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10. Troubleshooting

10.1. Faults and Initialization Issues

During initial setup of a Nuvation Energy BMS, there are two main classes of issues that can be
encountered:

1. Initialization issues

2. Triggering of faults

The first class of issues are encountered during initial deployment of a Nuvation Energy BMS,
particularly while attempting to power on the Stack Switchgear. When this event occurs, an operator
of the Operator Interface can open the Details|Safety accordion (

). That screen presents

a list of fault and warning triggers that may or may not be initialized. This section will provide details
on why the faults/warnings could not be initialized. Once all faults/warnings have been initialized,
Nuvation Energy BMS has been installed as expected (i.e. all inputs are receiving data). When this
occurs the software enters its operational mode.

The second class of issues occurs while Nuvation Energy BMS is operational. One or more faults can
be triggered causing Nuvation Energy BMS to exit its operating condition and open all contactors.
There are many faults that can be triggered. This section will describe the condition the fault monitors
and the meaning when that fault is triggered.

The following sections describe different classes of faults/warnings and issues surrounding any
initialization. In general, all warnings have a similar trigger condition as their corresponding fault. The
following discussion will focus on the term fault and all descriptions can be applied to the compatible
warning.

10.1.1. Cell Voltage Faults

stack_fault_cell_over

▪

Fault that is triggered when an installed cell voltage is above the

over

fault threshold

stack_fault_cell_hi

▪

Fault that is triggered when an installed cell voltage is above the

high

fault threshold

stack_fault_cell_lo

▪

Fault that is triggered when an installed cell voltage is below the

low

fault threshold

stack_fault_cell_under

▪

Fault that is triggered when an installed cell voltage is below the

under

fault threshold

10.1.1.1. Initialization Issues

These faults could fail to initialize through a number of possible conditions such as:

Nuvation Energy High-Voltage BMS - Product Manual

Document ID: NE-PM-003

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Rev 1.2, 2021-03-03

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Summary of Contents for NUV100-CI-12-1

Page 1: ...Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 Revision 1 2 2021 03 03 BMS Software Version Curie Update 1 2021 Nuvation Energy ...

Page 2: ...s 15 4 2 1 Getting Started 15 4 2 2 Ensure system is de energized 16 4 2 3 Grounding the Stack Switchgear 17 4 2 4 Connect Power In 18 4 2 5 Connect Fan Control 19 4 2 6 Connect E Stop 20 4 2 7 Connect Ethernet 22 4 2 8 Connect Link Bus 23 4 2 9 Connect Battery Stack and DC Bus 23 4 3 Cell Interface Mechanical Installation 25 4 3 1 Dimensions and Weight 25 4 3 2 Installation Location and Position ...

Page 3: ...Menu Options 57 6 3 1 Registers 57 6 3 2 Service 57 6 3 3 Connection 58 6 3 4 Locking and Unlocking 59 6 3 5 About 60 6 4 The Status Banner 62 6 4 1 Service Lockout Indication 62 6 4 2 Communication Loss 62 7 Communication Protocols 63 7 1 Modbus Protocol Support 63 7 1 1 Modbus TCP 63 7 1 2 Implemented MESA Models 63 7 1 3 MESA Model Structure and Nomenclature 64 7 1 4 Operational Cases for MESA ...

Page 4: ...us Faults 91 10 2 Lost Forgotten IP Address 91 10 2 1 Wireshark Windows Linux 92 10 2 2 Netdiscover Linux only 92 Appendix A Operating Limits 93 Stack Switchgear 93 External Specifications 93 Electrical Characteristics 93 Environmental Conditions 94 Standards and Certifications 94 Cell Interface 95 Electrical Characteristics 95 Environmental Conditions 96 Standards and Certifications 96 Maximum St...

Page 5: ...Interface and or the cells 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 Insulated handling is required of any connector carrying potentials over 60 V DC relative to chassis Please be aware of high voltages present in your system and follow all necessary safety p...

Page 6: ...nual providing Details about all the features offered by your Nuvation Energy High Voltage BMS Mounting and wiring instructions to install this product safely Guidance on integrating the device into your energy storage system Guidance on operating the Nuvation Energy BMS Operator Interface This document applies to Nuvation Energy BMS Curie Update 1 software release Firmware version 4 106 1 Operato...

Page 7: ...cept 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 ...

Page 8: ...Nuvation Energy High Voltage BMS into a rack mountable unit which includes stack monitoring electrical disconnects pre charging current sensing fuses and a safety relay for E Stop It also includes supporting components like power supplies indicator LEDs and external facing connectors Cell Interface modules in each stack connect directly to battery cells to measure cell voltages and temperatures an...

