Order Number LIB1708001IE
Installation Manual
Lithium-ion Battery Module
Model DCB-105
for Serial connection
Request to contractors
●Read the Installation Instructions thoroughly and install the system correctly and safely. In particular, carefully read the “Safety precautions” before starting construction.
●If any accidents or damage are caused due to construction that was carried out using a method that is not described in the Installation Manual or that does not use the specified parts, we do not bear responsibility. Also, failures caused by such construction methods are not covered by the product warranty.
●After completing construction, be sure to check the system operation. ●Maintenance check is necessary to keep the product in a good state and achieve the
each function in a good state and use them safely. Please carry out maintenance check and replace the product beyond the life time from a point of view of the preventive maintenance.
© 2017 Sanyo Electric Co., Ltd. All right reserved. Unauthorized copying and distribution is a violation of law.
Table of contents
Page
Safety Precautions …………………………………………………………… 3 Product overview ……………………………………………………………… 8 Introduction …………………………………………………………………… 9 Names and functions ………………………………………………………… 12 Installation …………………………………………………………………… 13 Operation ……………………………………………………………………… 20 External Dimensions …………………………………………………………… 23 Check points after construction work ………………………………………… 24 Appendix1. How to store battery more than 6 months …………………… 25 Revision History …………………………………………….………………..……26
Notice
●Please consider this manual to reach the hand of a installer and maintenance person in charge.
●Operators and maintenance person should read this manual thoroughly before operating or maintaining on the product.
●Please store this manual so that it can be readily referred to at all times.
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Safety Precautions Please observe safety precautions fully.
●Before starting construction, read this Installation manual and install the battery system correctly and safely.
●Assign a "legal qualified person" to perform the electrical work.
●If any accidents or damage are caused due to construction that was carried out using a method that is not described in the Installation Instructions, we do not bear responsibility.
●If any abnormalities are found during construction, stop the construction immediately and contact your service representative or repair shop.
●Always use the accessory parts and specified members for system installation and wiring.
●Never use any construction methods that are not described in the Installation manual, and never fabricate the system.
■The below explains what will happen if someone fails to heed a particular precaution statement.
Danger |
Danger statements are used to indicate hazards or unsafe practices |
witch COULD result in severe personal injury or death. |
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Warning |
Warning statements are used to indicate hazards or unsafe |
practices which COULD result in serious personal injury or product or |
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property damage. |
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Caution |
Caution statements are used to indicate hazards or unsafe practices |
which COULD result in minor personal injury or product or property |
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damage. |
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Danger
HAZARD OF SHOCK, BURN, FIRE, AND EXPLOSION
(1) Electrical Shock
Do not touch the terminals of DCB-105 without protectors.
Be grounded with the specified conditions. Between the positive and the negative terminals output high voltage. Electric shock impairs health damage or may cause threat to life. More than 2,000 meters higher, risks of an electric shock will be increased.
(2) Immersion
Do not immerse DCB-105 in liquid such as water, beverages, or other fluids.
Do not expose to corrosive substances such as sea breeze, steam or chemicals. Do not install in the humid places or places to condensation. Exposure to liquid may damage DCB-105 or the circuit board. This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(3) High Temperature
Do not use or place DCB-105 near flame, heater or high temperature environment. Subjecting DCB-105 to high temperature may damage the battery cell separator and cause internal short circuit. This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(4) Charge Conditions
Only charge DCB-105 within the specified conditions. (e.g., temperature range, voltage, current and etc.)
Charging with unspecified conditions (e.g., over charge or abnormal current) may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(5) Reverse Polarity
Check the positive (+) and the negative (-) terminals.
If DCB-105 is connected with a reversed polarity, unexpected reactions may occur. This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
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Safety Precautions Please observe safety precautions fully.
Danger (continued)
(6) Direct Connection
Do not connect directly DCB-105 to AC power or unspecified DC power.
This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(7) Use in Other Equipment
Do not use DCB-105 for any other purposes or connecting unspecified equipment. If DCB-105 is used with unapproved applications or systems, DCB-105 may be damaged, leak electrolyte, generate heat, smoke, catch fire, or explode.
