Nuvation Energy S801 User manual

Nuvation Energy Multi-Stack Controller
Product Manual
Document ID: NE-PM-004 | Revision: 2.0, 2022-05-18
BMS Software Version: Curie Update 3
© 2022 Nuvation Energy

Table of Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
1.1. About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê2
2. Battery Topology Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê3
3. System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê4
3.1. Multi-Stack System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê5
3.2. Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.2.1. Main Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.2.2. Unified View Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê7
3.2.3. Communications & Data Analytics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8
3.2.4. Maintenance and Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê8
4. Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
4.1. Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
4.1.1. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
4.1.2. Installation Location and Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê9
4.2. Multi-Stack Controller Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.2.1. Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.2.2. Step 1: Connect Stack Switchgear Communications . . . . . . . . . . . . . . . . . . . . . . . . . Ê11
4.2.3. Step 2: Connect External Network or System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê12
4.2.4. Step 3: Verify Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê13
4.3. Multi-Stack Controller First Power-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14
4.3.1. Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê14
4.3.2. Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê15
5. Using the Multi-Stack Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17
5.1. Access the Multi-Stack Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17
5.1.1. External Computer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17
5.1.2. Launch Multi-Stack Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê17
5.2. The Status Banner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê19
5.2.1. Communication Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê19
5.3. The Dashboard Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê20
5.3.1. Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê20
5.3.2. Pack Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê21
5.3.3. Pack Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê21
5.3.4. State-of-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê22
5.3.5. Depth-of-Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê22
5.3.6. Stack Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê22
5.3.7. Stack Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê23
5.3.8. Cell Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê24
5.3.9. Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê25
5.3.10. Nuvation Energy BMS Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê26
5.4. The Stack Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê29
5.4.1. Pack Connection/Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê30
5.4.2. Stack Enable and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê30

5.4.3. Stack Service Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê30
5.4.4. Stack COM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê31
5.5. The Details Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
5.5.1. Information Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
5.5.2. Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê33
5.5.3. Current Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê34
5.5.4. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê34
5.6. The Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê36
5.6.1. Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê36
5.6.2. Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê36
5.6.3. Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37
5.6.4. Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê37
5.6.5. Locking and Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê42
5.6.6. About. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê43
6. Using the Platform Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê44
6.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê44
6.2. Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê45
6.2.1. Installing a Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê45
6.2.2. Upgrading a Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê45
6.3. Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê46
6.3.1. Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê46
6.4. Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê48
6.4.1. Create a System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê48
6.4.2. Upload a backup file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê48
6.4.3. Backup Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê49
6.5. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê50
6.5.1. Upgrading the Multi-Stack Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê50
6.5.2. Factory Reset the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê51
6.5.3. Rebooting and Powering off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê51
6.5.4. Setting the Date, Time, and Timezone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê51
7. Communication Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê52
7.1. Modbus Protocol Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê52
7.1.1. Modbus TCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê52
7.1.2. Implemented MESA Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê52
7.1.3. MESA Model Structure and Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê53
7.1.4. Operational Cases for MESA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê55
7.1.5. Accessing MESA Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê57
8. External Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60
8.1. Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60
8.2. SFP+ Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60
8.3. Power Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60
8.4. DC Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê60
9. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê61
9.1. Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê61

9.1.1. Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê61
9.1.2. Controller Heartbeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê61
9.1.3. Ready Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê62
9.1.4. Firmware Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê62
9.2. Lost/Forgotten IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê63
9.2.1. Wireshark (Windows/Linux) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê63
9.2.2. Netdiscover (Linux only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê63
Appendix A: Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê64
Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê64
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê64
Standards and Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê64
Appendix B: Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê66
Power Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê66
Appendix C: Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê67
Excess Cable Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ê67

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 Multi-Stack Controller
have been made.
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.
Nuvation Energy Multi-Stack Controller - Product Manual
Document ID: NE-PM-004 1Rev 2.0, 2022-05-18
Curie Update 3

1. Introduction
Thank you for choosing Nuvation Energy.
The Nuvation Energy BMS is an enterprise-grade battery management system with features that
extend battery life, ensuring pack-level safety, data-analytics, and remote management.
The Nuvation Energy Multi-Stack Controller aggregates information and provides a unified interface to
a large multi-stack battery system.
1.1. About this Manual
This Nuvation Energy Multi-Stack Controller: Product Manual is a comprehensive manual, providing:
▪Details about all the features offered by your Nuvation Energy Multi-Stack Controller
▪Mounting and wiring instructions to install this product safely
▪Guidance on operating the device to control your multi-stack energy storage system
This document applies to Nuvation Energy BMS Curie Update 3 software release
(Firmware version 4.106.3, Multi-Stack Operator Interface version 0.56.1). Content
may be inaccurate or incomplete for other versions.
We thrive on your feedback and what we build is driven by your input.
Please submit support tickets to [email protected].
Nuvation Energy Multi-Stack Controller - Product Manual
Document ID: NE-PM-004 2Rev 2.0, 2022-05-18
Curie Update 3

