Nuvation Energy High-Voltage BMS User manual

Nuvation Energy High-Voltage BMS
Installation Guide
Document ID: NE-IG-001 | Revision: 2.1, 2020-03-13
© 2020 Nuvation Energy

Table of Contents
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
1.1. About this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
2. System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê3
3. High-Voltage Stack Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê4
3.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê4
3.2. Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê4
3.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.3.1. Link Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.3.2. CAN 485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê6
3.3.3. Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.3.4. GPIO-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8
3.3.5. GPIO-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
3.3.6. Stack Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê10
4. Nuvation Energy Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.2. Mechanical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.3. Mechanical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.3.1. Optional DIN rail mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12
NRND variant with DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê13
4.4. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14
4.4.1. Link Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14
4.4.2. Link In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê15
4.4.3. Battery Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê16
Battery Cell Connecter for Cell Interface - 12 channel . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17
Battery Cell Connecter for Cell Interface - 16 channel . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê20
Battery Cell Connecter for Cell Interface - 12V 4 channel . . . . . . . . . . . . . . . . . . . . . . . . . Ê23
4.5. Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê25
5. High-Voltage Power Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê27
5.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê27
5.2. Mechanical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê27
5.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê28
5.3.1. Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê28
5.3.2. Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê31
5.3.3. External Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê32
5.3.4. Stack Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
5.3.5. Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê34
5.3.6. Current Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê34
5.3.7. Stack Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê35
6. Nuvation Energy BMS: Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37
6.1. Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37
6.2. Excess Cable Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê38

6.3. System Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê38
6.3.1. DC Filtering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê39
6.3.2. Stack Controller Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê40
6.3.3. Link Bus Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê41
Appendix A: Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê42
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê42
Reset to Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê42

Important Safety Information
The content in this document must be followed in order to ensure safe operation of Nuvation
Energy BMS.
Do NOT energize the system until all connections to the Cell Interface and
Power Interface modules have been made.
Insulated handling is required of any connector carrying potentials over 600 V
DC relative to chassis.
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 Nuvation Energy BMS.
You must use proper electrical safety precautions when handling any part of
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.

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.
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 1Rev 2.1, 2020-03-13

1. Introduction
Thank you for choosing Nuvation Energy BMS.
Nuvation Energy High-Voltage BMS is an enterprise-grade battery management system with features
that extend battery life, ensuring pack-level safety, data-analytics, and remote management.
You can take advantage of the highly configurable browser-based user interface and custom-tune
Nuvation Energy BMS to your specific target application.
1.1. About this Guide
This Nuvation Energy High-Voltage BMS: Installation Guide provides wiring instructions to connect
your Nuvation Energy High-Voltage BMS 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.
We thrive on your feedback and what we build is driven by your input. Please submit support
tickets to [e-mail].
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 2Rev 2.1, 2020-03-13

2. System Overview
The Nuvation Energy High-Voltage BMS family includes several modules that operate together as a
complete system. Available modules are listed below.
Table 1. High-Voltage BMS Modules
Model Module Name
NUV100-SC High-Voltage Stack Controller
NUV100-PI-HE High-Voltage Power Interface
NUV100-CI-12-1 Cell Interface - 12 channel
NUV100-CI-16-1 Cell Interface - 16 channel
NUV100-CI-4M12-1 Cell Interface - 12V 4 channel
Generally, a single High-Voltage BMS system uses 1 Stack Controller, 1 Power Interface, and 1 or
more Cell Interface modules. An example configuration is shown in Figure 1
Figure 1. Nuvation Energy High-Voltage BMS System Overview
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 3Rev 2.1, 2020-03-13

