ZJBENY BCP Series User manual

DLB Box
Manual
DLB Box
Manual
Address :
TEL : [phone] Email : [e-mail]
ZHEJIANG BENYI NEW ENERGY CO.,LTD.
Changjiang Rd, Wenzhou Daqiao Industry Park,
Beibaixiang Town, Yueqing, Wenzhou City, Zhejiang Province, China, 325600
VERSION : 20221210
For the latest version of specification, please refer to www.beny.com or contact to [email protected]
We reserve the right to explain the terms of specification.

1. About DLB
2. DLB Model Selection
3. How DLB Box Works?
4. How to install the DLB box?
5. How to Set the Max Grid Current on DLB Box?
6. DLB Troubleshooting
1. About solar DLB
2. Solar DLB Model Selection
3. How the solar DLB box works?
3.1. CT Installation Diagram
3.2. Once the inverter is too far to install PV CT
3.2.1. How to set on DLB box when you can not install PV CT
4. How to install the DLB box?
5. lnstrustions for using solar DLB
6. Solar DLB Troubleshooting
Normal DLB
Solar DLB
01
01
03
07
11
13
14
15
17
17
21
22
23
29
31
CONTENTS

01 02
1.About DLB
DLB (Dynamic Load Balancing) is available in the BCP series AC EV Charger for home use,
when the EV charger is working with other household appliances at the same time, the DLB
box can maintain the dynamic balance of the total household current and ensure the safety of
electricity to avoid home over load.
Normal DLBNormal DLB
2. DLB Model Selection
Model BCP-DLB-01S BCP-DLB-03S
Number of
Current
Transformers 13
Display OLED
Installation
Communication
Extreme Mode √ √
Allow Distance
between DLB
and Charger
Current
Transformer
Default Length
More than 300M
1.5m(Can be customized up to 15 meters)
Rail installation/screw fixing
RS485(Use RJ45 interface to connect with network)
The DLB Extreme Mode:
For a smart ev charger can be actived via APP setting.
For a unsmart ev charger can be actived via DIP switch (the third one);
How to Active Extreme Mode?
What is Extreme Mode?
Restart to charging once there is enough current like 10A for charger.
In this mode, charging will be stopped once the home loads keep increasing to avoid home
over load.
If the Extreme Mode is not turned on, the EV charger will not stop charging due to the DLB
limit, and the lowest current that DLB can limit will be 6A.
Phase Single Phase Three Phase

3. How DLB Box Works?
1 Phase System with DLB: BCP-DLB-01S (Correct Installation)
L
N
PE
CT
Clamp
EV Charger
Distribution Board Household Loads
Grid
Electric Car
DLB
Ethernet cable
1 Phase System with DLB: BCP-DLB-01S (Incorrect Installation Demo)
CT
Clamp
EV Charger
or
Home Port CT clamped lncorrect
Grid Distribution Board Household Loads
Electric Car
DLB
Ethernet cable
L
N
PE
03 04
Normal DLBNormal DLB
3 Phase System with DLB: BCP-DLB-03S (Correct Installation)
CT
Clamp
EV Charger
Distribution Board Household Loads
Grid
Electric Car
L1
L2
L3
N
PE
DLB
Ethernet cable
3 Phase System with DLB: BCP-DLB-03S (Incorrect Installation Demo)
CT
Clamp
DLB
EV Charger
Distribution Board Household Loads
Grid
Electric Car
L1
L2
L3
N
PE
CT Clamped Incorrect
Ethernet cable

06
Normal DLBNormal DLB
Charging Current
of EV Charger
Household
Load Current
Grid Power
DLB Box
For Single Phase DLB System:
The Current of EVC = Max Grid Current(Set on DLB Box) - Household Load Current
For Three Phase DLB System:
Max Grid Current A Phase(Set on DLB Box) - Household Load Current A Phase
Max Grid Current B Phase(Set on DLB Box) - Household Load Current B Phase
The Current of EVC = The Minimum between:
Max Grid Current C Phase(Set on DLB Box) - Household Load Current C Phase
What the current is that you set on DLB box?
05
The Current of EVC = Max Grid Current (Set on DLB Box ) - Household Load Current
-EV Charger
The Current of EVC = Max Grid Current (Set on DLB Box )- Household Load Current
Grid Power Distribution
Board
DLB Box
Charging Current
of EV Charger
Household
Load Current
Charging Current
of EV Charger
DLB Box
1
2
Other household loads
are equivalent to EV Charger .
1
2
1
2
Multiple EV chargers System with DLB
1
2
2
1