2. Battery Topology Terminology
Energy storage systems are hierarchical in nature. Nuvation Energy has adopted the following
definitions for battery pack topology:
Cell
A Cell is the smallest unit of energy storage distinguishable by the battery management system.
One Cell, as defined from the perspective of the BMS, may actually consist of one or more
electrochemical cells connected in parallel. This subtlety is reflected in the nomenclature for
completeness. For example, a "1p" Cell refers to a single electrochemical cell, while a "2p" Cell
refers to two electrochemical cells connected together in parallel. From the perspective of the BMS,
these topologies appear identical except for the capacity of the Cells.
Group
A Group is a set of Cells connected in series and managed together. For example, 12 "1p" Cells in
series are referred to as a "12s1p" Group, while 16 "2p" Cells in series are referred to as a "16s2p"
Group. Grouping of Cells is highly application-specific and is defined in how BMS hardware
interfaces are physically wired up to Cells.
Stack
A Stack is one or more Groups connected in series. For example, five "14s2p" Groups connected in
series could be described as a "5g14s2p" Stack. However, it is far more common to describe it as
a "70s2p" Stack.
Bank
A Bank is one or more stacks connected in parallel. For example, three "70s2p" Stacks connected
in parallel are referred to as a "3x70s2p" Bank.
Pack
A Pack is one or more Banks connected in series.
Nuvation Energy Multi-Stack Controller - Product Manual
Document ID: NE-PM-004 3Rev 2.0, 2022-05-18
Curie Update 3

3. System Overview
The Nuvation Energy Multi-Stack Controller aggregates all battery stacks within a multi-stack energy
storage system. It enables operation of the overall system as a single unified battery, while still
providing stack-level control.
This product functions as a central battery control hub for other control systems. These may include
power conversion systems and/or energy controllers. Through this hub, such control systems can
obtain and respond to battery data and send control commands to the battery system.
The Multi-Stack Controller can be used to manage up to 36 battery stacks in parallel, and will bring
up stacks in the sequence best suited to the immediate use-case requirement, i.e. power, energy, or
capacity.
The Multi-Stack Controller provides two crucial battery-level software interfaces for large, multi-stack
battery applications:
1. Modbus TCP:
•Unified view of the entire battery conforming to open energy standards
•Conforms to MESA (Draft 3) Models: S801, S802, and S803
•Used directly by inverters and other grid infrastructure implementing the MESA (Draft 3)
standard
2. Web-based configuration and diagnostics:
•Hosts web-based tools that can be accessed from common web browsers
•Used to configure settings and view diagnostic information for the entire battery system
A few key system-level features that are also provided are:
▪System-wide statistics for voltages, temperatures, and currents
▪Current limiting algorithms for multi-stack battery systems
▪State-of-Charge algorithms for multi-stack battery systems
▪NTP client for BMS time synchronization
Figure 1. Nuvation Energy Multi-Stack Controller
Nuvation Energy Multi-Stack Controller - Product Manual
Document ID: NE-PM-004 4Rev 2.0, 2022-05-18
Curie Update 3

3.1. Multi-Stack System Architecture
A typical multi-stack system, equipped with Nuvation Energy’s suite of BMS products, is illustrated in
Figure 2. There is a hierarchy of battery management involved, each product fulfilling its role at a
different level:
▪At the cell level, a Nuvation Energy Cell Interface module measures voltage/temperature and
balances cells as required.
▪At the stack level, a Nuvation Energy Stack Switchgear unit measures current and
connects/disconnects its stack as required, as well as incorporates other stack safety features.
Battery safety is handled at the stack level.
▪At the system level, a Nuvation Energy Multi-Stack Controller unit manages all stacks as described
above.
For a given stack, the daisy-chained Cell Interface modules report data to and receive direction from
the Stack Switchgear. In turn, the Stack Switchgear reports data to and receives direction from the
Multi-Stack Controller. Here, a unified view and central control of the multi-stack system is provided
to the user as well as any external devices.
Nuvation Energy Cell Interface modules and Nuvation Energy Stack Switchgear units
are sold separately. Datasheets, along with product manuals, are available online at
https://www.nuvationenergy.com/technical-resources.
Figure 2. Multi-Stack Controller system diagram
Nuvation Energy Multi-Stack Controller - Product Manual
Document ID: NE-PM-004 5Rev 2.0, 2022-05-18
Curie Update 3

The Multi-Stack Controller is offered in variants based on the number of battery stacks to which it will
be connected. Variants are available in 4-stack increments, up to a maximum of 36 stacks.
The Multi-Stack Controller is available in a compact hardware form-factor or in a rack-mounted
hardware form-factor. This document describes the compact form-factor. The document for the rack-
mount form-factor is available upon request.
Designed in compliance with MESA (Modular Energy Storage Architecture) Open Standards for Energy
Storage (http://mesastandards.org/, draft 3), the Nuvation Energy Multi-Stack Controller was created
specifically for integration with a wide range of batteries and inverters, and is designed to work with
Nuvation Energy Stack Switchgear, Nuvation Energy High-Voltage BMS, and Nuvation Energy Low-
Voltage BMS.
Orderable part numbers are listed in Appendix B.
Nuvation Energy Multi-Stack Controller - Product Manual
Document ID: NE-PM-004 6Rev 2.0, 2022-05-18
Curie Update 3