Page 9: ...gh Voltage BMS configuration as shown in Figure 3 each Stack Switchgear unit is responsible for monitoring the state and safety of one battery stack All Stack Switchgear units connected to a single common DC bus in the system may be managed by a single Nuvation Energy Battery Control Panel where an Operator Interface provides a unified view and central control of the multi stack system Nuvation En...

Page 10: ...Figure 3 High Voltage BMS multi stack diagram Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 6 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 11: ... as required Daisy chaining the Cell Interface modules facilitates the design of flexible and scalable battery energy storage systems The Stack Switchgear has high voltage high current connectors that are accessible on the front of the unit These connect the battery stack to the rest of the system which is typically a common DC bus Safety precautions are required to handle and connect cables into ...

Page 12: ...t MCU to handle processes and decision making required to control the high current contactors The Stack Controller and Power Interface are UL recognized components for use in UL 1973 stationary battery energy storage systems For more information on the capabilities of the Stack Controller and Power Interface please refer to the datasheets available online at https www nuvationenergy com technical ...

Page 13: ... mF at 1250 V As a custom request the pre charge resistor can be sized specific to the end application 3 2 5 Fuses Inline fuses are used on both the positive and negative connections and are sized according to the Stack Switchgear variant See Table 2 for the fuse ratings for each Stack Switchgear variant The fuses interrupt a short circuit event two of them are used to provide redundancy and to pe...

Page 14: ...ts of the Nuvation Energy Cell Interface The NUV100 CI 12 1 Cell Interface 12 channel can monitor up to 12 series connected cells The NUV100 CI 16 1 Cell Interface 16 channel can monitor up to 16 series connected cells The NUV100 CI 4M12 1 Cell Interface 12V 4 channel can monitor up to 4 series connected 12V lead acid cells Note that cell balancing is not supported in Cell Interface 12V 4 channel ...

Page 15: ...cially critical when working with live voltages 4 1 Stack Switchgear Mechanical Installation 4 1 1 Dimensions and Weight The Stack Switchgear is 4U rack units tall The unit weighs 23 kg 50 7 lbs Figure 6 Stack Switchgear Dimensions Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 11 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 16: ...d the screws cannot extend into the Stack Switchgear more than 8 mm High voltage and high power elements that exist inside the unit could arc to the screw if it intrudes too deep into the unit Fasteners for attaching the brackets to the end desired surface are not provided due to the application specific nature In order to source these fasteners however note that the corresponding bracket slots ha...

Page 17: ...ront or both rear brackets on the posts at the desired location 2 Install the other pair of brackets on the Stack Switchgear 3 Have one person support the Stack Switchgear in the desired position 4 Attach the Stack Switchgear with brackets installed to the posts Figure 8 Rack mount 2 post 19 Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 13 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 18: ...nstall the brackets on the Stack Switchgear 2 Place the Stack Switchgear on the shelf at the desired location 3 Attach the Stack Switchgear with brackets installed to the shelf Figure 10 Shelf mount Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 14 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 19: ...upport nuvationenergy com if there is a change in the system design that would require a Stack Switchgear configuration update 4 2 1 Getting Started Step 1 Ensure system is de energized Step 2 Ground the Stack Switchgear Step 3 Connect Power In Step 4 Connect Fan Control Step 5 Connect E Stop Step 6 Connect to external PC Step 7 Connect Cell Interface Link bus Step 8 Connect Battery Stack and DC B...

Page 20: ...wer to the internal contactors it does not physically break the connection this is done by the contactors themselves In the event of damage to the internal contactors i e a welded contactor the service disconnect switch cannot guarantee that the DC bus has been disconnected from the battery It is therefore recommended to check for voltage present on the Battery Stack and DC Bus terminals with a vo...

Page 21: ...e 15 Grounding stud The Stack Switchgear must be bonded to the rack or Earth through a suitably sized conductor by NEC standards From NFPA 70 Table 250 122 the wire size must be chosen based on the rating of the automatic over current device in the circuit as shown in Table 3 Table 3 Minimum grounding wire size Stack Switchgear Current Rating A Grounding Wire AWG Copper Aluminum 100 8 6 200 6 4 30...

Page 22: ...nternal AC to DC converter is selected the 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 Stack Switchgear Ordering Information An inline breaker provides the ability to turn off input power for the Stack Switchgear It also protects the system by tripping if the input current exceeds 5 A For specifications of this inp...

Page 23: ... connector Remove the tool to secure the conductor in place For stranded wires the use of ferrules is recommended An inline breaker provides the ability to turn off fan control for the Stack Switchgear It also protects the system by tripping if the amperage exceeds 5 A For specifications of this input see Stack Switchgear For the breaker s safety mechanism to work as expected the fan control wirin...