(8) Incineration and Heat
Keep DCB-105 away from heat or fire. Heating DCB-105 and may cause it to be damaged, leak electrolyte, generate heat, smoke, catch fire, or explode.
(9) Short-Circuit
Do not connect between the positive (+) and the negative (-) terminals with a conductive material (e.g., wire, a cable, etc.).
Do not carry or store DCB-105 with metal objects. If DCB-105 is shorted, DCB-105 may be overheated. This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(10) Contamination
Do not install DCB-105 in bad environment places where have smoke, dust or liquid. Protect from the contamination such as insects, small animals or other creatures.
If DCB-105 is shorted or the inside of protection is damaged with a contamination, DCB105 may be damaged, leak electrolyte, generate heat, smoke, catch fire, or explode.
(11) Impact and Penetration
Avoid excessive impact to DCB-105. Do not penetrate DCB-105 with a nail or strike with a hammer. If subjected to a hard strike or penetrated by an object, DCB-105 may be damaged or destroyed, thereby causing an internal short-circuit.
This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(12) Soldering
Do not directly solder to DCB-105.
Soldering directly DCB-105 may cause a function or a safety error.
This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode. (13) Disassembly
Do not disassemble or modify the Battery Module.
Disassembly or modification of the Battery Module may damage the protection circuit. This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(14) Charge in High Temperatures
Do not charge the Battery Module in high temperature environment.
If the Battery Module is charged with exposing high temperature, the Battery Module’s protection circuit may be activated and stop or fail the charging.
This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
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Safety Precautions Please observe safety precautions fully.
Warning
(1) Magnetism
Do not place DCB-105 near strong magnetism. (e.g., electromagnetic cooker, etc. ) This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(2) Mixed Use
Do not mix with other batteries.
DCB-105 should not be used with other batteries having a different capacity, chemistry, manufacturing date or manufacturer. This could cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(3) Rust, Discoloration and Deformities
Immediately stop using DCB-105 if there are noticeable abnormalities, such as smell, heat, discoloration, or deformity. DCB-105 may be defective
and could leak electrolyte, generate heat, smoke, catch fire, or explode with continued use.
(4) Charging Error
If the charging process does not finish within the specified condition, stop using DCB-105. This may cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(5) Leakage 1
Do not use a leaking DCB-105. If DCB-105 has an irritating odor or observes leakage, DCB-105 should be kept away from flame or high temperature environment. If it's exposed to open flame, DCB-105 could ignite or explode.
(6) Leakage 2
Do not touch a leaking DCB-105. If liquid leaking from DCB-105 gets into eyes, immediately flush the eyes with clean water and ask a medical check. If it's untreated, it may cause a significant eye damage.
(7) Transport
In order to prevent from short-circuit or damages during transport, securely pack DCB-105 in a case or a carton box.
(8) Wiring
Do not use longer power cable than needed length between Upper device and DCB-105 and among DCB-105s to avoid the damage to DCB-105.
Do not coil the power cable to avoid the damage to DCB-105..
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Safety Precautions Please observe safety precautions fully.
Caution
(1) Exposure to Direct Sunlight
Do not use or leave DCB-105 in a location exposed to excessive heat,
such as in direct sunlight or in a car. It could cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode. It may also cause damage to DCB-105’s performance and life.
(2) Static Electricity
Do not use DCB-105 where static electricity is generated as it may damage
the protection circuit. If the protection circuit fails, DCB-105 may be damaged, leak electrolyte, generate heat, smoke, catch fire, or explode.
(3) Charging Temperature Range
Only charge DCB-105 within operating temperature range. Charging outside of this temperature range could cause DCB-105 to leak electrolyte, generate heat. It may also cause damages to DCB-105's performance and life.
(4) Manual
Please read a system manual, an installation manual and a specification before use.
Keep this installation manual with a system manual and a specification for future reference.
(5) First Time Usage
Please contact the supplier if DCB-105 gives off an unusual odor, generates heat, or shows signs of rust prior to its initial use.
(6) Flammable Materials
Do not charge or discharge near flammable materials. Doing so could result in fire.
