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3.2. Cell Interface Installation

3.2.1. Electrical Connections

The Cell Interface module has 4 connectors. Each connector is described in the following sections in
detail.

Link Out

The Link Out connector provides 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 this Cell Interface.

Connect the Cell Interface that is measuring the next series-connected cell above the most positive
cell connected to this connector.

Nuvation Energy Stack Switchgear - Product Manual

Document ID: NE-PM-003

Rev 1.0, 2020-09-03

Summary of Contents for Stack Switchgear

Page 1: ...Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 Revision 1 0 2020 09 03 2020 Nuvation Energy...

Page 2: ...p 46 5 Using the Stack Switchgear 47 5 1 Service Disconnect 47 5 2 Panel Status LEDs 48 5 2 1 Power LED 48 5 2 2 Activity LED 48 5 2 3 Fault LED 48 6 Nuvation Energy BMS Software Setup 49 6 1 Install...

Page 3: ...Status 65 7 2 The Details Tab 68 7 2 1 Overview 68 7 2 2 Addressing 68 7 2 3 Battery 68 7 2 4 Current Limiter 69 7 2 5 Safety 69 7 2 6 Cell Voltages 70 7 2 7 Thermistor Temperatures 71 7 2 8 Open Wire...

Page 4: ...Characteristics 84 Environmental Conditions 85 Appendix B Changing the Nuvation Energy BMS Network Configuration 86 BMS Network Configuration 86 Overview 86 Modifying the Network Settings 86 Appendix...

Page 5: ...y 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 o...

Page 6: ...cities 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 BM...

Page 7: ...family 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 Manual This Nuvation Energy...

Page 8: ...in Nuvation Energy Stack Switchgear NUVSSG Datasheet available online at https www nuvationenergy com technical resources Table 1 Nuvation Energy Stack Switchgear variants Maximum Voltage Rating Maxim...

Page 9: ...bus in the system may be connected to a single Nuvation Energy Battery Control Panel where an Operator Interface provides a unified view and central control of the multi stack system Nuvation Energy C...

Page 10: ...Figure 3 Stack Switchgear multi stack diagram Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 6 Rev 1 0 2020 09 03...

Page 11: ...0 7 lbs Its overall dimensions as well as mounting specific ones are shown in Section 2 1 1 4 Please refer to https www nuvationenergy com technical resources for access to CAD files Rack Mount 19 As...

Page 12: ...respectively Note that third party side support 2 post extension brackets are available though not necessary One example is Hammond Manufacturing s RDAB2U26 product details are available on their web...

Page 13: ...rests with the aid of shelf mount brackets as shown in Figure 7 Figure 7 Shelf mount Dimensions This section provides detailed drawings of the Stack Switchgear and its mounting provisions Nuvation Ene...

Page 14: ...Figure 8 Dimensions overall Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 10 Rev 1 0 2020 09 03...

Page 15: ...Figure 9 Dimensions rack mount 19 Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 11 Rev 1 0 2020 09 03...

Page 16: ...Figure 10 Dimensions shelf mount Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 12 Rev 1 0 2020 09 03...

Page 17: ...Figure 11 Dimensions 2 post rack mount 19 Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 13 Rev 1 0 2020 09 03...

Page 18: ...nergy Stack Switchgear internally includes the following major hardware components Nuvation Energy High Voltage Stack Controller Nuvation Energy High Voltage Power Interface Current measuring shunt Nu...

Page 19: ...ve sides of the stack Nuvation Energy BMS opens the contactors either by request of an external controller or in fault conditions A third high voltage contactor is used in the pre charge circuit see S...

Page 20: ...ay for monitoring an external E Stop signal A safety relay is used to ensure the relay cannot fail shorted This relay meets the requirements of the following standards EN 954 1 EN 60204 1 VDE 0113 1 a...

Page 21: ...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...

Page 22: ...ftware registers and the Operator Interface may be not be as intuitive as the aforementioned order i e order of increasing potential Table 4 Link Bus connector pinout Pin Name Description Connected to...

Page 23: ...positive is at pin 2 and the negative is at pin 3 pin 1 can be left unconnected For available Stack Switchgear options refer to Nuvation Energy Stack Switchgear NUVSSG Datasheet available online at h...

