High Voltage Battery Management System. NUV100 Datasheet , Rev. 1.9

Transcription

1 High Voltage Battery Management System NUV100 Datasheet , Rev. 1.9 Nuvation Energy 2017

2 Table of Contents System Overview... 4 Nuvation BMS High-Voltage Stack Controller... 5 Hardware Overview... 5 Ethernet... 5 USB 2.0 Host... 5 CAN GPIO-Out... 5 GPIO-In... 6 Link Out... 6 Stack Bus... 6 Indicator LEDs... 6 Operating Limits... 7 Mechanical Overview Nuvation BMS High-Voltage Power Interface Hardware Overview Contactors Interlock External Power Stack Power Current Shunt Thermistor Stack Bus Indicator LEDs Reset Push-Button Operating Limits Mechanical Overview Nuvation BMS High-Voltage Cell Interface Hardware Overview Battery Cells Temperature Sensors Link In Link Out Indicator LEDs Operating Limits Mechanical Overview Ordering Information List of Tables Table 1: SC Electrical Characteristics... 7 Table 2: SC Environmental Conditions... 9 Table 3: PI Electrical Characteristics Table 4: PI Environmental Conditions Table 5: CI Electrical Characteristics Table 6: CI Environmental Conditions

3 List of Figures Figure 1: Nuvation High-Voltage BMS Example System Diagram... 4 Figure 2: Mechanical Drawing of SC DIN Enclosure Figure 3: Mechanical Drawing of Model HE DIN Enclosure Figure 4: Mechanical Drawing of CI DIN Enclosure Figure 5: Mechanical Drawing of CI Bulkhead Enclosure

4 System Overview Nuvation High-Voltage BMS is generally comprised of the following modules: 1 Nuvation BMS High-Voltage Stack Controller 1 Nuvation BMS High-Voltage Power Interface 1 or more Nuvation BMS High-Voltage Cell Interfaces An example configuration is shown in Figure 1. Main Contactor Link Out Cell Interface Current Limiter Pre-Charge Contactor Link In Link Out System Monitor Charger/System Charger/System Cell Interface Charger/System Charger/System Ethernet CAN 485 GPIO-Out GPIO-In Stack Controller Link In Link Out Stack Bus 24VDC Current Shunt Stack Bus External Power Stack Power Power Interface Current Shunt Interlock Contactors Stack Contactor Figure 1: Nuvation High-Voltage BMS Example System Diagram 4

5 Nuvation BMS High-Voltage Stack Controller Hardware Overview The Nuvation BMS High-Voltage Stack Controller (SC) module contains the central MCU which handles all the processes and decision making required by Nuvation High-Voltage BMS. The external interfaces to this module are: 10/100 Base-T Ethernet RJ45 jack USB 2.0 Host A connector Isolated CAN 2.0 port RS-485 (Modbus) connector Four (4) opto-isolated digital outputs Four (4) opto-isolated digital inputs Link Bus connector Stack Bus connector Three (3) Indicator LEDs The SC does not have high-voltage connectors and does not connect to any battery stackreferenced signals, making it safe to handle and connect to external equipment. The following subsections describe the external interfaces in more detail. For wiring/pin-out information, please refer to the Nuvation High-Voltage BMS Installation Guide. Ethernet The Ethernet jack is a standard RJ45 Cat5e rated jack. This interface is used as the primary means of connecting an external system to the BMS to configure the operating parameters and observe the status. It is also used as a means of controlling an external battery charger/inverter and communicating with the vehicle central controller, grid-attached site controller, etc. The two LEDs on the Ethernet jack indicate link status (green LED) and network activity (yellow LED). USB 2.0 Host The USB 2.0 Host connector is a standard Type-A connector. Contact Nuvation Energy for support if USB connectivity is desired for your specific application. CAN 485 The CAN 485 connector is a 12-pin Micro-Fit 3.0 Molex connector. This interface provides an isolated CAN 2.0 port as well as a non-isolated RS-485 (Modbus) port. This interface can be used to control an external battery charger/inverter and communicating with the external system (vehicle central controller, grid-attached controller, etc). GPIO-Out The GPIO-Out connector is a 10-pin Micro-Fit 3.0 Molex connector. This interface provides four (4) isolated outputs (output of a solid-state relay) to allow an external 5