Page 24: ...tate Internally the E Stop input is connected to the safety relay coils while the E Stop output 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 Switchgear unit in addition to itself this allows the two Stack Switchgear units to share an E Stop circuit For app...

Page 25: ...Figure 17 E Stop circuit internal supply Figure 18 E Stop circuit external supply Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 21 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 26: ...y 3 E Stop Out E Stop Output Return External E Stop Circuitry 4 E Stop Out E Stop Output 24 V DC External E Stop Circuitry 4 2 7 Connect Ethernet Figure 19 Ethernet Connector The Ethernet connector is a standard RJ45 Ethernet jack It may be used to connect the Stack Switchgear to an external system such as A laptop to configure operating parameters and observe status A local area network LAN conne...

Page 27: ...uld be completed last In order to reduce the risk of a short only install one connection at a time The Stack Switchgear is configured for a specific battery topology based on the details provided to Nuvation Energy during order fulfillment Failure to use the same number of Cell Interface modules and or using a different battery topology will result in undesirable Stack Switchgear behavior Please c...

Page 28: ...0 to 60 in lbs The battery stack terminals are always energized and should be handled as such Although the DC bus terminals are disconnected from the battery by the Stack Switchgear unit s contactors the DC bus can still be energized by other components on the DC bus e g power conversion system or other stacks The DC bus terminals should always be treated as though they were energized A simple vol...

Page 29: ...ate and the necessary hardware to securely mount the bulkhead enclosure of the Cell Interface to EN50022 compliant DIN rails 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 assembly holds the module approximately 7 mm away from the inside lip of the DIN rail The Mounting Bracket offsets the Cell...

Page 30: ...IN 4 3 2 Installation Location and Position Figure 22 Nuvation Energy Cell Interface Module The Cell Interface is available in a bulkhead mountable enclosure which has five metal walls leaving Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 26 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 31: ...s easy installation and maintenance If mounting a Cell Interface PCB assembly only no enclosure note that the Cell Interface contains high voltage signals reaching as high as 1250 V DC Care must be taken when mounting the PCB into a metal enclosure 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 enclos...

Page 32: ... refer to Section 8 2 for connector pin out and specifications Connection sequence Step 1 Connect Temperature cable for temperature measurement of the cells Step 2 Connect Battery Cells cable to battery voltage sense leads Step 3 Connect Link Bus cable to BMS module s The wiring of the battery cell voltage and temperature sensing should be verified before connecting to the Cell Interface modules T...

Page 33: ...or cell temperature Figure 24 2 Thermistor cable NUVW A18A12 020 Figure 25 7 Thermistor cable NUVW A19A12 020 2 to 7 thermistors are supported to accommodate systems requiring Nuvation Energy BMS to meet functional safety requirements Cable Isolation Because the sensors are referenced to the CELL0 or BLOCK0 input on the Cell Interface care must be taken to ensure that they are electrically isolate...

Page 34: ...lls Similarly if powering the Cell Interface 16 channel module or the Cell Interface 12V 4 channel module from the cells i e not powering from the Link Bus the cells are connected as two groups and a minimum of 11 V must be present between the most negative and most positive cells of each group 4 4 3 1 Connection Procedure The Stack Switchgear is pre configured to expect a defined battery topology...

Page 35: ...ace 4 4 3 1 1 Battery Cell Connector for Cell Interface 12 channel Figure 26 Battery Cells cable NUVW A08Z12 020 for Cell Interface 12 channel Figure 27 Example wiring 12 cells in a Cell Interface 12 channel Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 31 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 36: ...Figure 28 Example wiring 8 cells in a Cell Interface 12 channel Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 32 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 37: ... channel Figure 29 Battery Cells cable NUVW A09Z12 020 for Cell Interface 16 channel Figure 30 Example wiring 16 cells in a Cell Interface 16 channel Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 33 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 38: ...Figure 31 Example wiring 11 cells in a Cell Interface 16 channel Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 34 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 39: ... variant Figure 32 Battery Cells cable NUVW A10Z12 020 for Cell Interface 12V 4 channel Figure 33 Example wiring 4 blocks in a Cell Interface 12V 4 channel Figure 34 Example wiring 3 blocks in a Cell Interface 12V 4 channel Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 35 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 40: ...dules in the Link Bus chain The amount of current supplied by this connector is the sum of current consumed by all subsequent Cell Interface modules in the Link Bus chain Connection Procedure 1 Connect one end of the cable to the Link Out connector on the Stack Switchgear 2 Connect the other end of the Link Bus cable to the Link In connector on the Cell Interface 3 For multiple Cell Interface modu...

