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BYD DC Power Supply System

for
MEA



Version No. / Modification No.: A/0


2013.06.14

I

Content
1 Project Introduction ............................................................................................................................... 1
2 Supply Range .......................................................................................................................................... 2
3 System Solution ..................................................................................................................................... 2
3.1 System Characteristics and Technical Strength ......................................................................... 2
3.2 System Technical Parameters ..................................................................................................... 4
3.3 System Protection Design ........................................................................................................... 4
3.4 System Function Design .............................................................................................................. 5
3.4.1 Battery System .................................................................................................................. 6
3.4.1.1 Battery .................................................................................................................... 6
3.4.1.1.1 Single Cell ..................................................................................................... 7
3.4.1.1.2 Battery Module ............................................................................................ 8
3.4.1.2 Battery Cabinet Design ........................................................................................... 9
3.4.1.3 BMS Design ........................................................................................................... 11
3.4.2 Charger ............................................................................................................................ 20
3.4.3 Communication Topology ............................................................................................... 21
3.4.4 Control Strategy .............................................................................................................. 21
4 System Installation Requirements ...................................................................................................... 22


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1 Project Introduction
(1) Background
MEA now has almost 200 substations in operation. Most of them are transforming
voltage from transmission voltage (115kV or 69 kV) to distribution voltage (24 kV or 12
kV) system. In each substation there are many switching equipment for the control,
operation and protection of the power delivery system.
These switchgears are all powered by DC source located within each substation, both
in normal operation and during the power outage.
These DC source come from Battery. They are all Ni-Cd battery now. BYD will provide
Li-iron phosphate 110VDC power supply system to replace the Ni-Cd system.

(2) Technical Requirements
Load: DC110V, 300Ah, 5hours backup
Voltage controlled shall be within 1% regardless of variation in load between
0 and 100%
Frequency variation 50Hz5%
Main voltage fluctuations 10%

(3) Environment Requirements
Altitude :approximately mean sea level
Maximum ambient temperature :40
Average ambient temperature in any one year :30
Average relative humidity in any one year :79%
Average maximum relative humidity in any one year :94%







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2 Supply Range
This 110VDC power supply system consists of Li-iron phosphate battery, battery
management system and DC charger. Supply range is showed as below:
Table 2-1-1 Supply range list
Items Name Type Unit Quantity Remarks
1 Battery C12 pcs 72
2 BMS Set 1
3 DC Charger Including power module and switches Set 1
4 Cable
Including power cable, communication
cable and distribution cable
Set 1


3 System Solution
3.1 System Characteristics and Technical Strength
Adopt BYD mature, safe and reliable Li-iron phosphate battery which already been
widely used in DC power system of BYD PV station and energy storage system,
other battery energy storage system and BYD electric vehicle e6 and K9.
The design and testing for Li-iron phosphate battery are followed UL 1642.5
th and
IEEE 1625-2004 standard.
Modularized design with simple configuration, easy for maintenance and
Installation.
Intelligent BMS with balancing for single cell and battery and battery module
dynamic consistency to ensure reliable and long time operation for battery system.

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Fig.3.1-1BYD 1MWpPV Station DC Power System

Fig.3.1-2 BYD 1MW-4MWhBattery Energy Storage System DC Power System


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3.2 System Technical Parameters
Rated capacity for energy storage: 39 kwh
Input voltage/frequency: 230/400 50Hz; three phases four lines
Output voltage: 110VDC

Table 3.2-1 System Parameters
ITEMS PARAMETERS REMAKS
1 System rated voltage DC110V
2 Input voltage range 400V10%
3 Input frequency range 50Hz5%
4 Rated output voltage DC115V
5 Output voltage range DC115V1%
6 Ripple factor 0.5%
7 Voltage stabilization accuracy 0.5%
8 Current stabilization accuracy 0.5%
9 Current-sharing unbalance 5%
10 Noise 55dB(A)
11 Allowed ambition temperature +0+40
12 Allowed relative humidity 10%95% Non-condensing
13 Allowed Elevation 2000m
14 Installation Indoor IP20
15 External communication type CAN


3.3 System Protection Design
There are perfect protections for battery system and DC charger to ensure the system
and maintenance workers safety. System protection includes but not limited below
items:
Automatic recovery protection
Below protections are all automatic protections. At the same time, adjustments for
the system failure warning value through remote or local monitoring system are
allowed; receive the control system warning information from clients side then
response as requirements to lowest the system potential damages.