6 system to receive digital input from the SC. The functionality of this interface is configured by the end-user to match their needs. GPIO-In The GPIO-In connector is an 8-pin Micro-Fit 3.0 Molex connector. This interface provides four (4) isolated inputs (cathode of an optocoupler) to allow an external system to send digital output to the SC. The functionality of this interface is configured by the end user to match their needs. Link Out The Link Out connector is a 4-pin Micro-Fit 3.0 Molex connector. This interface is used to connect the SC to the string of one or more Cell Interface modules. The Link In connector on the Cell Interface module monitoring the lowest-potential cell in the series battery stack is connected to this connector via a Link Bus cable. The Link Out connector also provides operating power to the Cell Interface modules. Stack Bus The Stack Bus connector is a 6-pin Mini-Fit Jr. Molex connector. This interface is used to connect the Power Interface to the SC. The SC is powered from the Stack Bus. Indicator LEDs The three (3) LEDs are used by the SC to indicate health and functional status to the user. All LEDs are controlled by the central MCU. The Power LED indicates the MCU is operational, the Activity LED indicates the MCU is processing data and the Fault LED indicates a fault has occurred in Nuvation High-Voltage BMS. 6

7 Operating Limits This section states the operating limits of the Stack Controller module. WARNING: Exceeding the maximum ratings will damage the module. Table 1: SC Electrical Characteristics Symbol Parameter Conditions Min Typ Max Units Stack Bus Specifications +VSYS Rterm StackbusP StackbusN Input Voltage Vdc Input Current +VSYS = 24Vdc Adc Termination resistance tolerance Ω Power rating W Dominant Output Vdc Recessive Output Vdc Output Current madc Output Signal Rise Time ns Output Signal Fall Time ns Dominant Output Vdc Recessive Output Vdc Output Current madc Output Signal Rise Time ns Output Signal Fall Time ns Link Bus Specifications Output Voltage - +VSYS - Vdc +VBUS Output Current +VBUS = 24Vdc Adc IP_LINK Output Current madc IN_LINK Output Current madc USB Specifications +5V_USB USB Current madc USB_Data USB supported datarates Ethernet Specifications ETH_Protocol Ethernet data speeds Base-T ETH_Connector Ethernet jack rating - Cat5e - GPIO-Out Vmax Imax Ron Open Blocking Voltage Closed Maximum Curent Closed-State Resistance Between *_A and *_B, or between *_B and *_A Between *_A and *_B, or between *_B and *_A Between *_A and *_B, or between *_B and *_A Vdc madc Ω 7

8 Symbol Parameter Conditions Min Typ Max Units Turn-On Turn-Off GPIO-In Turn On Threshold Voltage Vdc Turn-On Threshold Current madc Turn-Off Threshold Voltage 3-5 Vdc Turn-Off Threshold Current madc Vmax Off Voltage Iin = 0mA Vdc Imax On Current Vin = 0V madc +VCAN Rterm CAN_P CAN_N CAN Specifications Input Voltage Vdc Input Current +VCAN = 12Vdc madc Termination resistance tolerance Ω Power rating W Dominant Output Vdc Recessive Output Vdc Output Current madc Output Signal Rise Time ns Output Signal Fall Time ns Dominant Output Vdc Recessive Output Vdc Output Current madc Output Signal Rise Time ns Output Signal Fall Time ns Isolation Rated Isolation Vrms +VMOD Rterm Modbus Specifications Output Voltage - +VSYS - Vdc Output Current +VMOD = 24Vdc Adc Termination resistance tolerance Ω Power rating W Vod Driver differential output V Io Output current ma tr Output Signal Rise Time us tf Output Signal Fall Time us 8

9 Table 2: SC Environmental Conditions Symbol Parameter Conditions Min Typ Max Units Thermal Specifications Ta Operating Temperature C Storage Temperature C Humidity Specifications RH Operational RH 5-85 % Storage RH 5-85 % Shock and Vibration Specifications Vertical Vertical shock/vibration m/s 2 Longitudinal Longitudinal shock/vibration m/s 2 Transverse Transverse shock/vibration m/s 2 The SC has also met industry standards CISPR 22 Class A and IEC/EN for EMC/EMI and ESD respectively. All components are EU RoHS/China RoHS compliant. 9