3. High-Voltage Stack Controller
3.1. Overview
The High-Voltage Stack Controller module monitors and controls all Cell Interface modules in a single
battery stack. The built-in Stack Bus receives power and communication from the Power Interface
module. The Link Bus provides power and communication for all connected Cell Interface modules.
Ethernet, CAN and RS-485 (Modbus) are included. No high-voltage or high-current interfaces are
present on the Stack Controller, making this module easy and safe to connect to for service
operations.
There is only one model of the Stack Controller, the NUV100-SC.
3.2. Mechanical Dimensions
The overall dimensions of the Stack Controller are 104.4 mm X 121.58 mm X 40.6 mm.
It comes standard with DIN clips that enable the Stack Controller module to be securely mounted to
EN50022-compliant DIN rails. The clips add an extra 19.6 mm to the overall width of the Stack
Controller module, bringing it from 104.4 mm to 124 mm. The clips also hold the module
approximately 7 mm away from the inside lip of the DIN rail.
Extra space should be provided around the module to allow for easy installation/maintenance.
The Stack Controller weighs approximately 525 g.
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 4Rev 2.1, 2020-03-13

Figure 2. Mechanical Drawing of Stack Controller
3.3. Electrical Connections
The Stack Controller module has 7 connectors. Each connector is described in the following sections
in detail.
3.3.1. Link Out
The Link Out connector provides power and communication to the Cell Interface modules. The
amount of current supplied by this connector is the sum of current consumed by all Cell Interface
modules in the system. Connect the Cell Interface module which is measuring the most negative cell
in the stack to this connector.
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 5Rev 2.1, 2020-03-13

Table 2. Link Out: Molex Micro-Fit 3.0 Connector
Molex 43025-0400
Manufacturer Molex Incorporated
Housing 43025-0400
Housing material Nylon UL94V-0
Circuits 4
Crimp terminal 43030-0002
Wire gauge range AWG20-24 stranded
Table 3. Link Out Connector Pin Assignment
Pin Connection Description Connected to Device
1 VBUS DC power from Stack Controller, with Fault
Pilot Signal
Cell Interface
2 COM Power return from Stack Controller Cell Interface
3 IPA Link Bus differential pair plus Cell Interface
4 IMA Link Bus differential pair minus Cell Interface
3.3.2. CAN 485
The CAN 485 connector contains both isolated CAN and non-isolated RS-485 (Modbus) connections.
Isolated CAN requires 5.5-12 Vdc sourced from an external power supply to operate. 120 Ω
termination for CAN is added by connecting pins 3 and 9 together. 150 Ω termination for Modbus is
added by connecting pins 6 and 12 together.
Keep the termination wire length short for best results. Connect external equipment to this connector.
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 6Rev 2.1, 2020-03-13

Table 4. CAN 485: Molex Micro-Fit 3.0 Connector
Molex 43025-1200
Manufacturer Molex Incorporated
Housing 43025-1200
Housing material Nylon UL94V-0
Circuits 12
Crimp terminal 43030-0002
Wire gauge range AWG20-24 stranded
Table 5. CAN 485 Connector Pin Assignment
Pin Connection Description Connected to Device
1 -V_isoCAN Power return from Pin 7 External Equipment
2 CAN_N CAN bus differential pair negative External Equipment
3 EXTCAN_TERM1 Termination Resistor; Short to Pin 9 to add
120Ω bus termination
CAN 485 Connector
4 COM Power return from SC External Equipment
5 MODBUS_N MODBUS differential pair negative External Equipment
6 EXTMOD_TERM1 Termination Resistor; Short to Pin 12 to add
150Ω bus termination
CAN 485 Connector
7 +12V_isoCAN +5.5~12Vdc isolated CAN bus power External Equipment
8 CAN_P CAN bus differential part positive External Equipment
9 EXTCAN_TERM2 Termination Resistor; Short to Pin 3 to add
120Ω bus termination
CAN 485 Connector
10 +VSYS +24Vdc Power supply External Equipment
11 MODBUS_P MODBUS differential pair positive External Equipment
12 EXTMOD_TERM2 Termination Resistor; Short to Pin 6 to add
150Ω bus termination
CAN 485 Connector
3.3.3. Ethernet
The Ethernet connector is a standard RJ45 Ethernet jack. Connect external equipment to this
connector.
Table 6. Ethernet Connector Pin Assignment
Nuvation Energy High-Voltage BMS - Installation Guide
Document ID: NE-IG-001 7Rev 2.1, 2020-03-13