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Battery over-current protection
Single cell over/low voltage protection
Single cell over/low temperature protection
AC over/low voltage protection
DC over/low voltage protection
Communication abnormal protection
Manual recovery protection
If failure value is in the range of protection, the protection can be recovered
automatically. When the value is over the protection range, manual recovery or
replacing is needed.
Battery short-circuit protection
Battery isolated monitoring
Short-circuit protection
Grounding failure protection
Emergency stop protection
Contactor abnormal protection
Grounding protection

3.4 System Function Design
This system consists of battery system and DC charger. 36pcs C12 batteries are in
series as one array, two arrays are in parallel as one battery group to connect with one
6.6KW power module to realize uninterrupted DC power supply as below:

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400V
AC
SOURCE
DCLOAD
CB2
100A
CB3
100A
CB4
100A
CB1
32A
Batteryand
BMS
Charger
MK
DW

Fig.3.4-1 DC Power Supply Topology
Working principle of the DC power supply system:
(1) When the AC input is normal, 400VAC will be transferred to 110VDC through
power rectification module to provide power supply to the 110VDC loads.
400V AC SOURCECB1MKCB2DWCB4DC LOAD
When the battery capacity is not enough, power from 400VAC will also charge
the battery. 400V AC SOURCECB1MKCB2CB3Battery.
(2) CB3 is a polar switch module which can be controlled, when the battery is
fully charged, battery cannot be charged continually; when there is no
electricity from grid, battery will provide power continually through CB3 with
seamless switch.
(3) When there is something wrong with the grid, close the discharging loop
through CB3, battery will provide power to the loads continually.
BatteryCB3DWCB4DC LOAD.
When the AC power recovery, battery will stop discharging, the system will
work as (1).

3.4.1 Battery System
3.4.1.1 Battery

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3.4.1.1.1 Single Cell
Adopt BYD C12 Li-iron phosphate battery with squareness aluminum shell through
strict producing and checking to ensure the quality of the battery.

Fig.3.4-2 BYD C12 Single Cell

Table 3.4-1 C12 Single Cell Parameters
NO. ITEM PARAMETER REMARK
1 Cell type C12
2 Nominal Voltage(V) 3.2
3 Cell charge cut-off voltage (V) 3.6
4 Cell discharge cut-off voltage (V) 2.8
5 Cell nominal capacity(Ah) 200
6 Cell nominal capacity (Wh) 640
7 Volume ratio of energy (Wh/L) 182.5
8 Weight ratio of energy (Wh/kg) 106.7
9 Voltage sampling channel 1
10 Temperature sampling channel 1
11 Enclosure material Aluminum
12 Cell shell flame retardant rating ULV-0
13 Cell dimension(mm) 58146417
14 Cell weight(kg) 6.0

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3.4.1.1.2 Battery Module
Each battery module consists of 4 single cells in series. Single cells voltage and
temperature monitoring are included in the battery module. Each single cells rated
capacity is 190Ah; named voltage is 3.2V, 4 cells in series as one 12.8V 190Ah battery
module. Battery module can increase the safety, reliability and easy for installation
and maintenance.
enclosure
BMU
cell module

Fig.3.4-3 Battery Module

Table 3.4-2 Parameters for Battery Module
NO. ITEM PARAMETER REMARK
1 Battery module nominal Voltage(V) 12.8
2 DOD 90%~95%DOD Recommend
3 Battery module charge cut-off voltage (V) 3.6V Cells highest voltage
4 Battery module discharge cut-off voltage (V) 2.8V Cells lowest voltage
5 Charge current (A) 40A(Standard)
200A(Max. constant current)

6 Discharge current (A) 40A(Standard)
400A(Max. constant current
@25)

7 Nominal working temperature () 25

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NO. ITEM PARAMETER REMARK
8 Working voltage range () +10~+40 Without derating
9 Connection method between modules Bolt or connector
10 Enclosure material PPO
11 Modules Dimension(mm) 474285170mm
12 Sampling circuit interface Connector type: Tyco
connector 1318774-1

13 Voltage sampling channel number 4
14 Voltage sampling frequency >1Hz
15 Voltage sampling Accuracy 2%
16 Temperature sampling channel number 4
17 Temperature sampling frequency >0.25Hz
18 Temperature sampling Accuracy 2