10 Mechanical Overview The overall dimensions of the SC are 104.4mm X mm X 40.6mm. It comes standard with DIN clips that enable it to be securely mounted to EN50022-compliant DIN rails. The clips add an extra 19.6mm to the overall width of the SC module, bringing it from 104.4mm to 124mm. Extra space should be provided around the module to allow for easy installation/maintenance. The SC weighs approximately 536g. Units: Inch Figure 2: Mechanical Drawing of SC DIN Enclosure 10

11 Nuvation BMS High-Voltage Power Interface Hardware Overview The Nuvation BMS High-Voltage Power Interface (PI) module contains a redundant MCU which handles all the processes and decision-making required by Nuvation High-Voltage BMS to control the high-current contactors. The external interfaces to this module are: Four (4) high-current contactor coil drivers Nuvation BMS Interlock input External Power input Stack Voltage input Current Shunt input Current Shunt thermistor input Stack Bus connector Three (3) Indicator LEDs Reset push-button The PI has high-voltage connectors and connects to battery stack-referenced signals. Safety precautions are required to handle and connect cables into this module. The following subsections describe the external interfaces in more detail. For wiring/pin-out information, please refer to the Nuvation High-Voltage BMS Installation Guide. Contactors The Contactors connector is a 12-pin Mini-Fit Jr. Molex connector. This interface is used to provide or select contactor coil operating power, either from an external power supply (24V max), or from a loop-back connection from the BMS internal 24V (nominal) source. Also, the Contactors connector connects to up to four (4) external contactor coils. Each output is capable of sourcing a maximum of 2.8A continuously. If coil operating power is provided from an external power source, the sum of all four output currents must not exceed 5A continuous. If coil operating power is provided from the internal power source, the sum of all four output currents must not exceed 2.8A or 2.9A minus 31.7mA per Cell Interface connected in the system, whichever is lower. Coil high-side drive and return outputs are provided at the connector. The return is referenced to the PI chassis. Contactor coil back-emf is internally clamped at 40V. Interlock The Interlock connector is a 3-pin Micro-Fit 3.0 Molex connector. This interface is used as a means of selecting the high-current contactor behaviour. By closing external contacts (or by attaching a permanent jumper link) connected to selected pin pairs on the Interlock connector, energizing of the contactors is done under BMS software control only, or through BMS software control qualified with a redundant hardware-based fault detection signal. 11

12 If no connection is made to the Interlock connector (all connector pins open), the external contactors cannot be energized. External Power The External Power connector is a 2-pin Mini-Fit Jr. Molex connector. This interface is used to supply AC or DC power to Nuvation BMS. The external power supply must be isolated from the battery stack and chassis ground. Stack Power The Stack Power connector is a 3-pin Mini-Fit Jr. Molex connector. A single pin of this interface is used to connect the PI to the most positive end of the stack to facilitate overall stack voltage measurement. Current Shunt The Current Shunt connector is a 4-pin Mini-Fit Jr. Molex connector. This interface is used to connect the PI to a current shunt at the most negative end of the stack, for stack charge and discharge current measurement as well as to facilitate overall stack voltage measurement. Note that full stack potential exists between the Stack Power and Current Shunt connectors. Also, potentially dangerous voltages may be present between either or both of these connectors and earth or chassis ground, including the Power Interface and Stack Controller enclosures, if provided. Appropriate safety precautions must be observed. Thermistor The Thermistor connector is a 2-pin Micro-Fit 3.0 Molex connector. The thermistor must be electrical isolated from the battery stack. Contact Nuvation Energy for support if temperature compensation of the high-current shunt is desired for your specific application. Stack Bus The Stack Bus connector is a 6-pin Mini-Fit Jr. Molex connector. This interface is used to connect the PI to the Stack Controller. The PI supplies power to the Stack Controller via the Stack Bus. Indicator LEDs The three (3) LEDs are used by the PI to indicate health and functional status to the user. All LEDs are controlled by the redundant MCU. The Power LED indicates that the MCU is operational, the Activity LED indicates the MCU is processing data and the Fault LED indicates a fault has occurred in Nuvation High-Voltage BMS. Reset Push-Button The reset push-button is accessible through a small hole in the enclosure (if provided). It resets the PI s redundant MCU and cycles power on the Stack Bus, thereby resetting the Stack Controller and all Link Bus powered Cell Interfaces. The button needs to be held for 0.5s to issue the reset. 12