(7) Leakage3
If electrolyte leaks from DCB-105 and comes into contact with skin or clothing, immediately flush with water. Otherwise, it may cause skin irritation.
(8) Handling of Exposed Contacts or Conductors
If DCB-105 has a system interface consisting of stripped lead wires or exposed contact plates, handle with due care. In order to prevent from short-circuit or damages, temporarily insulate exposed contacts and conductors with an insulator such as
polypropylene tape or polyvinylchloride tape. Short-circuit could cause DCB-105 to leak electrolyte, generate heat, smoke, catch fire, or explode.
(9) Pile up
Do not pile up the Battery Module without the packaging.
Deformation due to the weight of the Battery Module may cause the Battery Module to leak electrolyte, generate heat, smoke, catch fire, or explode.
The Battery Module which is piled up may cause injury by falling.
(10) Recycling
When disposing of DCB-105, please recycle it according to local rules and regulations. (11) Extended Storage
When DCB-105 is shipped, DCB-105 is in a state called “Shut-down-mode”. This is to prevent over discharge. When DCB-105 is left without an operation for a long time, please disconnect If DCB-105 is stored for more than 6 months, charge or store DCB-105 by the specified method . (Refer Appendix 1)
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Safety Precautions Please observe safety precautions fully.
Caution (continued)
(12) Usage locations
Do not store or use DCB-105 in the following locations.
-Locations exposed to or that may be exposed to excess steam, oil steam, smoke, dust, salt, corrosive substances, sulfide explosive/flammable gases, chemicals, or fire, etc.
-Locations where vibration or mechanical shock occur.
-Outdoors without waterproof or dust-proof cabinet
-Locations subject to rain without waterproof
(13)Installation
Do not install the Battery Module in the following conditions.
-Make sure that the voltage difference between the modules are within 1.5V, when they are connected in parallel.
-Be careful not to short the terminals of modules.
-Make sure that the cable length is not loose and not too tight.
-Keep the appropriate torque for screws.
-Do not hold the Battery Module only by brackets in a cabinet.
-Do not connect “red (+)” and “black (-)” cables inversely.
-Use insulated tools, insulated gloves, personal protective equipment, and clothing. Require the preparation of equipment for the sake of safe installation.
-Do not set the Battery Module upside down.
-Do not repair or disassembly the any parts including PCB, SCP or Fuse.
(14)Recommended parts
Use the evaluated specified parts for a connection.
If any parts are needed to be changed, added or eliminated, please consult SANYO before finalizing product specifications.
(15) Temperature difference in cabinet
The temperature difference in a cabinet must be managed to be within 5°C (16) Start-up for operation
Make sure that there is a no connection mistake in wirings before turn on the power switch.
(17) Cabinet
A metal case is recommended as cabinet's material for the safety. SANYO highly recommends a steel material for the cabinet.
The steel can mitigate the damage, which is caused by fire and explosion of the battery, on the surroundings of the system.
SANYO cannot take liability for any damages and loss caused by the submerge of the system that could cause catch fire and electric spark.
(18) Weight
Install DCB-105 in a location where is able to supports its weight. DCB-105 is recommended to lift by more than two persons.
(19) Store
Do not store DCB-105 in an unstable place. This may cause a damage, a breakdown, or injury.
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Product Overview
This system is an energy storage system using Li-ion battery for home use.
System diagram
The system diagram with DCB-105 is as shown below. DCB-105 has limitation to number of connected units, up to 6. (i.e., To use 7 units or more is not allowed.)
Upper Device (Provided by Contractor)
DCB-105
(Can be connected up to 6 units)
Cables
DCB-105 requires following cables for the installation. Note that these cables are not delivered with DCB-105. Therefore, contractors of DCB-105 need to prepare these items.
Cable |
Description |
Scope |
No. |
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Power cable connecting between BMSS and Battery Modules |
Contractor |
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RJ45 communication Cable From Upper DCB-105 to lower DCB-105 |
Contractor |
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RJ45 communication Cable From DCB-105 to Upper device |
Contractor |
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Functions
DCB-105 Monitor voltage , current and temperature about Li-ion batteryCalculate remain capacity of Li-ion battery (SOC).
Self interruption in case of over charge
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