Nuvation Energy BMS User manual

Nuvation Energy Low-Voltage BMS
Installation Guide
2019-08-27

Table of Contents
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
1.1. About this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
2. System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê3
3. Battery Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.2. GPIO Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.3. CAN Bus and RS485 / Modbus RTU Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê6
3.4. Power Supply, Current Shunt, and Contactor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê6
3.5. Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê6
3.6. Electric Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.6.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.6.2. J1: Link Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.6.3. J2: Ethernet / Modbus TCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8
3.6.4. J3: CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8
3.6.5. J4: RS485 / Modbus RTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
3.6.6. J5: Control / GPIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
3.6.7. J6: Contactors / -V Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
3.6.8. J7: Current Shunt / +V Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê15
3.6.9. J8: Cell Voltage / Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17
3.7. Grounding and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê27
4. Cell Interface Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê31
4.1. Scaling to over 16 channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê31
4.1.1. Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê32
4.2. Mechanical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê32
4.2.1. Optional DIN rail mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
4.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê35
4.3.1. Link Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê35
4.3.2. Link In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê35
4.3.3. Battery Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37
4.3.4. Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê43
5. Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê46
5.1. Enabling Battery Controller expansion with Cell Interface module . . . . . . . . . . . . . . . . . . . Ê46

Important Safety Information
The content in this document must be followed in order to ensure safe operation of Nuvation
Energy BMS.
Do NOT connect the J7: Current Shunt / +V Power connector to the Battery
Controller until all other connections have been made.
Properly insulate or remove any unused wires. Unused wires can couple
excessive system noise into Nuvation Energy BMS which can disrupt
communication and lead to undesirable behaviors.
Please be aware of high voltages present in your system and follow all
necessary safety precautions.
The provided module enclosures are not fire enclosures.

Depending on battery chemistry, there might be a nominal voltage per cell
which adds up in series and is always present. There are many different
battery chemistries with different current capacities, and so high voltage with
high current capacity may be present while connecting the Nuvation Energy
BMS. You must use proper electrical safety precautions when handling any part
of the Nuvation Energy BMS.
Neither Nuvation Energy or any of its employees shall be liable for any direct,
indirect, incidental, special, exemplary, personal or consequential harm or
damages (including, but not limited to, procurement or substitute goods or
services; loss of use, data, or profits; or business interruption) however caused
and on any theory of liability, whether in contract, strict liability, or tort
(including negligence or otherwise) arising in any way out of the use of this
product.