13 Operating Limits This section states the operating limits of the Power Interface module. WARNING: Exceeding the maximum ratings will damage the module. Table 3: PI Electrical Characteristics Symbol Parameter Conditions Min Typ Max Units External Power Specifications Input DC Voltage Vdc Input AC Voltage Vac +VIN +VSYS Rterm StackbusP StackbusN +VCOIL +VINT COIL(n) Input DC Current +VIN = 24Vdc Adc Input AC Current +VIN = 24Vac Aac Input Isolation from Chassis/COM Stack Bus Specifications Vrms Output Voltage Vdc Output Current +VSYS = 24Vdc Adc Termination resistance tolerance Ω Power rating W Dominant Output Vdc Recessive Output Vdc Output Current madc Output Signal Rise Time ns Output Signal Fall Time ns Dominant Output Vdc Recessive Output Vdc Output Current madc Output Signal Rise Time ns Output Signal Fall Time ns External Coil Power Supply Input External Coil Power Supply Continuous Current External Coil Power Supply Pulse Current (<300µs) Internal Coil Power Supply Voltage Internal Coil Power Supply Current Contactors Specification Vdc +VCOIL = 24Vdc Adc +VCOIL = 24Vdc Adc - +VSYS - Vdc Adc Coil Driver Output Voltage - +VCOIL - Vdc Coil Driver Output Current +VCOIL = 24Vdc Adc 13

14 Symbol Parameter Conditions Min Typ Max Units Interlock Specifications OVERRIDE DRV OverRide Voltage Output +VCOIL = 24Vdc Vdc OverRide Current Output +VCOIL = 24Vdc madc Drv Voltage Output +VCOIL = 24Vdc Vdc Drv Current Output +VCOIL = 24Vdc madc VSHUNT_REF Vdiff Current Shunt Specifications Reference Output Voltage Vdc Reference Output Current µadc Differential voltage between VSHUNT_BAT and VSHUNT_LOAD Vdc Vmes Measurement resolution nvdc PS_COM Stack Power supply return current +VBAT = 150Vdc madc Thermistor Specifications +VTHERM Rt Thermistor Output Voltage Vdc Thermistor Output Current +VTHERM = 2.5Vdc µa Thermistor Resistance at 25 C kω 14

15 Table 4: PI Environmental Conditions Symbol Parameter Conditions Min Typ Max Units Thermal Specifications Ta Operating Temperature C Storage Temperature C Humidity Specifications RH Operational RH 5-85 % Storage RH 5-85 % Shock and Vibration Specifications Vertical Vertical shock/vibration m/s 2 Longitudinal Longitudinal shock/vibration m/s 2 Transverse Transverse shock/vibration m/s 2 The PI has also met industry standards CISPR 22 Class A and IEC/EN for EMC/EMI and ESD respectively. The PI has been designed to meet EN high voltage creepage/clearance distances to prevent arching to the metal enclosure. All components are EU RoHS/China RoHS compliant. 15

16 Mechanical Overview The overall dimensions of the PI Model HE are mm X mm X 48.60mm. It comes standard with DIN clips that enable it to be securely mounted to EN50022-compliant DIN rails. The clips add an extra 20mm to the overall width of the PI module, bringing it from mm to mm. Extra space should be provided around the module to allow for easy installation/maintenance. The PI Model HE can contain high-voltage signals. It is possible to have signals 1250Vdc away from earth ground. Care must be taken when mounting the PCB into a metal enclosure to ensure the metal walls remain the correct distance from the exposed conductor on the PCB. Using the 1250Vdc as an example, the metal walls must be at least 4.2mm from the nearest exposed conductor and not touch the PCB or any component on the PCB, including the connector housings. The PI model HE weighs approximately 791g. Units: Inch Figure 3: Mechanical Drawing of Model HE DIN Enclosure 16

