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Table 23. Contactors: Molex MiniFit Jr Connector

Molex 39-01-2125

Manufacturer

Molex Incorporated

Housing

39-01-2125

Housing material

Nylon UL94V-0

Circuits

12

Crimp terminal

39-00-0181

Wire gauge range

AWG18-24 stranded

Table 24. Contactor Connector Pin Assignment

Pin

Connection

Description

Connected to Device

1

COIL1_HI

Positive Coil 1

Contactor 1 positive coil connection

2

COIL2_HI

Positive Coil 2

Contactor 2 positive coil connection

3

COIL3_HI

Positive Coil 3

Contactor 3 positive coil connection

4

COIL4_HI

Positive Coil 4

Contactor 4 positive coil connection

5

No Connect

Not Connected

No Connect

6

COM

Negative reference for external
supply

External Power Supply

7

COM

Negative Coil 1

Contactor 1 negative coil connection

8

COM

Negative Coil 2

Contactor 2 negative coil connection

9

COM

Negative Coil 3

Contactor 3 negative coil connection

10

COM

Negative Coil 4

Contactor 4 negative coil connection

11

+VINT

PI Power Supply

Connect to Contactors connector Pin 12 if
driving contactor coil from Power Interface
power supply

12

+VCOIL

12~24V Contactor Coil Power
Supply

Connect to external power supply or
Contactors connector Pin 11 if driving
contactor coil from Power Interface power
supply

Nuvation Energy High-Voltage BMS - Installation Guide

Document ID: NE-IG-001

29

Rev 2.1, 2020-03-13

Summary of Contents for High-Voltage BMS

Page 1: ...Nuvation Energy High Voltage BMS Installation Guide Document ID NE IG 001 Revision 2 1 2020 03 13 2020 Nuvation Energy...

Page 2: ...RND variant with DIN rail mounting 13 4 4 Electrical Connections 14 4 4 1 Link Out 14 4 4 2 Link In 15 4 4 3 Battery Cells 16 Battery Cell Connecter for Cell Interface 12 channel 17 Battery Cell Conne...

Page 3: ...6 3 System Noise 38 6 3 1 DC Filtering 39 6 3 2 Stack Controller Grounding 40 6 3 3 Link Bus Power 41 Appendix A Factory Reset 42 Overview 42 Reset to Factory Defaults 42...

Page 4: ...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 Nuvat...

Page 5: ...n 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...

Page 6: ...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...

Page 7: ...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 tha...

Page 8: ...nk 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 sys...

Page 9: ...ace 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 Mo...

Page 10: ...tive External Equipment 6 EXTMOD_TERM1 Termination Resistor Short to Pin 12 to add 150 bus termination CAN 485 Connector 7 12V_isoCAN 5 5 12Vdc isolated CAN bus power External Equipment 8 CAN_P CAN bu...

Page 11: ...sed to connect _A pins to their corresponding _B pins Each output is rated for 60 V DC 400 mA max and the signals connected to each output must be within 50 V DC from chassis earth ground There is no...

Page 12: ...ect external equipment to this connector Connect a pin to its corresponding COM to turn the input on Table 9 GPI Molex Micro Fit 3 0 Connector Molex 43025 0800 Manufacturer Molex Incorporated Housing...

Page 13: ...e 11 Stack Bus Molex MiniFit Jr Connector Molex 39 01 2065 Manufacturer Molex Incorporated Housing 39 01 2065 Housing material Nylon UL94V 0 Circuits 6 Crimp terminal 39 00 0181 Wire gauge range AWG20...

Page 14: ...losure has five metal walls leaving the bottom of the unit fully exposed It must be mounted to a metal bulkhead panel such that the panel covers the exposed bottom side The NUV100 CI 12 1 and NUV100 C...

Page 15: ...50022 compliant DIN rails as shown in Figure 4 The Mounting Bracket kit assembly adds an extra 14 2 mm to the overall width of the Cell Interface module bringing it from 104 4 mm to 118 6 mm The kit a...

Page 16: ...he information below is provided for the purpose of updating DIN rail mechanical designs The clips add an extra 19 6 mm to the overall width of the standard Cell Interface module bringing it from 104...

Page 17: ...es power and communication to the Cell Interface modules above this Cell Interface The amount of current supplied by this connector is the sum of current consumed by all Cell Interface modules above t...

Page 18: ...ides power and communication to this Cell Interface from the Cell Interface modules below this Cell Interface or from the Stack Controller if this Cell Interface is measuring the most negative cell in...

Page 19: ...ltage input and a means for balancing the cells The cable wire should be rated for at least 750mA to survive worse case current Pins 8 16 17 and 18 are No Connect in the Cell Interface 12 channel mode...

Page 20: ...terminal of Cell 4 4 CELL6 Cell 6 voltage sense Connect to positive terminal of Cell 6 5 CELL8 Cell 8 voltage sense Connect to positive terminal of Cell 8 6 CELL10 Cell 10 voltage sense Connect to pos...

Page 21: ...nnect to positive terminal of Cell 11 16 No Connect Not Connected No Connect 17 No Connect Not Connected No Connect 18 No Connect Not Connected No Connect The following is an example wiring guide for...