0807
Network cable - 5m
(RJ45 TIA/EIA-568B
8-core cat5 twisted pair cables)
Din rail fixing parts M4*30 expansion screw kit
Please double check your accessories
X2 X2
Din rall 105mm
Current Transformer
(1-phase DLB)*1
or
(3-phase DLB)*3
X1
X1 X1
4. How to install the DLB box?
Normal DLBNormal DLB
X1
Normal DLB box
Network Cable Recommended
Rj45
TIA/EIA-568B
Rj45
TIA/EIA-568B
8-core cat5 twisted pair cables
Length
Network cable connection
Connect the DLB box with charger by the network cable.

CT installation of single phase DLB Box (BCP-DLB-01S)
Make CT clamp on house mains cable.
(Including some of or all of house loads and EV charger power cable)
Red cable of CT should be connected to L1A at the home port;
Blue cable of CT should be connected to L1B at the home port.
09 10
Normal DLBNormal DLB
L1A L1BL2A L2BL3A L3B
Home Port
Network cable
Distribution Board
L N PE
CT installation of Three phase DLB Box (BCP-DLB-03S)
Make CT clamp on house mains cable.
(Including some of or all of house loads and EV charger power cable)
Red cable of CT should be connected to L1A, L2A, L3A at the home port;
Blue cable of CT should be connected to L1B, L2B, L3B at the home port.
L1A L1BL2A L2BL3A L3B
Home Port
Network cable
PENL3L2L1
Distribution Board

11 12
5. How to Set the Max Grid Current on DLB Box?
For 1 Phase DLB box 0/40A
0/40A
0/40A
40
40
40
50
40
40
Press "+" and "-" at
the same time to jump
50
40
40
Press "+", "-" to
adjust the value
For 3 Phase DLB box
Wait for 5S till
automatic set
0/40A
30
Press any button
Press "+", "-" to
adjust the value
40
Current measurement
current
Wait for 5S to
automatically save
Set value
Press any button
Normal DLBNormal DLB

13
LED light status
The yellow light of the charger
light board lights for 1s, then
the red light flashes for one
time, and this happened in turn.
The yellow light of the charger
light board lights on for 1s,and
then the red light flashes twice
in succession.This happens in
turn.
Fault type
DLB offline
DLB current
abnormal
Potential Cause
RS485 cable is not
connected firmly
CT is clamped on
the wrong power
cord
CT open coil is not
connected firmly
The connection
between the CT
cable and the DLB
is loose
Action
Replace
RS485 cable
Reconnect
Check if the CT
position is correct
Reconnect
Reconnect
The DLB box doesn’t
measure the charging
current of EV charger,
check whether the
cable is connected.
Check if the CT
position is correct
Yellow light
on for 1s
Red light
flashes 1
time
Yellow light
on for 1s
The red
light flashes
twice
in a row
RS485 cable is
damaged
Normal DLB
14
1. About solar DLB
Solar DLB (Dynamic Load Balancing) is available in the BCP series AC EV charger for home
and solar home use, controlling and monitoring the different powers from PV to make
different modes come true.
*Pure PV Mode (Almost 0 power from grid)
*Hybrid Mode
*Full Speed Mode (As faster charging as possible)
Solar DLB box can be used for the home without solar power as normal DLB box.
Solar DLB
Solar DLB