17 Nuvation BMS High-Voltage Cell Interface Hardware Overview The Nuvation BMS High-Voltage Cell Interface (CI) module contains interface and measurement circuitry which converts the cell voltage and temperature to a digital value read, and to relay that data to the Stack Controller (SC) module. It also enables/disables cell balancing as required. The external interfaces to this module are: Battery Cells connector Temperature Sensors connector Two (2) Link Bus connectors Two (2) Indicator LEDs The CI has high-voltage connectors and connects to battery stack-referenced signals. Safety precautions are required to handle and connect cables into this module. The CI is available in three variants: the CI-12 which supports up to 12 cells and 8 temperature sensors, the CI-16 which supports up to 16 cells and 8 temperature sensors, and the CI-4M12 which supports up to four cells of nominally 12V each and 8 temperature sensors. The following subsections describe the external interfaces in more detail. For wiring/pin-out information, please refer to the Nuvation High-Voltage BMS Installation Guide. Battery Cells The Battery Cells connector is an 18-pin Micro-Fit 3.0 Molex connector. This interface is used to connect the battery cell voltage sense wires to the module s measurement and balancing circuitry. If cell balancing is used, these wires carry the balancing current, and should be sized appropriately. Note that balancing is not supported in the CI-4M12 variant. For each CI module used, the cells connected to it are referenced to its CELL0 input, which is connected to the negative end of the most negative connected cell. When not powering the CI module from the Link Bus: In the CI-12 variant, a minimum of 11V must be present between the CELL0 input and the most positive connected cell In the CI-16 and CI-4M12 variants, cells are connected as two groups; a minimum of 11V must be present between the most negative and most positive for each group. There is no minimum cell voltage when powering the CI from the Link Bus. Temperature Sensors The Temperature Sensors connector is a 16-pin Micro-Fit 3.0 Molex connector. This interface is used to connect up to eight 10kΩ NTC thermistors to the CI module. The 17

18 sensors are referenced to the module s CELL0 input, so care must be taken to ensure that they are electrically isolated from any common or ground potential, and from all other cell voltage terminals of the local CI module and of any other CI modules in the particular installation. These sensors are used by Nuvation BMS to sense over and under temperature conditions. Link In The Link In connector is a 4-pin Micro-Fit 3.0 Molex connector. This interface is used to connect the CI module to the next lower-potential CI module or to the Stack Controller if the CI is the lowest potential CI in the chain. A Link Bus cable is used to connect the Link In connector to either the Link Out connector on the next lowerpotential CI or to the Link Out connector on the Stack Controller. The CI also accepts power from this connector to power itself and any higher-potential CIs connected to the Link Out connector. Link Out The Link Out connector is a 4-pin Micro-Fit 3.0 Molex connector. This interface is used to provide the data channel and power source to higher-potential CI modules in the chain. The Link Out connector is to be unconnected if the CI is the highest potential CI in the chain. Indicator LEDs The two (2) LEDs are used by the CI to provide a rudimentary indication of the functional status of the module. The Activity LED indicates that the CI module has received a communication packet from the SC via the Link Bus, and the Fault LED indicates that a fault has occurred in Nuvation High-Voltage BMS. 18

19 Operating Limits This section states the operating limits of the Cell Interface module. WARNING: Exceeding the maximum ratings will damage the module. Table 5: CI Electrical Characteristics Symbol Parameter Conditions Min Typ Max Units +VBUS Link In Specifications Input Voltage Vdc Input Current, CI-12 Input Current, CI-16 +VBUS = 24Vdc, Link Out disconnected +VBUS = 24Vdc, Link Out disconnected madc madc IP_LINK Output Current madc IN_LINK Output Current madc +VBUS Link Out Specifications Output Voltage - +VBUS - Vdc Output Current +VBUS = 24Vdc madc/ci- 16 IP_LINK Output Current madc IN_LINK Output Current madc Battery Cells Specification C(n) - C(n-1) Input Cell Voltage Range +VBUS = 24Vdc 0-5 Vdc Vsum Voltage between C0 and C12 Voltage between C0 and C8 Voltage between C8 and C16 CI-12, +VBUS = 0Vdc CI-16, +VBUS = 0Vdc CI-16, +VBUS = 0Vdc Vdc Vdc Vdc TME Total Measurement Error +VBUS = 24Vdc ±0.1 ±1.2 ±1.6 mvdc I(n) Cell Balancing Current C(n) - C(n-1) = 4Vdc madc I(n) Rt(n) T(n) Output Current to Temperature Sensor Temperature Sensor Resistance at 25 C Input Temperature Sensor Voltage Range Temperature Sensors Specifications ua kω Cell 0 = 0V 0-3 V 19