Page 41: ...een detected the next step will be to clear this fault The service disconnect switch can be put in the ON position Faults are latching i e will remain in faulted state until cleared even if fault condition is removed Begin by clearing all faults If any faults remain investigate the cause of each fault and resolve the issue The faults are described in the Section 10 1 Once all faults are cleared th...

Page 42: ...s that the Stack Switchgear is communicating with the Battery Control Panel or an external controller and is receiving a heartbeat signal Figure 37 Activity LED Fault LED The FAULT LED red indicates that the system is in a fault state and requires attention to become operational The Operator Interface s fault page can be used to find the nature of the fault Figure 38 Fault LED 4 5 1 2 Cell Interfa...

Page 43: ...ult This LED is not used in normal operations It is available to support on site troubleshooting Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 39 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 44: ...your computer 3 Releases follow a naming convention similar to nuvation hv bms babbage 18 08 1 zip The package should be extracted to a folder with the same name to avoid overwriting other releases or files present in the same directory Browser Compatibility The Operator Interface currently supports the most recent versions of Mozilla Firefox and Google Chrome Other browsers such as Internet Explo...

Page 45: ...ss must be the same as the battery management system The Host ID number can be any number from 2 to 255 as long at it is not the same as the Host ID of the battery management system For example if the battery management system IP address is 192 164 1 21 the IP address of the PC could be 192 168 1 12 or 192 168 1 49 or any 192 168 1 x where x is not 21 If you have multiple stacks note down the Host...

Page 46: ...ady in use Refer to the instruction above to determine a valid IP address for the PC Subnet Mask 255 255 255 0 Default gateway The Network ID must be the same as the battery management system and the Host ID should be 1 For example if the battery management system IP address is 192 168 1 21 the gateway address would be 192 168 1 1 Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 0...

Page 47: ...gy Operator Interface html file in your web browser This is usually done by double clicking on the file If your default browser is not a supported browser you may need to specify the browser to use For example on Windows you may need to right click on the file select Open with and then choose Chrome or Firefox from the list Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 43 R...

Page 48: ...rmal operational range The cause of the warning should be identified and a corrective action should be performed For instance if the warning is a thermistor temperature measurement has become too hot the battery system should be cooled to bring the measurement back into the normal operational range A Fault indicates the state of the battery system has been detected outside of its safe operational ...

Page 49: ...the blue arc indicates the battery stack cannot be charged or discharged in its present condition A negative current value indicates the battery stack is charging A positive current value indicates the battery stack is discharging 6 1 4 State of Charge The State of Charge radial gauge shows the battery stack s State of Charge The battery stack is empty when the State of Charge value is 0 and full ...

Page 50: ...erage cell voltage measurements within the stack The high cell voltage and low cell voltage warning and fault threshold is visualized on the gauge with yellow 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 The maximum and minimum cell location in the...

Page 51: ...ed 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 occurred The maximum and minimum cell location in the stack and their temperature values are shown below the gauge along with the average cell temperature value Nuvation Energy High Voltage BMS Product Manual Docu...

Page 52: ...nection state number of cells balancing maximum charge current limit maximum discharge current and the time and date of the last update of the Dashboard 6 1 8 1 Operation Status Nuvation Energy BMS operation state is shown in the big status circular indicator Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 48 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 53: ...l 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 to equalize the battery stack voltage to the system DC bus voltage Stack Connected in a green oval indicates the battery stack is available to be charged or discharged Clicking the Connect button initiates t...

Page 54: ...cated 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 tablet it does not come from Nuvation Energy BMS If the communication with a Nuvation Energy BMS is lost a notification banner appears at the top of the display screen The information shown on the Dashboard represents the last data received and...

Page 55: ...formation You can have multiple accordions expanded at the same time Figure 45 Nuvation Energy BMS Operator Interface Details tab screenshot 6 2 1 Addressing The Addressing accordion presents the addressing information for your Nuvation Energy BMS Figure 46 Addressing accordion in Details Tab 6 2 2 Battery The Battery accordion contains values on the overall battery stack This information is ident...

Page 56: ...on the Dashboard Figure 48 Current Limiter accordion in Details Tab 6 2 4 Safety The Safety accordion contains a comprehensive list of all possible Nuvation Energy BMS faults and warnings as well as the overall status of the battery stack An active fault or warning is shown as Tripped In normal operation all warnings and faults should be clear and the battery stack can be charged and discharged Nu...