16
15
2. Solar DLB Model Selection
Model
Operating Mode
BCP-DLB-11M BCP-DLB-13M
PV
Night Automatic
Full Speed Mode
PV
PV to Normal
/Normal to PV √ √
Number of Current
Transformers 26
OLED
Display
More than 300M
Distance between
DLB box and RV
charger suppert
Current
Transformer
Default Length
1.5m(Can be customized up to 15 meters)
Installation Rail installation/Screw fixing
Communication RS485(Use RJ45 interface to connect with network)
In this mode, once the household load continues to increase and the photovoltaic power
generation is not enough to maintain the minimum current of the EV charger, it will stop
charging to avoid using too much grid power (this power depends on the set value). When the
EV charger has enough current (eg 10A), restart charging.
Extreme Mode
√ √
√ √
What is PV Extreme Mode?
We can set the Night Automatic Mode through APP.
How to Active Night Automatic Full Speed Mode?
What is Night Automatic Full Speed Mode?
In this mode the EV charger will remain charged at full speed (Pm20:00- Am6:00). Note: The
coin cell battery is not installed in the original factory charger (the battery is installed by
yourself if required), the EV charger will lose this configuration after restarting, and it needs to
reconnect the APP to configure it.
Pure PV Mode
The EV charger in the pure PV mode will control its own
charging current as much as possible, so that the actual
input value of the grid current is as close as possible to
0A.
Hybrid Mode
The EV charger in hybrid mode will control its own
charging power to keep the grid input power as close as
possible to the DLB setting.
Full Speed Mode
When the EV charger is working in full speed mode, the
DLB will no longer limit the charging current of the EV
charger, and the charging pile will use the maximum
current supported for charging.
Full Speed Mode
Hybrid Mode
Pure PV Mode
4.6kW
Introduction to the three modes of DLB
Solar DLBSolar DLB
Phase Single Phase Three Phase

1817
3.1 CT Installation Diagram
3. How the solar DLB box works?
1 Phase System with DLB： BCP-DLB-11M (Correct Installation)
1
If it is impossible to connect due to distance or other reasons, you can refer to the
installation method described in the following chapters and don't need to install the CT
clamp.
Solar DLBSolar DLB
L
N
PE
EV Charger
Grid
Distribution Board Household Loads
Electric Car
Inverter Solar Panel
Ethernet cable
1
L
N
PE
Home Po rt PV Port
1 Phase System with DLB： BCP-DLB-11M (Incorrect Installation Demo)
1 Phase System with DLB： BCP-DLB-11M (Incorrect Installation Demo)
L
N
PE
EV Charger
Grid
Distribution Board Household Loads
Electric Car
Inverter Solar Panel
Ethernet cable
Home Po rt PV Port
PV Port CT Clamped Incorrect
L
N
PE
Home Port CT
clamped Incorrect
EV Charger
Grid
Distribution Board Household Loads
Electric Car
Inverter Solar Panel
Ethernet cable
Home Po rt PV Port

19 20
Solar DLBSolar DLB
3 Phase System with DLB： BCP-DLB-13M (Correct Installation)
L1
L2
L3
N
PE
L1
L2
L3
N
PE
EV Charger
Grid
Distribution Board Household Loads
Electric Car
Inverter Solar Panel
Ethernet cable
Home Po rt PV Port
3 Phase System with DLB BCP-DLB-13M ：(Incorrect Installation Demo)
Home Port CT clamped Incorrect
EV Charger
Grid
Distribution Board Household Loads
Electric Car
Inverter Solar Panel
Ethernet cable
Home Po rt PV Port
L1
L2
L3
N
PE
L1
L2
L3
N
PE
CT Clamped
Incorrect
Charging Power
of EV Charger
PV Output
Power
Household
Load Power
Grid Power
DLB Box
What the current is that you set on Solar DLB box?
“The allowable power of EVC”=Max grid power (set via DLB)*(Phase of the current EV
charger)”+“The sum of the three phase
power of PV power” - “The sum of the three phase power of household load”
“The allowable power of EVC”=
“Max grid power”(set via DLB) + “PV output power”- “household load power”
For 1-Phase Solar DLB System:
For 3-Phase Solar DLB System:
3 Phase System with DLB BCP-DLB-13M ：(Incorrect Installation Demo)
PV Port CT
Clamped Incorrect
L1
L2
L3
N
PE
L1
L2
L3
N
PE
EV Charger
Grid
Distribution Board Household Loads
Electric Car
Inverter Solar Panel
Ethernet cable
Home Po rt PV Port
CT Clamped Incorrect

2221
Solar DLBSolar DLB
3.2.1 How to set on DLB box when you can not install PV CT
0.0 0.0 0.0
Disable
Solar CT
Yes No
Solar mode
Solar CT
Press "-" and "+"
for mode selection,
press simultaneously to enter
Press any button
Press "-" to select YES,
press "+" to select NO and save
Press "-" and "+"
for mode selection,
press simultaneously to enter
Solar CT
3.2 Once the inverter is too far to install PV CT
1 Phase System with Solar DLB
EV Charger
L
N
PE
3 Phase System with Solar DLB
Distribution Board Household Loads
Electric Car
Grid Distribution Board Household Loads
Inverter Solar Panel
Distribution Board Household Loads
EV Charger
Grid
Inverter Solar Panel
Electric Car
Ethernet cable
Ethernet cable
L1
L2
L3
N
PE