20 Table 6: CI Environmental Conditions Symbol Parameter Conditions Min Typ Max Units Thermal Specifications Ta Operating Temperature C Storage Temperature C Humidity Specifications RH Operational RH 5-85 % Storage RH 5-85 % Shock and Vibration Specifications Vertical Vertical shock/vibration m/s 2 Longitudinal Longitudinal shock/vibration m/s 2 Transverse Transverse shock/vibration m/s 2 The CI has also met industry standards CISPR 22 Class A and IEC/EN for EMC/EMI and ESD respectively. The CI has been designed to meet EN high voltage creepage/clearance distances to prevent arcing to the metal enclosure. All components are EU RoHS/China RoHS compliant. 20

21 Mechanical Overview The overall dimensions of the CI are 104.4mm X mm X 40.6mm. It comes standard with DIN clips that enable it to be securely mounted to EN50022-compliant DIN rails. The clips add an extra 19.6mm to the overall width of the CI module, bringing it from 104.4mm to 124mm. Extra space should be provided around the module to allow for easy installation/maintenance. The CI can also come in a bulkhead-mountable enclosure. The enclosure has five metal walls, leaving the bottom of the unit fully exposed. It must be mounted to a metal bulkhead panel so that the panel will become the missing side. The module will produce up to 24W (32W if it is the CI-16 model) during cell balancing. A portion of this heat will be transferred to the bulkhead. The CI can contain high-voltage signals. Each CI can be another 60V away from earth ground up to a maximum of 1250Vdc. Care must be taken when mounting the PCB into a metal enclosure to ensure the metal walls remain the correct distance from the exposed conductor on the PCB. Using the 1250Vdc as an example, the metal walls must be at least 4.2mm from the nearest exposed conductor and not touch the PCB or any component on the PCB, including the connector housings. The CI with DIN mountable enclosure weighs approximately 538g. Units: Inch Figure 4: Mechanical Drawing of CI DIN Enclosure 21

22 The CI with bulkhead mountable enclosure weighs approximately 450g. Units: Inch Figure 5: Mechanical Drawing of CI Bulkhead Enclosure 22

23 Ordering Information Model Number NUV100-SC NUV100-SC-U NUV100-PI-HE NUV100-PI-HE-U NUV100-CI-12 NUV100-CI-12-1 NUV100-CI-12-U NUV100-CI-16 NUV100-CI-16-1 NUV100-CI-16-U NUV100-CI-4M12 NUV100-CI-4M12-1 NUV100-CI-4M12-U Description Stack Controller with DIN Enclosure Stack Controller PCB (no enclosure) Power Interface External Power with DIN Enclosure Power Interface External Power PCB (no enclosure) Cell Interface 12-cell with DIN Enclosure Cell Interface 12-cell with Bulkhead Enclosure Cell Interface 12-cell PCBA (no enclosure) Cell Interface 16-cell with DIN Enclosure Cell Interface 16-cell with Bulkhead Enclosure Cell Interface 16-cell PCBA (no enclosure) Cell Interface 4x12V-block with DIN Enclosure Cell Interface 4x12V-block with Bulkhead Enclosure Cell Interface 4x12V-block PCBA (no enclosure) DISCLAIMER: From time to time Nuvation Energy will make updates to the Nuvation BMS in response to changes in available technologies, client requests, emerging energy storage standards and other industry requirements. The product specifications in this document therefore, are subject to change without notice. 23