3.4.1.2 Battery Cabinet Design
36 cells are in series as one array, 2 arrays are in parallel as one group using 2 units
BYD BMS. Two arrays battery, fuse type isolated switch, contactor, checking unit,
sampling line, BMS control unit are all placed in one battery cabinet.
+
QS
KM
CT
R
BMS
36batterycell
_

Fig.3.4-4 Battery Array Intelligent Sketch

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Fig.3.4-5 Battery Cabinet Design and Installation Sketch (for reference)

Fig.3.4-6 Appearance of Battery Cabinet (for reference)



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The intelligent type for battery system and voltage range is all suitable for the power
module voltage output and loads voltage requirements.
Table 3.4-2 Battery System Parameters
Items Specification Remarks
1 Cells quantity for one battery array 36pcs
2 Battery array parallel quantity 2array
3 Battery array voltage range 100.8V129.6V This range can be set through software.
4 Battery rated voltage 115.2V Rated voltage for single cell can be limited.

3.4.1.3 BMS Design
The proposed unit adopts BYD self-developed battery management system for the
LiFePO4 battery, each battery management system including:
Battery management unit (BMU);
Battery Gateway Unit (BGU);
Battery electrical controlling Unit (BECU);
Battery stack management unit (BSMU).
The functions of BMS shows below ensure normal, stable and reliable operation of the
batteries.
Battery status monitor
Operation control
Insulation monitor
Dynamic balancing management
Protection alarm
Communication
1) BMS Principle and Characteristic
The BMS monitors the voltage and temperature of single cells, and the current of the
battery string in real time. It calculates the State of Charge (SOC), State of Health (SOH)
of the battery string, detects the insulation status, and also communicates with the

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upper machine, sends alarm information, conducts protection action, balance cells
and so on.
IMD
Module 10
Module 18
BMU10
BMU18
BGU2
BSMU
BECU 2
VT
VT
CAN
CAN
Module 1
Module 9
BMU1
BMU9
BGU1 BECU 1
VT
VT
CAN
CAN

Fig.3.4-7 Schematic diagram of BMS structure

a) BMU Principle and Characteristic
Every module is equipped with one BMU, the functions of BMU are as following:
Monitor the voltage of each single cell in the module and track the real-time
battery voltage changes;
Monitor the temperature of each single cell in the modules and track
real-time battery temperature changes.
Battery balancing -balance cells to ensure battery consistency;
With isolation CAN communication interface transmitting battery voltage,
temperature and alarm information, and also communicate with BGU to
accept system level management.


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Fig.3.4-8 Schematic diagram of BMU installed position

b) BGU Principle and Characteristic
Each battery string is furnished with one BGU. The BGU communicates with the
BMU on the battery module in real time through CAN interface to monitor the
battery status of battery modules and send the battery voltage, temperature and
alarm information to the upper management unit. The upper management unit
will then control battery modules working status based on the information sent
by BGU to ensure safety operation of the module.


Fig3.4-9 Schematic diagram of BGU enclosure

c) BECU Principle and Characteristic
Each battery string is furnished with one BECU. The BECU communicates with the BGU
of the battery string through CAN interface to manage the working of the whole string,
controlling the battery string working state base on the information sent by the BGU,
to insure the safety operation of the battery string.


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Fig.3.4-10 Schematic diagram of BECU enclosure
The functions of the BECU contain:
Battery information management: cooperate with BGU, BMU to manage the
voltage and temperature of every cell, deal with the alarm information sent
by BGU, BMU and then feed back to the upper manager;
Monitoring and control of the battery string state including voltage monitor,
temperature monitor and current detection, etc.;
Control of the on-gird operation or off-gird standby status of the battery
string;
Battery balancing control: manage the balancing of the whole string and
cooperate with the BMU to balance battery;
Power circuit relay control: control the on and off of the battery string circuit
to make the battery string status (on-grid or off-grid) controllable;
Pre-charge circuit relay control: control the on and off of the pre-charge
circuit relay;
Alarm: take judgment of any battery string fault and send alarm information
base on the state of monitored information;
Communication: provide communication interface to send information to the
upper system and meanwhile accept the management from the upper
system;
Charge and discharge management: control the start and stop of battery
string charge/discharge, monitor the battery operation state during the
charge or discharge process;

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Self-protection: when the BECU detects serious fault of the battery string (i.e.
no upper management instructions issued), the BECU will automatically enter
the protection state, opening the power circuit switch, stopping execute
charge/discharge command and sending fault alarm information.

d) BSMU Principle and Characteristic
The battery stack management unit (BSMU) manages multiple strings, namely one
BSMU corresponds with multiple BECU to form a battery stack system. The BSMU
is in charge of the operation of the whole battery stack.