23 24
Network Cable Recommended
Rj45
TIA/EIA-568B
Rj45
TIA/EIA-568B
8-core cat5 twisted pair cables
Length
Network cable connection
Connect the DLB box with charger by the network cable.
Solar DLBSolar DLB
4. How to install the DLB box?
M4*30 expansion screw kit
Please double check your accessories
Network cable - 5m
(RJ45 TIA/EIA-568B
8-core cat5 twisted pair cables)
Din rail fixing parts
X2 X2
Din rall 105mm
Current Transformer
(1-phase Solar DLB)*2
or
(3-phase Solar DLB)*6
X1
X1 X1 X1
Solar DLB box

CT installation of single phase solar DLB Box (BCP-DLB-11M)
Make CT clamp on house mains cable.
(Including some of or all of house loads and EV charger power cable)
Red cable of CT should be connected to L1A at the home port and PV port;
Blue cable of CT should be connected to L1B at the home port and PV port.
2625
Solar DLBSolar DLB
DLB voltage signal acquisition line connection (single phase)
L1
NCT Clamp of PV Port
L1(A,B)
CT Clamp of Home Port
L1(A,B)
L1A L1B L2A L2B L3A L3B
L1 L2 L3 N
L1A L1B L2A L2B L3A L3B
Distribution Board
Network cable
Home port and PV port
L1A L1BL2A L2BL3A L3B
L1A L1BL2A L2BL3A L3B
L N PE
Home CT
PV CT
Inverter
Distribution Board
L
N
PE

Solar DLBSolar DLB
DLB voltage signal acquisition line connection (three-phase)
L1L2
L3N
CT Clamp of PV Port
L1(A,B),L2(A,B),L3(A,B)
CT Clamp of Home Port
L1(A,B),L2(A,B),L3(A,B)
L1A L1B L2A L2B L3A L3B
L1 L2 L3 N
L1A L1B L2A L2B L3A L3B
Distribution Board
CT installation of three phase solar DLB Box (BCP-DLB-13M)
Make CT clamp on house mains cable.
(Including some of or all of house loads and EV charger power cable)
Red cable of CT should be connected to L1A, L2A, L3A at the home port and PV port;
Blue cable of CT should be connected to L1B, L2B, L3B at the home port and PV port.
Home port and PV port
L1A L1BL2A L2BL3A L3B
L1A L1BL2A L2BL3A L3B
Network cable
PENL3L2L1
Distribution Board
PV CT
Inverter
Home CT
L1
L2
L3
N
PE
27 28

29 30
How to switchover between solar DLB and normal DLB?
0.0 0.0 0.0
Switch to
PV Mode
Yes No
Switch to
Normal Mode
Yes No
0 0 20
Long press buttons
for 5 seconds
0/40A
0/40A
0/40A
5. lnstrustions for using solar DLB How to switchover between different Modes of solar DLB?
Solar mode
Press "+", "-" to
adjust the mode
Wait for 5S to
automatically save
Only PV Mode
Full Speed Mode
0 0 0
Press any button
Hybrid Mode
4.6kW
press simultaneously
Solar DLBSolar DLB

31
6. Solar DLB Troubleshooting
LED light status
The yellow light of the charger
light board lights for 1s, then
the red light flashes for one
time, and this happened in turn.
The yellow light of the charger
light board lights on for 1s,and
then the red light flashes twice
in succession.This happens in
turn.
Fault type
DLB offline
DLB current
abnormal
Potential Cause
RS485 cable is not
connected firmly
CT is clamped on
the wrong power
cord
CT open coil is not
connected firmly
The connection
between the CT
cable and the DLB
is loose
Action
Replace
RS485 cable
Reconnect
Check if the CT
position is correct
Reconnect
Reconnect
The DLB box doesn’t
measure the charging
current of EV charger,
check whether the
cable is connected.
Check if the CT
position is correct
Yellow light
on for 1s
Red light
flashes 1
time
Yellow light
on for 1s
The red
light flashes
twice
in a row
RS485 cable is
damaged
Solar DLB