When it is 125, it means the rated power is 125kVA;
And so on.
Voltage type mark
H represents high-voltage.
Isolation type mark
B represents non-isolated power.
Device type mark
M represents modular device.
Figure2-3 Model meaning
2.2 Apperance and Structure
2.2.1 Apperance
The appearance of the PCS is as shown in Figure2-4.

2 Overview
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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Figure2-4 Appearance
Table2-1 Component illustration
No.
Name
Illustration
○
1
Display panel
It is used to indicate the current work status of the PCS.
○
2
AC breaker
It is the connection switch of the PCS and grid.
○
3
DC switch
It is the connection switch of the PCS and battery.
○
4
Handle
It is used to carry the PCS
○
5
Fan
It is used to cool down the PCS
○
6
Bottom board
It is used to connect electrical wires
Display Panel
There are 5 status indicators on the front panel of the PCS (as shown in Figure2-5), which can
indicate the current work status of the PCS. The status of each indicator is shown in Table2-2.

Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
2 Overview
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Figure2-5 Operation panel
Table2-2 Indicator status illustration
No.
Silk-screen
Color
Meaning
Status illustration
○
1
POWER
Green
Work power
indicator
On: the inner power of the PCS has been
established.
Off: the inner power of the PCS has not been
established.
○
2
BATT.
Green
Battery connection
indicator
On: the battery has been connected and meets
the work condition.
Off: the battery voltage does not meet the
work condition.
○
3
RUN
Green
Running status
indicator
On: in grid-tied operating status.
Flicker (flickers 2 times every second):
operating in VSG status
Flicker (flickers 1 time every 2 seconds):
off-grid operating
Off: not operating
○
4
FAULT
Red
Fault alarm
indicator
On: there is fault on PCS
Flicker: there is alarm on PCS
Off: there is no fault or alarm
○
5
BT
Green
Bluetooth
indicator
On: the Bluetooth is normally connected
Flicker: the Bluetooth is ready to connect
Off: the power of Bluetooth is not established

2 Overview
Power Conversion System BCS-B-HM Series (75K-125K)
User Manual
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All rights reserved © Kehua Data Co., Ltd.
AC breaker and DC switch
The AC breaker (the position is shown as ○ 2 in Figure2-4) is the connection switch between the
PCS and the grid. DC switch (the position is shown as ○ 3 in Figure2-4) is the connection switch
between the PCS and battery. When necessary, they can safely disconnect the connection of grid,
PCS and battery. In order to ensure the safety of the operator, make sure that the AC breaker and DC
switch are turned off under the following conditions.
While installing and wiring, the AC breaker and DC switch must be placed to OFF position.
Before maintenance, set the AC breaker and DC switch to OFF position and wait for 10 minutes.
Use a multimeter to measure the DC bus voltage inside the PCS, only when the voltage is lower
than 10V, you can perform the maintenance.
Bottom board layout
The PCS's bottom layout is shown as Figure2-6.
Figure2-6 Bottom layout
Table2-3 Mark illustration
No.
Mark
Illustration
Remarks
○
1
-
Breather valve
Used to balance the pressure difference
between inside and outside of the PCS.
○
2
AC PORT
AC output wiring hole
Used to connect the wires of AC side
○
3
N
Reserved
Reserved