Page 24: ...tput is connected to the internal 24 V DC power supply One Stack Switchgear unit s E Stop output is capable of driving the E Stop inputs for up to two Stack Switchgear units i e one other Stack Switch...

Page 25: ...at the bottom of the connector Remove the tool to secure the conductor in place For stranded wires the use of ferrules is recommended Table 7 E Stop pinout Pin Name Description Connected to Device 1...

Page 26: ...reely enter into the circular opening at the bottom of the connector Remove the tool to secure the conductor in place For stranded wires the use of ferrules is recommended An inline breaker provides t...

Page 27: ...the internal wiring implementation of the fan control parts shown above Figure 15 Battery cooling fan control wiring diagram Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 23 R...

Page 28: ...uit Corp LCMA50 8 L Flexible snap on terminal covers are included Table 9 High power connections Name Description Connected to Device Battery Negative terminal of battery stack Battery stack Battery P...

Page 29: ...itchgear Current Rating A Grounding Wire AWG Copper Aluminum 100 8 6 200 6 4 300 4 2 Figure 16 Grounding stud An M8 lug not included should be used e g Panduit Corp LCMA50 8 L along with an M8 screw a...

Page 30: ...nterface variant must be used i e all NUV100 CI 12 1 or all NUV100 CI 16 1 or all NUV100 CI 4M12 1 There are 3 variants of the Nuvation Energy Cell Interface The NUV100 CI 12 1 Cell Interface 12 chann...

Page 31: ...osure to ensure that the metal walls remain a safe distance from the exposed conductor on the PCB Using 1250 V DC as an example the metal walls of the enclosure must be at least 4 2 mm from the neares...

Page 32: ...he older Cell Interface DIN Mount variant has been discontinued and is NRND not recommended for new design New designs should use Cell Interface Bulkhead variant with the Cell Interface Mounting Brack...

Page 33: ...Figure 20 Mechanical Drawing of Cell Interface with DIN Enclosure NRND Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 29 Rev 1 0 2020 09 03...

Page 34: ...on the shelf at the desired location 3 Attach the Stack Switchgear with brackets installed to the shelf For rack installations i e using the NUVP SSG RB 19 1 Install the third party side support angl...

Page 35: ...ll the Link Bus cable between the Stack Switchgear and the first Cell Interface in the Link Bus chain 7 Install the connection to the battery and the DC bus This step is done with live voltage for thi...

Page 36: ...ication 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 this Cell Interface...

Page 37: ...des 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 38: ...onnector provides cell voltage 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...

Page 39: ...ge AWG20 24 stranded Battery Cell Connector for Cell Interface 12 channel Table 16 Cell Interface 12 channel Battery Cell Connector Pin Assignment Pin Connection Description Connected to Device 1 CELL...

Page 40: ...sense Connect to positive terminal of Cell 7 14 CELL9 Cell 9 voltage sense Connect to positive terminal of Cell 9 15 CELL11 Cell 11 voltage sense Connect to positive terminal of Cell 11 16 No Connect...

Page 41: ...Figure 21 Example wiring 12 cells in a Cell Interface 12 channel Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 37 Rev 1 0 2020 09 03...

Page 42: ...nnel 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...

Page 43: ...est 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 posit...

Page 44: ...Figure 23 Example wiring 16 cells in a Cell Interface 16 channel Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 40 Rev 1 0 2020 09 03...

Page 45: ...tor 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 Connec...

Page 46: ...Not 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 C...

Page 47: ...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 48: ...15 TEMP7_R External Temperature Probe Input 7 10 k NTC Thermistor 16 TEMP8_R External Temperature Probe Input 8 10 k NTC Thermistor For safety certified applications there must be at least two but no...

Page 49: ...ermal consistency for all temperature measurements for each Cell Interface The constraint is described in detail in the Sensor Fault Detection section within the Nuvation Energy BMS Safety Manual Nuva...

Page 50: ...k either through a network switch or directly to a computer laptop s network adapter The default IP address of the Stack Switchgear is 192 168 1 21 Refer to the Section 6 for instructions on using the...

Page 51: ...ut tag out The OFF position is vertical The ON position is horizontal The service disconnect switch removes power to the internal contactors it does not physically break the connection this is done by...

