Nuvation energy Nuvg5 User manual

Nuvation Energy G5 High-Voltage BMS

NUVG5 Product Manual

Document ID: NE-DS-011 | Revision: 1.0, 2023-05-19

BMS Software Version: G5 Faraday

Table of Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2

1.1. About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2

2. Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê3

2.1. G5 Stack Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5

2.2. G5 Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7

2.3. G5 BMS Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8

2.3.1. Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8

2.3.2. G5 BMS Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8

2.3.2.1. Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9

3. Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê10

4. Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12

4.1. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12

4.2. G5 Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê13

4.2.1. Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê13

4.2.2. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14

4.2.2.1. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14

4.2.2.2. Installation Location and Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14

4.2.2.3. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê15

4.2.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê16

4.2.3.1. Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê16

4.2.3.2. Connect the Cell Voltage and Temperature Cable . . . . . . . . . . . . . . . . . . . . . . . . Ê16

4.2.3.3. Connect the Link Bus Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17

4.3. G5 Stack Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê18

4.3.1. Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê18

4.3.2. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê19

4.3.2.1. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê19

4.3.2.2. Installation Location and Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê20

4.3.2.3. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê20

4.3.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê25

4.3.3.1. Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê25

4.3.3.2. Ensure system is de-energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê26

4.3.3.3. Ground the G5 Stack Switchgear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê26

4.3.3.4. Connect Power In and Fan Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê27

4.3.3.5. Connect control to General Purpose Input/Output (GPIO) cable . . . . . . . . . . . . . . Ê28

4.3.3.6. Connect Ethernet cable to external computer . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê28

4.3.3.7. Connect Link Out cable to G5 Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê29

4.3.3.8. Set the Config Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê30

4.3.3.9. Connect Battery Stack and DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê30

4.3.3.10. Energize G5 Stack Switchgear and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê32

4.4. G5 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33

4.4.1. Download and Install the G5 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33

4.4.2. Connect to the G5 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33

4.5. First Power-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê36

5. Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

5.1. Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

5.1.1. G5 Stack Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

5.1.1.1. External Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

5.1.1.2. Electrical Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

5.1.2. G5 Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê40

5.1.2.1. Electrical Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê40

5.1.2.2. Maximum Stack Deployment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê41

5.1.3. Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê41

5.2. Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê42

5.2.1. G5 Stack Switchgear Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê42

5.2.2. G5 Cell Interface Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê43

5.3. Using the Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê44

5.3.1. The Dashboard Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê44

5.3.1.1. Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê44

5.3.1.2. Stack Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê45

5.3.1.3. Stack Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê45

5.3.1.4. State-of-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê45

5.3.1.5. Depth-of-Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê46

5.3.1.6. Cell Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê46

5.3.1.7. Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê47

5.3.1.8. Nuvation Energy BMS Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê48

5.3.2. The Details Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê51

5.3.2.1. Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê51

5.3.2.2. Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê51

5.3.2.3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê52

5.3.2.4. Cell Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê53

5.3.2.5. Thermistor Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê54

5.3.2.6. Open Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê54

5.3.2.7. SoC Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê55

5.3.3. The Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê57

5.3.3.1. Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê57

5.3.3.2. Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê57

5.3.3.3. Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60

5.3.3.4. Locking and Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60

5.3.3.5. About. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê61

5.3.4. The Status Banner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê62

5.3.4.1. Service Lockout Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê62

5.3.4.2. Self Check Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê62

5.3.4.3. Communication Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê62

5.3.4.4. Communication Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê63

5.3.4.5. G5 BMS Firmware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê73

6. Instructions for Stack Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê81

Appendix A: Battery Topology Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê82

Appendix B: Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê83

Excess Cable Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê83

Appendix C: Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê84

G5 Stack Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê84

G5 Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê85

Appendix D: Mating Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê86

G5 Stack Switchgear Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê86

Power and Fan Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê86

I/O Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê86

Linkbus Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê88

Ethernet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê88

Battery and DC Bus High Current Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê89

Earth Bonding Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê89

G5 Cell Interface Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê90

Cell Voltage and Temperature Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê90

Link In Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê91

Link Out Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê92

The content in this document must be followed in order to ensure safe operation of Nuvation

Energy BMS.

The G5 High-Voltage BMS is to be installed in a location with restricted access.

Only skilled persons may install or service a system containing hazardous

voltages that may be present when the system is energized.

Do NOT energize the system until all connections to the Stack Switchgear unit

and Cell Interface modules have been made.



The wiring of the battery cell voltage and temperature sensing should be

verified before connecting to the Cell Interface modules. The temperature

sensing must be isolated from the cell voltage sensing. Although the Cell

Interface includes protective circuitry to make it more resilient to brief wiring

errors, the same circuitry can result in the battery cells being slowly

discharged. Over time, these wiring errors can cause damage to the Cell

Interface and/or the cells.

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.



Nuvation Energy BMS relies on your system charger to charge the battery

cells; do not leave your charger off while Nuvation Energy BMS is powered

from the stack for prolonged periods of time. Nuvation Energy BMS should be

shut down when the system is in storage to minimize the drain on the cells.

Insulated handling is required of any connector carrying potentials over 60 V

DC relative to chassis.

Please be aware of high voltages present in your system and follow all

necessary safety precautions.

The provided module enclosures are not fire enclosures.

Nuvation Energy G5 High-Voltage BMS - NUVG5 Product Manual

Document ID: NE-DS-011 1Rev 1.0, 2023-05-19

G5 Faraday

1. Introduction

Thank you for choosing Nuvation Energy.