Fig.3.4-11 Schematic diagram of BSMU
BSMU functions contain:
Information management: collect and deal with the information of the
corresponding battery strings and send out the necessary information to the
upper monitoring system.
Battery status monitoring: monitor the state of each string and control the
battery to carry out on-grid or off-grid action to manage the battery
operation state.
Event statistic and logging: cooperate with the relative storage devices to
storage the working events, and by the logging of the events, the history can
be checked and analyzed.
Communication: communicate with other devices through CAN or RS485
interface to manage the system working mode together.

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Insulation detection: Each battery management systems are equipped with
insulation monitor equipment (IMD) and this device is mainly used to detect
the insulation character between DC system power circuit and the earth.
Once the insulation grade drop, the insulation monitor will send alarm signals
immediately and the BSMU will prohibit the charging or discharging of the
battery strings. Principle of the insulation detect unit is shown as below.

IMD
cathode
anode

battery
string

Fig.3.4-12 Schematic diagram of IMD application
2) BMS Functions
a) Detection
(i) Detect single cell voltage and temperature in real time;
(ii) Detect the total voltage of the battery string to determine whether the
battery strings can connect to the grid;
(iii) Detect the charge or discharge current of the battery string in real time. With
high sampling frequency, current change can be quickly followed;
(iv) Detect the state of fuse and power circuit repair switch to determine whether
the system can operation;
(v) Detect the insulation state of power circuit to earth to determine whether

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insulation reducing situation occurs.

b) Dynamic Balancing Management
As many batteries work in series, capacity imbalance between the cells will affect the
whole string capacity. The string available capacity then decreases due to battery
capacity imbalance. As the total available string capacity is decided by the lowest
battery capacity, the battery balancing is necessary to keep the string available
capacity.
BYD BMS adopts dynamic balancing method and all batteries can be automatically
balanced online.
The BMU, cooperated by the BECU and the BGU, decides whether the batteries need
balancing according to the status of single cells and the use state of the battery string.
When the single cell voltage imbalance, the single cell status differ within the string.
The BMU will start battery balancing action to make the whole string batteries charge
and discharge status to be consistent.
Advantages of BMU balancing function:
Online balancing;
Dynamic balancing: Synchronization balancing can be achieved during battery
operation;
Cumulative effect: the longer of the usage time the more obvious of the
effect;
Small current balancing help to reduce the cost and loss;
No additional lines needed, system reliability increased;
c) Statistic Storage Function
The BMS can collect statistics of the maximum voltage, minimum voltage,
maximum temperature, minimum temperature of single cells in each string
and the maximum allowable charge and discharge current of each battery
string;

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The BMS collects charge and discharge capacity of every battery and battery
stack system and calculates the SOC,SOH of battery strings and battery
stacks;
The BMS can record battery stack system events for historical inquiry and
in-depth analysis.

d) Data Uploading and Receiving Control Order Function
BMS can send the voltage, temperature, current, power; working condition, SOC and
SOH information to the monitoring system through communication interface and
receive the orders from monitoring system.

e) Charge and Discharge Management
The BMS monitors the battery status in real time. When the voltage of single cell
exceeds the working voltage range, the BMS will send alarm information to the
controller and notice controller to stop charging or discharging. In extreme cases, for
instance there is big battery fault but controller makes no corresponding action, the
BMS will cut off the power line switch automatically to quit charge/discharge.
When the unit is running, if faults such as sampling failure of battery voltage and
temperature, insulation fault of the power circuit to ground and communication fault,
etc. occur, the BMS will notice the controller to stop running to avoid harm.

f) Safety Management
(i) Monitor the voltage and temperature of each single cell to prevent battery
against overcharge, over discharge and over-temperature, thus to insure the
safety of battery usage. According to the monitoring temperature, control the
refrigeration and ventilation devices.
(ii) When battery string needs to be used in parallel, the BSMU will evaluate
whether the strings are ready for parallel or not base on the total string
voltage. If the voltage difference between the battery strings is large, the

