Battery Cluster Control Box (BCCB)

Basic Information

The battery cluster control box controls the entire battery system. It includes the BMS Master Control Unit (BAMU) , the BMS Master Control Unit (BCMU) , an insulation tester, air circuit breakers, fast-acting fuses, a DC-DC isolated power supply, vacuum contactors, copper busbars and connectors, audible and visual alarms, an HMI display, start /stop / emergency stop buttons, wiring harness, and enclosure. Features include a compact size and light weight; bidirectional active balancing; and an integrated circuit design that is resistant to current surges, achieving a lifespan of 10,000 100A live switching cycles (compared to approximately 1,000 cycles for typical products ). The system is compatible with both 768V, 4- string , 3- cluster configurations and 960V, 5 -string , 3- cluster configurations .

Certification

CE and IEC compliant

Product Features

• BMS control function: BMS has bidirectional 4A active balancing current, monitors the voltage and temperature of all single battery cells in real time, and calculates the SOC value with an error of no more than ± 3% . It has high temperature alarm and battery cell over-voltage and under-voltage alarm and executes corresponding early warning control strategies, ensuring battery safety to the greatest extent.
• Battery cluster converging function: includes converging of three battery clusters, air switch over-current protection, fast fuse short-circuit protection, current detection and SOC calculation for each cluster . Each cluster has an independent vacuum contactor controller output terminal power connection and shutdown.
• Insulation monitoring function: Real-time monitoring of the insulation resistance between the battery and the chassis frame, and output of early warning or alarm signals to prevent dangerous situations caused by electric shock and short circuit, thereby improving system safety.
• Intelligent charging and discharging function: The industrial computer in the chassis has powerful control functions, fully automatically controlling the connection between the battery cluster and the ship’s DC busbar, realizing intelligent charging and discharging. The engine ECU is controlled through CAN communication to control the inrush current during charge and discharge conversion to within 100A . The vacuum contactor has a power-on and power-off life of up to 10,000 times.
• In-cabin display function: BCCB is equipped with an HMI touch screen that can display the working status of the battery cluster and all parameters of the battery cells in real time.
• Ship cockpit monitoring function: The BCCB communicates with the cockpit and uploads all data to the touch screen of the cockpit instrument panel, including all information such as battery cluster power, SOC , total voltage and current, charge and discharge power, battery cell temperature and battery compartment temperature . It can also monitor the operating conditions of the battery pack, ship generator and drive system.
• High industry certification standards : The components used strictly comply with the certification requirements of mainstream classification societies. The shell is made of aluminum alloy box with good heat dissipation and has IP 54 protection level, which can prevent the impact of water leakage above the cabin.

Application Scenarios

Applications

Thousand-ton electric ship battery cluster control system

Specifications

Item	Parameters	Description
Rated voltage and operating voltage range	Rated voltage: 768 V Voltage range: 670 ~ 847V Rated voltage: 960 V Voltage range: 840-1060 V	Adapt to two different battery cluster specifications
Rated current	160A (continuous) / 250 (short-time peak)	The continuous current must match the discharge capacity of the battery cluster, and the peak current must support short-term overload (e.g., ≤10s).
System Architecture	Master control unit (BAMU) + cluster control unit (BCMU)	BAMU is responsible for overall control, BCMU manages a single battery cluster and supports parallel expansion of multiple clusters.
Protection level	IP 54	Dust-proof and waterproof, suitable for different installation environments.
Operating temperature	-25°C ~ +55°C	BCCB operating temperature range (not cell temperature).
Heat dissipation method	Forced air cooling (standard)	Adopt negative pressure air duct structure
Dimensions WDH	760 ×160×460 mm (box size only)	The dimensions do not include the three-color indicator light protruding from the outside of the box

FAQ

What types of ship systems is the BCCB suitable for?

The BCCB is designed for specific types of ship systems:

• Suitable for thousand-ton electric ship battery cluster control system
• System compatible with 768V, 4-string, 3-cluster and 960V, 5-string, 3-cluster configurations
• Adapts to two different battery cluster specifications

The product has wide applicability:

• Suitable for various inland cargo ships and engineering vessels
• Can be used in large-capacity energy storage systems for electric container ships
• Supports parallel expansion of multiple clusters to meet different power requirements

What are the main functional features of the BCCB?

The BCCB features multiple advanced functional characteristics:

• BMS control function: Bidirectional 4A active balancing current, real-time monitoring of voltage and temperature of all single battery cells
• Battery cluster converging function: Includes converging of three battery clusters, air switch over-current protection, fast fuse short-circuit protection
• Insulation monitoring function: Real-time monitoring of insulation resistance between battery and chassis frame, outputting early warning or alarm signals
• Intelligent charging and discharging function: Fully automatic control of connection between battery cluster and ship's DC busbar
• In-cabin display function: Equipped with HMI touch screen to display real-time battery cluster status and all battery cell parameters
• Ship cockpit monitoring function: Uploads all data to the cockpit instrument panel touch screen
• High industry certification standards: Strictly complies with certification requirements of mainstream classification societies

Technical advantages:

• Calculates SOC value with error of no more than ±3%
• Features high temperature alarm and battery cell over-voltage and under-voltage alarm with corresponding early warning control strategies
• Ensures battery safety to the greatest extent

What are the voltage and current parameters of the BCCB?

The BCCB features flexible voltage and current parameters:

• Supports two specifications: 768V (670-847V) and 960V (840-1060V)
• Rated current is 160A (continuous) / 250A (short-time peak)
• Continuous current must match battery cluster discharge capacity
• Peak current supports short-term overload (e.g., ≤10s)

Performance characteristics:

• Integrated circuit design resistant to current surges
• Achieves lifespan of 10,000 100A live switching cycles (compared to approximately 1,000 cycles for typical products)
• Engine ECU controlled through CAN communication to control inrush current during charge and discharge conversion to within 100A
• Vacuum contactor has a power-on and power-off life of up to 10,000 times

Why choose the Battery Cluster Control Box (BCCB)?

There are several important reasons to choose our Battery Cluster Control Box (BCCB):

• Advanced Control Technology BMS with bidirectional 4A active balancing current, SOC calculation error of no more than ±3%
• High Reliability Design Integrated circuit design resistant to current surges, switching life up to 10,000 cycles
• Multiple Safety Protections Features high temperature alarm, battery cell over-voltage and under-voltage alarm, and insulation monitoring
• Intelligent Monitoring Equipped with HMI touch screen and ship cockpit monitoring function
• International Certification Complies with CE and IEC certification, strictly meets requirements of mainstream classification societies
• Flexible Configuration Supports both 768V and 960V voltage levels to meet different application requirements

These advantages make the BCCB the ideal choice for marine energy storage systems.

How does the BCCB perform in harsh environments?

The BCCB features excellent environmental adaptability:

• Operating temperature range: -25°C ~ +55°C, adapting to various climate conditions
• Protection level: IP54, dust-proof and waterproof, suitable for different installation environments
• Shell made of aluminum alloy box with good heat dissipation, preventing impact of water leakage above the cabin
• Adopts negative pressure air duct structure for good heat dissipation

The product also features:

• System architecture: Master control unit (BAMU) + cluster control unit (BCMU), supporting parallel expansion of multiple clusters
• Compact dimensions: 760×160×460mm (box size only)
• Powerful control functions for fully automatic control of connection between battery cluster and ship's DC busbar

These characteristics ensure the BCCB can operate stably and reliably in various complex environments.