Page 57: ...figured in the Configuration file Cells that are not configured are displayed as a hyphen Voltages in red indicate measurements which have triggered a Nuvation Energy BMS fault Voltages that are highlighted in yellow are open wires There is no differentiation between cells that are in the normal operating voltage range and cells that have triggered a Nuvation Energy BMS warning There is also no in...

Page 58: ...all Thermistors configured in the Configuration file Thermistors that are not configured are displayed as a dash Temperatures in red indicate measurements which have triggered a Nuvation Energy BMS fault There is no differentiation between thermistors that are in the normal operating temperature range and thermistors that have triggered a Nuvation Energy BMS warning Figure 53 Thermistor accordion ...

Page 59: ...re 55 Open Wire acquiring accordion in Details Tab Once the open wire scanning has completed and all diagnostics data is collected it is displayed in a tabular format with open wires highlighted in yellow Figure 56 Open Wire diagnostics accordion in Details Tab The diagnostic values displayed are ratios of Voltage Values very close to one 0 97 indicate a short condition Values approaching zero 0 0...

Page 60: ...1 Filtering Use the filter to show only ratios of Voltage that are above or below the specified value Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 56 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 61: ...nterface is locked the Register Browser is in a view only mode restricting the editing of registers It is possible to edit registers on multiple stacks using this interface which can result in unintended behavior It is recommended to only edit registers that start with pack_ or gbc_ using this interface Use the stack level Operator Interface to make edits to a connected stack Figure 57 Register Br...

Page 62: ...uration 6 3 2 3 Upgrade This is restricted option requiring the Operator Interface to be unlocked to access this option The firmware upgrade will erase the configuration file on your Nuvation Energy BMS Please remember to export and save your current configuration file to save your current configuration file for future reference Please contact support nuvationenergy com before attempting a firmwar...

Page 63: ... either instance is refreshed that tab will use the most recently set IP address 6 3 4 Locking and Unlocking The Operator Interface can be locked to prevent accidental or unintentional changes that could have serious impacts on the system To further secure the system a password can be set to ensure only authorized individuals can access these critical sections of the Operator Interface The Stack S...

Page 64: ...This screen displays version details for the underlying software for your Nuvation Energy BMS The name and number of the current software release are displayed at the top of the About screen In the screenshot below the release name is at the top in large blue letters The version number following the release name has a format of yy mm with yy representing the year and mm representing the month with...

Page 65: ... information for identifying the configuration and images is provided to ensure the correct version of firmware and configuration is being used as specified at the factory Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 61 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 66: ...kely scenario that the Stack Switchgear is in service lockout please contact support nuvationenergy com When the system is either entering exiting or is in service lockout a banner is displayed indicating this to the user Figure 61 Operator Interface Service Lockout indicator Figure 62 Operator Interface Exiting Service Lockout indicator Figure 63 Operator Interface Entering Service Lockout indica...

Page 67: ...S are described in the sections below Detailed register maps for all Draft 3 models are found in the document MESA Energy Storage Information Models_Draft_3 xlsx found at the Nuvation Energy technical resources located at https www nuvationenergy com technical resources 7 1 2 1 Common Model This model primarily contains information to identify the device e g manufacturer model serial number as wel...

Page 68: ...s size A Repeating block describes a set of related points i e usually for a string of batteries of which there could be multiple instances of the Repeating blocks The points within a repeating block are the same but these sets of blocks are concatenated sequentially For example in the 803 model there is a set of repeating blocks that describe data for a particular stack string of batteries Access...

Page 69: ... String Event 2 803 StrConFail String Connection Fail 7 1 3 4 Scale Factors All MESA points are integer values signed or unsigned To account for different range values beyond the data size i e greater than 65535 for an unsigned 16 bit value or some fractional value i e 1 1 some MESA points have scale factors associated with them The scale factor is another point within the model which contains a s...

Page 70: ...01 No Bit field of all faults warnings of a the BMS 802 Fixed Vol 40105 Yes External DC voltage of the battery system 802 Fixed MaxBatACha 40106 Yes Charge current limit calculated by the BMS 802 Fixed MaxBatADischa 40107 Yes Discharge current limit calculated by the BMS 803 Fixed BTotDCCur 40127 Yes Total DC current of the battery system A controller may also want to command Nuvation Energy BMS t...

Page 71: ...xed Vol 40105 Yes External DC voltage of the battery system 802 Fixed MaxBatACha 40106 Yes Charge current limit calculated by BMS 802 Fixed MaxBatADischa 40107 Yes Discharge current limit calculated by BMS 802 Fixed BSetOperation 40110 No BMS requested connection state of all stacks strings 803 Fixed BConStrCt 40118 No Number of stacks strings with contactor closed 803 Fixed BMaxCellVol 40119 Yes ...