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BSMU will not allow the battery string to be paralleled. And if the voltage
difference is small, the parallel can be gradually achieved by precharging the
circuit. The power resistance of pre-circuit can consume the rush current
generated during the parallel to mitigate the damage of rush current to the
high voltage devices and extend the device service life.
(iii) Connect fuses in series in the power circuit. When short-circuit or over-load
situation occurs outside the battery strings, the fuse will protect the battery,
cables and other components in the power circuit.
(iv) Insulation state inspection: when system power circuit leakage (the insulation
grade drop between power circuit and earth), the BSMU can detect fault
information through insulation detection device and request to stop system
operation and prohibit system charge/discharge.
(v) The output side of the battery string power circuit is parted by disconnector.
When maintenance needed, the disconnector can be opened to ensure the
safety and reduce accidents.
(vi) BMS can monitor each switch condition, fuse, temperature and humidity
in first loop to ensure the safety operation.
(vii) BMS can monitor the smog condition, if there is smog from fire, BMS will send
warning information to assort with other devices to act fire fighting.

g) Protection Functions
Under-voltage protection
Over-voltage protection
Over-temperature protection
Over-current protection
Temperature abnormal protection
Short-circuit protection
Electricity leakage protection

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Smog warning protection
Communication abnormal protection

h) Communication Function
Communicate with other devices through CAN or RS485 interface to coordinate and
manage the system working state.

3.4.2 Charger
The charger consists of power module and switch.
400V
AC
SOURCE
DCLOAD
CB2
100A
CB3
100A
CB4
100A
CB1
32A
Battery
Charger
MK
DW

Fig3.4-13 Charger Electric Configuration
Charger Performance Introduction
(1) Power Module MK
AC input voltage range for the power module MK is 40010%V, DC output
voltage is 100~150VDC continually adjusting, rated output voltage is 115VDC,
rated charging current is 60A. the efficiency of the rectifier is more than 90%
with the function of input over/low voltage protection, output over/low
voltage protection and warning,
(2) Switch CB3

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CB3 is a polar switch unit which also can be controlled. When the battery is fully
charged, it cannot be charged continually; when the grid power is off, battery will
provide power continually through CB3 with seamless switch.
(3) Step-down silicon chain DW
Adopt 35V-7 automatic step-down silicon chain to stabilize the voltage output to
provide stable DC power to the DC loads.

3.4.3 Communication Topology
The system has the function of local control, it supplies CAN (RS485 or Ethernet)
interface to communicate with the clients control system, and can be remote
controlled by the clients control system.
Charger
CAN (RS485 or Ethernet)
BMS CAN
DC power supply system
Control System
Provided by cilent

Fig3.4-14 Sketch map of the battery systems communication topology

3.4.4 Control Strategy
Grid is normal
The power module MK supplies power for the DC bus when grid is normal, and at
the same time, the control system will close the CB2 and CB3, then the charge
circuit is on and the battery is charged by the MK, if the output voltage of the MK
larger than the batterys, the battery will neither be charged nor discharged.
Grid is abnormal or power off
1) The output voltage of the MK may be too low or fluctuate when grid is
abnormal, if the output voltage of the MK is lower than the batterys, the

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CB3 discharge circuit will be on and the battery system compensates for
the bus bar voltage automatically to make sure that the output voltage is
stable.
2) When grid is power off, the output voltage of the MK is zero, at this time,
the CB3 discharge circuit will be on, and the battery system will supply
power for the load uninterruptedly. During the battery is discharging, the
control system will monitor each cells voltage, and if one of the cell
voltage of the battery string is lower than the discharge cut-off voltage,
the battery system will stop discharging.
State of charge
When grid is workable and the battery system is needed charged according to the
judge of the control system, the control system will send charge order to the lower
computer equipments and the CB3 charge circuit will be on .During the battery
system is charged, the control system will monitor each cells voltage, and if one of
the cell voltage of the battery string is over the charge cut-off voltage, the battery
system will stop charging.

4 System Installation Requirements
The DC power system should be installed on flat ground and leave enough space
before the tank, behind the tank and up the tank to meet the requirement of
installation, maintenance and cooling. The detailed requirements are as follows:
The installation site should be clean
The ground should be float and the gradient not over 1 degree so that the
tank will not swing.
The installation site should apart from the wall more than 1.5m
The door of the installation room should be over 3m while the width should
be over 2.5m
The altitude of the installation site should not be over 1000m
The temperature of the installation site should be 1040 and the
relative humidity should be RH10%75%
The bearing load of the installation building is 2 tons/square

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