The Nuvation Energy BMS relies on your system charger to charge the battery
cells; do not leave your charger off while the Nuvation Energy BMS is powered
from the stack for prolonged periods of time. The Nuvation Energy BMS should
be shut down when the system is in storage to minimize the drain on the cells.
Nuvation Energy Low-Voltage BMS - Installation Guide
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1. Introduction
Thank you for choosing Nuvation Energy BMS
Low-Voltage Battery Controller is an enterprise-grade battery management system with features that
extend battery life, ensuring battery safety, and cell balancing.
You can take advantage of the highly configurable browser-based user interface and custom-tune
Low-Voltage Battery Controller to your specific target application.
1.1. About this Guide
This Nuvation Energy Low-Voltage BMS: Installation Guide provides wiring instructions to connect
your Low-Voltage Battery Controller to your system.
Once you have successfully completed the installation process, please follow instructions in the
Operator Interface Manual for accessing and configuring the Nuvation Energy BMS Operator Interface
for the Battery Controller.
We thrive on your feedback and what we build is driven by your input. Please submit support
tickets to [e-mail].
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2. System Overview
The Nuvation Energy Low-Voltage BMS is a complete battery management system that provides cell
balancing and charge management for virtually any battery chemistry using a Battery Controller. The
Battery Controller is designed for input voltage of 11-60 V DC. It can manage up to 12 or 16 battery
cells in series, and can be expanded to manage additional cells with a Nuvation Energy Cell Interface
module.
An example 12 or 16 channel configuration is shown in Figure 1. This configuration requires a single
Battery Controller.
Figure 1. Nuvation Energy Low-Voltage BMS System Overview
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An example 24-channel configuration is shown in Figure 2. This configuration requires a Battery
Controller and a Cell Interface. Please see Section 4.1 for more details.
Figure 2. Low-Voltage BMS System Overview: 24-channel Application
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3. Battery Controller
3.1. Overview
Low-Voltage Battery Controller module safely manages up to 12 or 16 cells by measuring cell voltage,
temperature and current and applying software decision-making to control contactors, communicate
with energy storage controllers, and interface with general purpose I/O.
The Battery Controller is able to operate as a stand-alone battery management system, requiring no
additional Nuvation Energy BMS modules to manage a stack of up to 12 or 16 cells. Nuvation Energy
Cell Interface may be used to increase the stack size in systems that are rated less than 60 V DC.
The Battery Controller is available in two models:
•The NUV300-BC-12 which can monitor up to 12 series-connected cells
•The NUV300-BC-16 which can monitor up to 16 series-connected cells
3.2. GPIO Block
The GPIO and control inputs are accessible at the J5: Control / GPIO connector.
The general-purpose outputs from the Battery Controller are implemented using optical MOSFET
switches. These outputs are non-polarized, presenting an on-resistance of typically 2 Ω and capable
of carrying 400 mA of DC or RMS current when activated. Figure 3 shows a high level circuit diagram
for the GPO pins.
GPO_ISOx_B
60V DC Isolation
GPO_ISOx_A
Logic GPO
x4
GPIO
Figure 3. GPIO Circuit Diagram
The general-purpose and specific-purpose (FAULT_CLEAR, FACTORY_RESET, SHUTDOWN) inputs to the Battery
Controller are implemented using optical isolation components. The current source for these inputs is
provided in the Battery Controller and each input is activated by providing a simple contact closure to
the common point.
The BMS Enable input differs slightly from the other specific-purpose inputs. This control requires a
contact closure between the BMS_ENABLE# and VBOT signals and must not be referenced to the common
point of the other inputs. It is used to start the Battery Controller after it has been shut down due to
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activation of the SHUTDOWN input, low battery, or some other condition invoked under software control.
BMS_ENABLE# is pulled up to the battery stack positive (potentially 60 V away from VBOT) so the
switch/external controller must be tolerant of the maximum battery stack voltage.
3.3. CAN Bus and RS485 / Modbus RTU Block
The CAN Bus communication channel is available on the J3: CAN connector. The RS485 / Modbus RTU
communication channel is available on the J4: RS485 / Modbus RTU connector.
These communication channels are isolated from the battery stack and share their common reference
with each other, with the general-purpose I/O, and with the specialized control inputs. A 120 Ω bus
termination is required on each end of the bus for these communication channels. Termination is not
provided within the Battery Controller on stock production units.
3.4. Power Supply, Current Shunt, and Contactor Drivers
Operating power, including primary power source for operating the contactor coils, is connected to the
Battery Controller at two connectors: positive to the J7: Current Shunt / +V Power connector, and
negative to the J6: Contactors / -V Power connector.
The current shunt, which is connected in series with the battery stack at the positive end, connects its
sense points to the Battery Controller at the J7: Current Shunt / +V Power connector.
Up to 4 system contactors may be connected and controlled by the Battery Controller, connecting to
the Battery Controller at the J6: Contactors / -V Power connector.
3.5. Mechanical Dimensions
The overall dimensions of the Battery Controller are 220 mm X 125 mm X 30 mm. Extra space should
be provided around the module to allow for easy installation/maintenance.
Dimensions in the diagram below are shown in inches
The Battery Controller should be securely mounted in a vertical orientation, in an environment that
permits free movement of air through all ventilation slots for convection cooling. The Cell Connections
connector (J1) should be facing up or to the left. If it is to be used with a battery chemistry such as
lead-acid, which does not require balancing, the Battery Controller may be mounted horizontally, with
the ventilation slots oriented upwards. It is not advisable to mount the Battery Controller on the
underside of a horizontal surface.
The Low-Voltage Battery Controller weighs approximately 400 g.
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Figure 4. Mechanical Drawing of Battery Controller
3.6. Electric Connections
3.6.1. Overview
The Battery Controller module has eight connectors. Each connector is described in the following
sections in detail.
3.6.2. J1: Link Out
In certain situations, it may be required to monitor more than 16 cells in series, such as with 2V lead-
acid cells. This connector is used to connect to an additional Cell Interface module to manage more
cells and thermistors. See Section 4.1 for installation instructions for the Cell Interface.
Table 1 describes a typical compatible plug for the J1: Link Out jack.
Table 1. RJ-45 Plug Details
Conec 391J00039X
Manufacturer Conec
Housing 391J00039X
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Housing material Polycarbonate UL94V-0
Circuits 8
Crimp terminal insulation displacement
Wire gauge range AWG24-26 stranded or
solid
The Link Out interface connector is a standard RJ45 Cat5e rated jack. This interface is used to connect
the Battery Controller module to an expansion Cell Interface module to provide monitoring for
additional battery cells and thermistors.
Table 2. Link Out Connector Pin Assignment
Pin Connection Description Connected to Device
1 No Connect Not Connected No Connect
2 No Connect Not Connected No Connect
3 No Connect Not Connected No Connect
4 No Connect Not Connected No Connect
5 No Connect Not Connected No Connect
6 No Connect Not Connected No Connect
7 LINKBUS_N Link Bus differential pair negative Cell Interface
8 LINKBUS_P Link Bus differential pair positive Cell Interface
3.6.3. J2: Ethernet / Modbus TCP
The Ethernet / Modbus TCP jack is a standard RJ45 Cat5e rated jack. This interface is used as the
primary means of connecting an external system to the Battery Controller to configure the operating
parameters, observe the status, and perform maintenance such as firmware upgrades.
Table 1 describes a typical compatible plug for the J2: Ethernet / Modbus TCP jack.
Table 3. Ethernet / Modbus TCP Connector Pin Assignment
Pin Connection Description Connected to Device
1 TD_P Transmit differential pair positive External Equipment
2 TD_N Transmit differential pair negative External Equipment
3 RD_P Receive differential pair positive External Equipment
4 NUL45 Unused; connected to Pin 5 and terminated External Equipment
5 NUL45 Unused; connected to Pin 4 and terminated External Equipment
6 RD_N Receive differential pair negative External Equipment
7 NUL78 Unused; connected to Pin 8 and terminated External Equipment
8 NUL78 Unused; connected to Pin 7 and terminated External Equipment
3.6.4. J3: CAN
The CANBus 2.0 connector is a standard RJ45 Cat5e rated jack. This interface provides an isolated
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