Nuvation BMS NUV100-SC User manual

Installation Guide
Nuvation High-Voltage BMS™
2018-10-08, Rev. 2.0
© Copyright 2018, Nuvation Energy

Table of Contents
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
1.1. About this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
2. System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê3
3. Nuvation BMS™ 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.3.3. Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê6
3.3.4. GPIO-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.3.5. GPIO-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8
3.3.6. Stack Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
4. Nuvation BMS™ High-Voltage Cell Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê10
4.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê10
4.2. Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê10
4.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12
4.3.1. Link Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12
4.3.2. Link In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12
4.3.3. Battery Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê13
Battery Cell Connecter for Cell Interface - 12 channel . . . . . . . . . . . . . . . . . . . . . . . . . Ê14
Battery Cell Connecter for Cell Interface - 16 channel . . . . . . . . . . . . . . . . . . . . . . . . . Ê16
Battery Cell Connecter for Cell Interface - 12V 4 channel. . . . . . . . . . . . . . . . . . . . . . . Ê19
4.3.4. Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê21
5. Nuvation BMS™ High-Voltage Power Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê23
5.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê23
5.2. Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê23
5.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê24
5.3.1. Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê24
5.3.2. Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê27
5.3.3. External Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê28
5.3.4. Stack Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê28
5.3.5. Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê29
5.3.6. Current Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê29
5.3.7. Stack Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê31
6. Nuvation BMS: Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
6.1. Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
6.2. Excess Cable Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
6.3. System Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê34
6.3.1. DC Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê35
6.3.2. Stack Controller Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê36
6.3.3. Link Bus Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê36
Appendix A: Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

Reset to Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37

Important Safety Information
The content in this document must be followed in order to ensure safe operation of Nuvation
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
600Vdc relative to chassis.
Properly insulate or remove any unused wires. Unused wires can couple
excessive system noise into Nuvation 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
BMS. You must use proper electrical safety precautions when handling any
part of the Nuvation 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 BMS relies on your system charger to charge the battery
cells; do not leave your charger off while the Nuvation BMS is powered from
the stack for prolonged periods of time. The Nuvation BMS should be shut
down when the system is in storage to minimize the drain on the cells.
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1. Introduction
Thank you for choosing Nuvation BMS™
Nuvation 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 BMS™ to your specific target application.
1.1. About this Guide
This Installation Guide: Nuvation High-Voltage BMS™ provides wiring instructions to connect your
Nuvation High-Voltage BMS™ to your system.
Once you have successfully completed the installation process, please follow instructions in the
Operator Interface Guide for accessing and configuring the Nuvation BMS™ Operator Interface.
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 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 Nuvation BMS™ High-Voltage Stack Controller
NUV100-PI-HE Nuvation BMS™ High-Voltage Power Interface
NUV100-CI-12 Nuvation BMS™ High-Voltage Cell Interface - 12 channel
NUV100-CI-16 Nuvation BMS™ High-Voltage Cell Interface - 16 channel
NUV100-CI-4M12 Nuvation BMS™ High-Voltage Cell Interface - 12V 4 channel
Generally, a single High-Voltage BMS system uses 1 Stack Controller, 1 Power Interface, and 1 or
more Cell Interfaces. An example configuration is shown in Nuvation High-Voltage BMS™ System
Overview
Figure 1. Nuvation High-Voltage BMS™ System Overview
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3. Nuvation BMS™ High-Voltage Stack Controller
3.1. Overview
The Nuvation BMS™ 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 104.4mm X 121.58mm X 40.6mm.
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 19.6mm to the overall width of the Stack
Controller module, bringing it from 104.4mm to 124mm. The clips also hold the module
approximately 7mm 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 525g.
Figure 2. Mechanical Drawing of Stack Controller
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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.
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 5.5-12V sourced from an external power supply to operate.
120Ω termination for CAN is added by connecting pins 3 and 9 together. 150Ω 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.
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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 +5.5~12V 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 +24V 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
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
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Pin Connection Description Connected to Device
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
3.3.4. GPIO-Out
The GPIO-Out connector provides four (4) general-purpose outputs. Four (4) independent solid-
state relays are used to connect *_A pins to their corresponding *_B pins. Each output is rated for
60VDC, 400mA max., and the signals connected to each output must be within 50VDC from
chassis/earth ground. There is no polarity dependency between *_A and *_B pins.
Connect external equipment to this connector.
Table 7. GPO: Molex Micro-Fit 3.0 Connector
Molex 43025-1000
Manufacturer Molex Incorporated
Housing 43025-1000
Housing material Nylon UL94V-0
Circuits 10
Crimp terminal 43030-0002
Wire gauge range AWG20-24 stranded
Table 8. GPO Connector Pin Assignment
Pin Connection Description Connected to Device
1 GPO_ISO0_A Digital Output 0 External Equipment
2 GPO_ISO1_A Digital Output 1 External Equipment
3 GPO_ISO2_A Digital Output 2 External Equipment
4 GPO_ISO3_A Digital Output 3 External Equipment
5 COM Power return from SC External Equipment
6 GPO_ISO0_B Digital Output 0 External Equipment
7 GPO_ISO1_B Digital Output 1 External Equipment
8 GPO_ISO2_B Digital Output 2 External Equipment
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