Nuvation Energy’s Stack Switchgear provides an integrated battery stack management solution that

includes all the hardware and software required to integrate a battery stack into your energy storage

system. Each Stack Switchgear unit contains Nuvation Energy High-Voltage BMS modules and is

designed to be used with other products in the Nuvation Energy BMS family.

1.1. About this Manual

This Nuvation Energy G5 High-Voltage BMS: NUVG5 Product Manual is a comprehensive manual,

providing:

▪Details about all the features offered by your Nuvation Energy G5 High-Voltage BMS

▪Mounting and wiring instructions to install this product safely

▪Guidance on integrating the device into your energy storage system

▪Guidance on operating the Nuvation Energy BMS Operator Interface

This document applies to Nuvation Energy BMS G5 Faraday software release

(Firmware version 5.7.0, Operator Interface version 0.64.0). Content may be

inaccurate or incomplete for other versions.

We thrive on your feedback and what we build is driven by your input.

Please submit support tickets to [email protected].

Nuvation Energy G5 High-Voltage BMS - NUVG5 Product Manual

Document ID: NE-DS-011 2Rev 1.0, 2023-05-19

G5 Faraday

2. Product Overview

The Nuvation Energy G5 High-Voltage BMS provides cell-level and stack-level control for battery

stacks up to 1500 VDC. The G5 Stack Switchgear and G5 Cell Interface modules operate together as

a complete system called the G5 High-Voltage BMS.

Both Nuvation Energy G5 Stack Switchgear and G5 Cell Interface are designed to enable UL 1973

certification of the battery stack. The UL 1973 Recognized Nuvation Energy BMS (Note: certification

pending) in each stack ensures safe battery operation and significantly reduces the effort of certifying

the energy storage system to meet UL 1973 and UL 9540.

Figure 1. G5 High-Voltage BMS.

A single Nuvation Energy G5 Stack Switchgear unit manages each stack and connects it to the DC

bus of the energy storage system. The G5 Stack Switchgear is a pre-configured assembly that

incorporates the major functions of Nuvation Energy G5 High-Voltage BMS into a rack-mountable unit

which includes stack monitoring, electrical disconnects, pre-charging, current sensing, fuses, and fan

control.

G5 Cell Interface modules in each stack connect directly to battery cells to measure cell voltages and

temperatures and provide cell balancing.

Typically, a single battery stack uses one G5 Stack Switchgear and one or more G5 Cell Interface

modules. A breakdown of a single battery stack is shown in Figure 2

Nuvation Energy G5 High-Voltage BMS - NUVG5 Product Manual

Document ID: NE-DS-011 3Rev 1.0, 2023-05-19

G5 Faraday

Figure 2. G5 High-Voltage BMS single system diagram

In a multi-stack G5 High-Voltage BMS configuration, as shown in Figure 3, each G5 Stack Switchgear

unit is responsible for monitoring the state and safety of one battery stack. All G5 Stack Switchgear

units connected to a single common DC bus in the system may be managed by a single Nuvation

Energy Multi-Stack Controller and operated via the Nuvation Energy Operator Interface. The Operator

Interface GUI provides a unified view and central control of multi-stack system.

Figure 3. G5 High-Voltage BMS multi-stack diagram

Nuvation Energy G5 High-Voltage BMS - NUVG5 Product Manual

Document ID: NE-DS-011 4Rev 1.0, 2023-05-19

G5 Faraday

2.1. G5 Stack Switchgear

The following variants of the Nuvation Energy G5 Stack Switchgear are available:

▪G5 Stack Switchgear, 1500 V, 100 A

▪G5 Stack Switchgear, 1500 V, 200 A

▪G5 Stack Switchgear, 1500 V, 300 A

The high-level system design of G5 Stack Switchgear is shown in Figure 2. Within a battery stack, the

G5 Stack Switchgear connects to the daisy-chained Nuvation Energy G5 Cell Interface modules. The

G5 Cell Interface modules convert cell voltage and temperature measurements to digital values to be

relayed to the G5 Stack Switchgear, and enable or disable cell balancing as required. Daisy-chaining

the G5 Cell Interface modules facilitates the design of flexible and scalable battery energy storage

systems.

The G5 Stack Switchgear has high-voltage, high-current connectors that are accessible on the front of

the unit. These connect the battery stack to the rest of the system, which is typically a common DC

bus. Safety precautions are required to handle and connect cables into this unit.

Figure 4. Nuvation Energy G5 Stack Switchgear

The external interfaces to this unit are:

▪Battery Stack and DC Bus connectors

▪Service Disconnect Switch

▪10/100 Base-T Ethernet RJ45 jack (Modbus-TCP)

▪Link Bus RJ45 connector

▪Fan control input and output

▪Power In

▪Power LED and Fault LED

▪Earth bonding connection (grounding stud)

Nuvation Energy G5 High-Voltage BMS - NUVG5 Product Manual

Document ID: NE-DS-011 5Rev 1.0, 2023-05-19

G5 Faraday

▪Enable, Shutdown, and Disconnect inputs

▪General purpose I/O

▪Factory Reset and Under Voltage Lockout (UVLO) Enable Config Switch

▪AC Fan Circuit Breaker

Nuvation Energy G5 High-Voltage BMS - NUVG5 Product Manual

Document ID: NE-DS-011 6Rev 1.0, 2023-05-19

G5 Faraday

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