Page 22: ...Figure 6 Example wiring 12 cells in a Cell Interface 12 channel Nuvation Energy High Voltage BMS Installation Guide Document ID NE IG 001 19 Rev 2 1 2020 03 13...

Page 23: ...l Battery Cell Connector Pin Assignment Pin Connection Description Connected to Device 1 CELL0 Bottom reference of Cell Interface Connect to negative terminal of the lowest cell Cell 1 2 CELL2 Cell 2...

Page 24: ...t cell Cell 1 11 CELL3 Cell 3 voltage sense Connect to positive terminal of Cell 3 12 CELL5 Cell 5 voltage sense Connect to positive terminal of Cell 5 13 CELL7 Cell 7 voltage sense Connect to positiv...

Page 25: ...Figure 8 Example wiring 16 cells in a Cell Interface 16 channel Nuvation Energy High Voltage BMS Installation Guide Document ID NE IG 001 22 Rev 2 1 2020 03 13...

Page 26: ...r Pin Assignment Pin Connection Description Connected to Device 1 CELL0 Bottom reference of Cell Interface Connect to negative terminal of the lowest cell Cell 1 2 No Connect Not Connected No Connect...

Page 27: ...t Connected No Connect 12 No Connect Not Connected No Connect 13 No Connect Not Connected No Connect 14 No Connect Not Connected No Connect 15 No Connect Not Connected No Connect 16 No Connect Not Con...

Page 28: ...rom the cell voltage terminals in such a way that they will not make an electrical connection to a cell terminal in the event of vibration failures Connect 10 k NTC thermistors to this connector Table...

Page 29: ...robe Reference 7 10 k NTC Thermistor 8 VBOT External Temperature Probe Reference 8 10 k NTC Thermistor 9 TEMP1_R External Temperature Probe Input 1 10 k NTC Thermistor 10 TEMP2_R External Temperature...

Page 30: ...6 mm to the overall width of the Power Interface bringing it from 174 40 mm to 194 mm The clips also hold the module approximately 7 mm away from the inside lip of the DIN rail Extra space should be...

Page 31: ...h output is capable of sourcing a maximum of 2 8 A continuously If coil operating power is provided from an external power source the sum of all 4 output currents must not exceed 5 A continuous If coi...

Page 32: ...ve coil connection 5 No Connect Not Connected No Connect 6 COM Negative reference for external supply External Power Supply 7 COM Negative Coil 1 Contactor 1 negative coil connection 8 COM Negative Co...

Page 33: ...om the PI Figure 13 Example 2 coil wiring The following is an example 4 contactor implementation that is powered from an external power supply Figure 14 Example externally powered 4 coil wiring Nuvati...

Page 34: ...e energized open closed System contactors are controlled by Nuvation Energy BMS software but de energized if hardware based fault signaling detects a fault closed either open or closed System contacto...

Page 35: ...ernal Power connector accepts power from an external power supply This is the sole power source for Nuvation Energy BMS The external supply can be either 16 24 V AC or 13 34 V DC and must be isolated...

Page 36: ...ontroller to this connector Table 30 Stack Bus Molex MiniFit Jr Connector Molex 39 01 2065 Manufacturer Molex Incorporated Housing 39 01 2065 Housing material Nylon UL94V 0 Circuits 6 Crimp terminal 3...

Page 37: ...cordingly Connect the current shunt to this connector Table 32 Current Shunt Molex MiniFit Jr Connector Molex 39 01 4041 Manufacturer Molex Incorporated Housing 39 01 4041 Housing material Nylon UL94V...

Page 38: ...terminal to this connector Table 34 Stack Power Molex MiniFit Jr Connector Molex 39 01 4031 Manufacturer Molex Incorporated Housing 39 01 4031 Housing material Nylon UL94V 0 Circuits 3 Crimp terminal...

Page 39: ...ected to Device 1 VBAT_POS Overall Stack Positive Connect to most positive terminal of the battery stack 2 No Connect Not Connected No Connect 3 No Connect Not Connected No Connect Nuvation Energy Hig...

Page 40: ...ower connections on the Power Interface and the Battery Cells and Temperature Sensors connections on the Cell Interface and Ethernet and CAN interfaces on the Stack Controller It is acceptable as may...

Page 41: ...ly reducing the cable length is not possible Figure 16 Excess Cable Management Examples 6 3 System Noise High power inverters generate a lot of system noise especially on the DC bus This is due to the...

Page 42: ...a correctly wired system a communication fault points to elevated system noise that is disrupting communications If the system grounding scheme cannot be improved there are still a few techniques with...

Page 43: ...e inverter and the grid to remove the high current pulses Figure 18 Example Isolation Transformer Installation Diagram 6 3 2 Stack Controller Grounding If sc_stackbus communication faults are occurrin...

Page 44: ...n This provides a decent medium to couple system noise into the Link Bus which can result in sc_linkbus communication faults In systems where the cells can provide the necessary minimum operating volt...

Page 45: ...k Controller If a Factory Reset cable is unavailable connect an external 18 24V DC power supply to the Link Bus connector on the Stack Controller Pin 1 on the Link Bus connector is positive and Pin 2...

Page 46: ...ble technologies client requests emerging energy storage standards and other industry requirements The product specifications in this document therefore are subject to change without notice 2020 Nuvat...

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