Page 52: ...Activity LED The ACTIVITY LED blue indicates that the Stack Switchgear is communicating with the Multi Stack Controller or an external controller and is receiving a heartbeat signal Figure 29 Activity...

Page 53: ...zip the package to a suitable location on your computer 7 ZIP is a free tool that can be downloaded here http www 7 zip org 3 The archive s password is nuvation 4 Releases follow a naming convention s...

Page 54: ...tion Energy BMS is configured with a static IP address of 192 168 1 21 To connect to a Nuvation Energy BMS that is using the default IP address 1 Go to Control Panel All Control Panel Items Network Co...

Page 55: ...cable between Nuvation Energy BMS and the network adapter of your PC 6 Open the Nuvation Energy Operator Interface html file in your web browser This is usually done by double clicking on the file If...

Page 56: ...tors and GPOs When in Service Lockout you will not be able to access the Operator Interface dashboard 6 3 3 Upgrading the Firmware The Upgrade option will become available when Nuvation Energy BMS suc...

Page 57: ...l remain in Service Lockout You will need to import a valid configuration file before attempting to exit Service Lockout 6 3 4 Troubleshooting During the firmware upgrade if a failure is reported retr...

Page 58: ...If the failures persist please submit a support ticket with as much detail as possible to support nuvationenergy com Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 54 Rev 1 0 20...

Page 59: ...tware Reference Manual for details on how to create a configuration file for your setup For Nuvation Energy Low Voltage BMS installations To generate a configuration file visit the nCloud at https ncl...

Page 60: ...ile To edit the Configuration file open the file in any text editor Please backup the modified configuration file for future use Nuvation Energy BMS doesn t store the file internally it only stores th...

Page 61: ...file If you are using known good configuration files you should check this box Disabling this option tells Nuvation Energy BMS to not persist the newly imported configuration file On reboot Nuvation...

Page 62: ...During the configuration file import if you receive a Register Write failure error ensure you have valid entries in your configuration file For details on the various registers and their intended use...

Page 63: ...een imported 6 6 2 Calibration 1 Refer to the section Measurement Calibration in the Software Reference Manual for steps to calibrate the stack current voltage and temperature measurements 2 Fully cha...

Page 64: ...ges and information presented in the dashboard it is important to understand what a fault and a warning Nuvation Energy BMS status means A Nuvation Energy BMS Warning indicates the state of the batter...

Page 65: ...e are no faults or warning This is the normal state for Nuvation Energy BMS 7 1 3 Stack Voltage The stack voltage radial meter shows the total battery stack voltage Refer to the Stack Voltage Threshol...

Page 66: ...0 and full when the State of Charge value is 100 7 1 6 Depth of Discharge The Depth of Discharge radial gauge shows how much energy has been taken out of the battery stack In an ideal energy storage s...

Page 67: ...ow and red segments The blue segment depicts the acceptable cell voltage range If a triangle enters the yellow segment a warning has occurred If a triangle enters the red segment a fault has occurred...

Page 68: ...w and red segments The blue segment depicts the acceptable cell temperature range If a triangle enters the yellow segment a warning has occurred If a triangle enters the red segment a fault has occurr...

Page 69: ...stack connection state number of cells balancing maximum charge current limit maximum discharge current and the time and date of the last update of the Dashboard Operation Status Nuvation Energy BMS...

Page 70: ...red oval indicates the battery stack is unavailable to be charged or discharged Stack Pre charging in an orange oval indicates the battery stack has connected its pre charge circuit and is attempting...

Page 71: ...rator Interface had successfully communicated with Nuvation Energy BMS and updated all items in the Dashboard with values from Nuvation Energy BMS The time and date is based on the local computer tabl...

Page 72: ...le accordions expanded at the same time Figure 37 Nuvation Energy BMS Operator Interface Details tab screenshot 7 2 2 Addressing The Addressing accordion presents the addressing information for your N...

Page 73: ...The unit of the current limit values is mA Figure 40 Current Limiter accordion in Details Tab 7 2 5 Safety The Safety accordion contains a comprehensive list of all possible Nuvation Energy BMS faults...

Page 74: ...ence Manual document Figure 42 Bottom of Safety accordion in Details Tab 7 2 6 Cell Voltages The Cell Voltages accordion lists all installed cell voltage measurements Cells that are not installed are...