Page 72: ... the 803 Repeating block is 16 Modbus registers in length 7 1 5 Accessing MESA Models MESA models are located contiguously in the Modbus address space starting at a base address of 40000 The Common Model is always located first in this space The End Model is always last and is used to denote the end of MESA Modbus registers Each model located between the Common Model and the End Model has a numeri...

Page 73: ...onfiguration address 1 start reference 40000 PDU count 70 Communication 192 168 1 21 port 502 t o 1 00 s poll rate 1000 ms Data type 16 bit register output holding register table Polling slave Ctrl C to stop 40000 21365 40001 28243 40002 1 40003 66 40068 4660 40069 32768 As another example the complete S802 model for a system with one stack could be polled using the following command Nuvation Ener...

Page 74: ...dbus libraries and tools Protocol configuration MODBUS TCP Slave configuration address 1 start reference 40094 PDU count 22 Communication 192 168 1 21 port 502 t o 1 00 s poll rate 1000 ms Data type 16 bit register output holding register table Polling slave Ctrl C to stop 40094 802 40095 20 40114 2 40115 32768 Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 70 Rev 1 2 2021 0...

Page 75: ...ive terminal of DC bus External equipment DC Bus Positive terminal of DC bus External equipment 8 1 2 Ethernet The Ethernet jack is a standard RJ45 Cat5e rated jack Table 14 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 differ...

Page 76: ...ear Cell Interface 3 IPA Link Bus differential pair plus Cell Interface 4 IMA Link Bus differential pair minus Cell Interface Table 16 Link Bus 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 8 1 4 E Stop Supported Wire Diameter 22 AWG 12 AWG Tabl...

Page 77: ...2 AWG 12 AWG Table 18 Fan Control Connector Pin Assignment Pin Name Description Connected to Device AC DC Fan Input 1 G Ground Negative External power source 2 N Neutral NC External power source 3 L Line Positive External power source Fan Output 1 G Ground Negative External fan system 2 N Neutral NC External fan system 3 L Line Positive External fan system 8 1 6 Power In Table 19 Power In Connecto...

Page 78: ...onnected to Device 1 G Ground External power source 2 N Neutral External power source 3 L Line External power source Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 74 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 79: ... wires must be isolated from the cell voltage sensing leads Although the Cell Interface includes protective circuitry 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 or the cells The Stack Switchgear is pre configured to expect a defined battery topol...

Page 80: ... No Connect 17 No Connect Not Connected No Connect 18 No Connect Not Connected No Connect 8 2 1 2 Battery Cell Connector for Cell Interface 16 channel Table 22 Cell Interface 16 channel 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 voltage sense Co...

Page 81: ... to positive terminal of the lowest cell Cell 1 4 No Connect Not Connected No Connect 5 BLOCK2 Cell 2 voltage sense Connect to positive terminal of Cell 2 6 No Connect Not Connected No Connect 7 BLOCK3 Cell 3 voltage sense Connect to positive terminal of Cell 3 8 No Connect Not Connected No Connect 9 No Connect Not Connected No Connect 10 No Connect Not Connected No Connect 11 No Connect Not Conne...

Page 82: ...thermistors will result in undesirable Stack Switchgear behavior Please contact support nuvationenergy com if there is a change requiring a Stack Switchgear configuration update 2 to 7 thermistors are supported to accommodate systems requiring Nuvation Energy BMS to meet functional safety requirements Table 24 Temperature Sensors Molex Micro Fit 3 0 Connector Molex 43025 1600 Manufacturer Molex In...

Page 83: ...alled Not Installed Installed Not Installed Installed Installed Not Installed 4 Not Installed Installed Installed Installed Installed Not Installed Not Installed Not Installed 3 Not Installed Installed Installed Installed Not Installed Not Installed Not Installed Not Installed 2 Not Installed Installed Installed Not Installed Not Installed Not Installed Not Installed Not Installed 8 2 2 1 Thermal ...

Page 84: ...e 28 Link In Connector Pin Assignment Pin Connection Description Connected to Device 1 VBUS DC power from the Stack Switchgear with Fault Pilot Signal Previous Cell Interface in the Link Bus chain or Stack Switchgear 2 COM Power return from the Stack Switchgear Previous Cell Interface in the Link Bus chain or Stack Switchgear 3 IPA Link Bus differential pair plus Previous Cell Interface in the Lin...

Page 85: ...ed Table 29 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 30 Link Out Connector Pin Assignment Pin Connection Description Connected to Device 1 VBUS DC power from Stack Switchgear with Fault Pilot Signal Subsequent Cell Interface ...

Page 86: ...ts if necessary using the Operator Interface All faults must be cleared for Stack Switchgear to close contactors 3 Using the Operator Interface connect the stack by clicking the Connect button Refer to the Section 6 1 8 for instructions on connecting disconnecting a stack This initiates the connection sequence Wait for the connection state to show Connected The stack is now connected to the DC bus...

Page 87: ...s operating condition and open all contactors There are many faults that can be triggered This section will describe the condition the fault monitors and the meaning when that fault is triggered The following sections describe different classes of faults warnings and issues surrounding any initialization In general all warnings have a similar trigger condition as their corresponding fault The foll...

Page 88: ... i e Link Out instead of Link In Link Bus cables are damaged 10 1 2 Stack Voltage Faults stack_fault_voltage_over Fault that is triggered when the stack voltage is above the over fault threshold stack_fault_voltage_hi Fault that is triggered when the stack voltage is above the high fault threshold stack_fault_voltage_lo Fault that is triggered when the stack voltage is below the low fault threshol...

Page 89: ...arge_therm_hi Fault that is triggered when any thermistor measurement is above the high fault threshold during charge stack_fault_charge_therm_lo Fault that is triggered when any thermistor measurement is below the low fault threshold during charge stack_fault_charge_therm_under Fault that is triggered when any thermistor measurement is below the under fault threshold during charge 10 1 3 1 Initia...

Page 90: ...oller and Power Interface modules 10 1 5 Pre charge Faults stack_fault_precharge_timeout Fault that is triggered at the end of the pre charge period if the measured current exceeds the maximum pre charge current stack_fault_precharge_over_current Fault that is triggered at any time during the pre charge connection period if the stack current exceeds the fault threshold 10 1 5 1 Initialization Issu...

Page 91: ...erface modules The following table summarizes these initialization issues Fault Initialization Issues sc_fault_pi_interlock Stack Bus failure sc_fault_fault_pilot_state_mismatch Stack Bus failure stack_fault_coil_fail Stack Switchgear unit s internal Power Interface module s AFE disabled stack_fault_contactor_feedback_fail GPI not configured Stack Switchgear unit s internal Power Interface module ...

Page 92: ... The operator of the Operator Interface can attempt to clear the fault as described in Section 6 2 4 10 1 7 1 2 Clearing the Short Shunt Fault Is Not Immediate Issue Clearing the stack_fault_short_shunt fault might not occur immediately Workaround To determine when the fault can be cleared read the values of the stack_short_shunt_detector voltage_activity_threshold and stack_short_shunt_detector i...

Page 93: ...ally caused by incorrectly modifying the Stack Switchgear factory configuration file Contact support nuvationenergy com for a valid configuration file for the Stack Switchgear 10 1 9 Watchdog Faults stack_fault_power_wdt Fault indicating stack voltage and current data has not been updated periodically stack_fault_cell_wdt Fault indicating all cell data has not been updated periodically for every i...

Page 94: ...e have not been periodically validated against non volatile memory Typically disabled pi_fault_factory_verify_wdt Fault indicating the factory registers on the Stack Switchgear unit s internal Power Interface module have not been periodically being validated against non volatile memory Typically disabled 10 1 9 1 Initialization Issues The stack_fault_cell_wdt stack_fault_therm_wdt stack_fault_ci_w...

Page 95: ... volatile memory has been corrupted sc_fault_fw_mismatch Fault indicating that the internal Stack Controller and Power Interface modules firmware versions are different Contact support nuvationenergy com if this occurs sc_fault_clocks Fault indicating that the internal Stack Controller and Power Interface modules clocks are ticking at different rates This may indicate an overloaded system or malfu...

Page 96: ...rator Interface Refer to Section 5 2 for instructions 10 2 2 Netdiscover Linux only 1 Install netdiscover on a PC on Debian based systems use sudo apt install netdiscover 2 Connect the PC directly to the Ethernet port on the Stack Switchgear 3 Run sudo netdiscover i interface p where interface is the network interface connected to the Stack Switchgear 4 Either reboot the deStack Switchgearvice or ...

Page 97: ...e Threshold contactors open 0 Configurable 1250 V DC Vstack_uv Stack Under Voltage Threshold contactors open 0 Configurable V DC Idischarge_oc Stack Discharging Over Current contactors open 0 Configurable XXX A DC Icharge_oc Stack Charging Over Current contactors open 0 Configurable XXX A DC Battery Cell Specifications Cov Cell Over Voltage Threshold contactors open Configurable V Cuv Cell Under V...