Page 75: ...led thermistor temperature measurements Thermistors that are not installed are displayed as a dash Temperatures in red indicate measurements which have triggered a Nuvation Energy BMS fault There is n...

Page 76: ...es and collecting the data begins Figure 47 Open Wire aquiring accordion in Details Tab Once the open wire scanning has completed and all diagnostics data is collected it is displayed in a tabular for...

Page 77: ...Filtering You can filter the display to ratios with values above or below a value you specify Nuvation Energy Stack Switchgear Product Manual Document ID NE PM 003 73 Rev 1 0 2020 09 03...

Page 78: ...enerate a Configuration File for instructions For instructions on how to modify the configuration file or understand the various registers please refer to the Software Reference Manual for your Nuvati...

Page 79: ...The page will refresh and try to connect to this new IP 7 3 5 Locking and Unlocking When the Operator Interface is unlocked the lock indicator will be replaced with an unlock indicator Figure 49 Oper...

Page 80: ...representing the month within that year that this Nuvation Energy BMS package was released The version numbers below the release name are the version numbers of the individual software packages runnin...

Page 81: ...ice lockout a banner is displayed indicating this to the user Figure 52 Operator Interface Service Lockout indicator Figure 53 Operator Interface Exiting Service Lockout indicator Figure 54 Operator I...

Page 82: ...ation Energy BMS will flag all faults and notify other Operator Interfaces 7 5 2 Entering Service Lockout 1 Unlock the Operator Interface by clicking the menu and Unlock 2 From the menu select Service...

Page 83: ...that owns this lockout 7 5 5 Shutdown Timer for Battery Controller To protect your batteries a Low Voltage Battery Controller will automatically shutdown after an hour of being in Service Lockout The...

Page 84: ...are shown on the right side of the display Refer to the Software Reference Manual to the Troubleshooting section for details on how to address the uninitialized data registers If you just imported a...

Page 85: ...cleared for Stack Switchgear to close contactors Wait for the connection state to show Connected 3 Using the Operator Interface connect the stack by clicking the Connect button This initiates the con...

Page 86: ...d in its original packaging via pallet whenever possible When shipping with the Stack Switchgear already installed the product is rated for SAE J2380 random vibration and SAE J2464 shock Nuvation Ener...

Page 87: ...nt The impact of switching under load is significantly higher than at no load The safety relay fan relay and service disconnect switch s remaining lives are calculated by taking a baseline number TBD...

Page 88: ...l Parameter Min Typ Max Units Stack Switchgear Configuration 1250 V DC XXX A Vstack_ov Stack Over Voltage Threshold contactors open 0 Configurable 1250 V DC Vstack_uv Stack Under Voltage Threshold con...

Page 89: ...l Specifications Ta Operating Temperature 10 25 40 C Storage Temperature 10 25 40 C Humidity Specifications RH Operating Relative Humidity 5 65 Storage Relative Humidity 5 65 Nuvation Energy Stack Swi...

Page 90: ...menu select Registers to bring up the register browser page 3 Under the Manual Register Configuration panel expand the row for Component Name sc_ethernet The sc_ethernet component contains network se...

Page 91: ...nfiguration has been saved correctly by reading the error register The value will be 0 if no errors have occurred The network settings have been updated Any changes will take effect when Nuvation Ener...

Page 92: ...Interface The Battery Cells and Temperature Sensors connections on the Cell Interface The Ethernet and CAN interfaces on the Stack Switchgear unit s internal Stack Controller It is acceptable as may b...

Page 93: ...p in the cabinet This basic tactic has the undesirable effect of creating an air core transformer which will couple EMI into the cable extremely well The best solution to cable length management is to...

Page 94: ...stackbus_rxwdt trig sc_fault_stackbus_txwdt trig sc_fault_pi_afe_wdt trig sc_fault_controller_wdt trig The informative communication error registers are sc_linkbus_packets operation_read_errors sc_lin...

Page 95: ...tectors It might be necessary to install an isolation transformer between the inverter and the grid to remove the high current pulses Figure 59 Example Isolation Transformer Installation Diagram Link...

Page 96: ...s power can be disabled if the observed impact on performance is acceptable The power twisted pair must be disconnected in the Link Bus cable The Link Bus connector on the Stack Switchgear along with...

Page 97: ...lable 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 Nuv...

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