Page 98: ... J2464 shock and SAE J2380 random vibration For transportation it is recommended that the Stack Switchgear be shipped in its original packaging via pallet whenever possible Standards and Certifications Standard Certification Stationary Battery Safety UL Recognized internal Power Interface and Stack Controller modules UL 1973 file no MH64071 Functional Safety UL Recognized internal Power Interface ...

Page 99: ...etween C0 and C12 CI 12 VBUS 0 V DC 11 60 V DC Voltage between C0 and C8 CI 16 VBUS 0 V DC 11 40 V DC Voltage between C8 and C16 CI 16 VBUS 0 V DC 11 40 V DC Voltage between B0 and B2 CI 4M12 VBUS 0 V DC 14 40 V DC Voltage between B2 and B4 CI 4M12 VBUS 0 V DC 14 40 V DC TME Total Measurement Error CI 12 CI 16 VBUS 24 V DC 0 1 1 2 1 6 mV DC Total Measurement Error CI 4M12 VBUS 24 V DC 2 0 8 0 10 0...

Page 100: ...clearance distances for reinforced insulation rated to 1250 V DC All components are EU RoHS China RoHS compliant Standard Certification Stationary Battery Safety UL Recognized UL 1973 file no MH64071 Functional Safety UL Recognized UL 991 file no MH64071 UL 1998 file no MH64071 UL 1973 recognition ensures safe battery operation and significantly reduce the effort of certifying the energy storage s...

Page 101: ...d CI 4M12 Measurement Anti Aliasing Filter Cell Interface Chain Length Scan Rate Hz Off 1 5 53 Off 5 3 32 Off 10 2 22 Off 15 1 74 Off 20 1 38 Off 25 1 15 Off 30 0 91 Table 32 Cell Voltage Scan Rates for CI 12 Measurement Anti Aliasing Filter Cell Interface Chain Length Scan Rate Hz Off 1 6 01 Off 5 3 94 Off 10 3 03 Off 15 2 59 Off 20 1 97 Off 25 1 63 Off 30 1 44 Off 35 1 30 Off 40 1 08 Nuvation En...

Page 102: ...r 2 post 19 Rack NUVP SSG RB 23 2P Part Stack Switchgear Brackets for 2 post 23 Rack To attach these brackets to the unit fasteners M5 x 8 mm are included with any mounting bracket order If fasteners other than the provided hardware is used the screws cannot extend into the Stack Switchgear more than 8 mm High voltage and high power elements that exist inside the unit could arc to the screw if it ...

Page 103: ...g a Cell Interface PCB assembly only no enclosure note that the Cell Interface contains high voltage signals reaching as high as 1250 V DC Care must be taken when mounting the PCB into a metal enclosure 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 nearest e...

Page 104: ...ce the direction of current in one side of the figure 8 turns opposite to the current in the other side It is recommended to use the figure 8 method if physically reducing the cable length is not possible Figure 65 Excess Cable Management Examples System Noise High power inverters generate a lot of system noise especially on the DC bus This is due to the industry standards for AC harmonics and EMC...

Page 105: ...through as expected and can be verified by reading the register sc_controller_heartbeat value In 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 within High Voltage BMS or the battery area to try to decrease the amount of noise DC Filtering A DC filter...

Page 106: ...ween the inverter and the grid to remove the high current pulses Figure 67 Example Isolation Transformer Installation Diagram Link Bus Power While the communication interface between the Stack Switchgear and the Cell Interface is a daisy chain the power supplied to the Cell Interface from the Stack Switchgear is a bus This results in the power twisted pair in the Link Bus cable carrying power up t...

Page 107: ...he Cell Interface Link Bus power can be disabled if the observed impact on performance is acceptable The power twisted pair must be disconnected in the Link Bus cable so all Link Out and Link In connectors on the Stack Switchgear and the Cell Interface modules must have pins 1 and 2 unpopulated Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 103 Rev 1 2 2021 03 03 Curie Updat...

Page 108: ...echnologies client requests emerging energy storage standards and other industry requirements The product specifications in this document therefore are subject to change without notice 2021 Nuvation Energy Nuvation Energy High Voltage BMS Product Manual Document ID NE PM 003 104 Rev 1 2 2021 03 03 Curie Update 1 ...

Page 109: ... stack_fault_charge_therm_lo 85 stack_fault_charge_therm_over 85 stack_fault_charge_therm_under 85 stack_fault_ci_therm_consistency 88 88 stack_fault_ci_wdt 89 stack_fault_coil_fail 86 stack_fault_contactor_feedback_fail 87 stack_fault_discharge_current_hi 86 stack_fault_discharge_current_over 85 stack_fault_discharge_therm_hi 85 stack_fault_discharge_therm_lo 85 stack_fault_discharge_therm_over 8...

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