ALENCON BOSS 1000 Installation, Operation And Maintenance Manual

Bidirectional optimizer for storage systems

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Bidirectional Optimizer for Storage Systems (BOSS)

A unique DC-DC Optimizer to help medium and large

Energy Storage Systems (ESS)

, O

NSTALLATION

PERATION AND

AINTENANCE

ANUAL FOR

BOSS 1000

1500

USE WITH THE

AND

PM003 Revision 12

Alencon Systems LLC

330 Warminster Rd., Suite 380 | Hatboro, PA 19040 | USA

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Page 1 A unique DC-DC Optimizer to help medium and large Energy Storage Systems (ESS) NSTALLATION PERATION AND AINTENANCE ANUAL FOR BOSS 1000 1500 USE WITH THE PM003 Revision 12 Alencon Systems LLC 330 Warminster Rd., Suite 380 | Hatboro, PA 19040 | USA...
Page 2 BOSS – Installation, Operation and Maintenance Manual © 2009-2019 by Alencon Systems LLC This document is the confidential and proprietary information of Alencon Systems LLC. No part of this document may be photocopied, reproduced, stored in a retrieval system, or transmitted in any form or by any means whether electronic, mechanical, or otherwise without prior written permission.
Page 3: Table Of Contents
Understanding BOSS Hardware ....................18 BUS & Battery Cable Termination ..................20 Communication Ports ......................21 Fusing for Input and Output Wiring................... 22 Alencon Fused Electrical Disconnect (FEED) ............... 22 Alencon Communication Environment (ACE) Setup..............23 PODD Installation ........................23 Installation Options ......................23...
Page 4 Mounting Parts ......................... 23 PODD Setup ........................24 Communication Interface – “The HUB” ..................25 HUB Features .......................... 25 Alencon Devices Tab ....................... 25 Device Commands ......................25 Config Tab........................28 Interfacing with the BOSS ......................30 Powering the BOSS ......................... 30 Soft Pre-Charge of BOSS ......................
Page 5: General Information
String Power Optimizer and Transmitter Alencon Communication Environment – a communication system containing hardware and software elements provided by Alencon to control power conversion equipment. Alencon Communication, Monitoring and Control Software A l e n c o n S y s t e m s L L C - P a g e...
Page 6: Product Warranty
BOSS – Installation, Operation and Maintenance Manual Product Warranty Alencon Systems warrants to you, the original purchaser, that each of its products will be free from defects in materials and workmanship for five years from the date of purchase. Extended warrantees of an additional five (5), ten (10) and twenty (20) years are also available for purchase.
Page 7: Technical Support And Assistance
BOSS – Installation, Operation and Maintenance Manual Technical Support and Assistance 1. Visit the Alencon Systems web site at www.alenconsystems.com where you can find the latest information about the product. 2. Contact your distributor, sales representative, or Alencon Systems' customer service center for technical support if you need additional assistance.
Page 8: Packing List
BOSS – Installation, Operation and Maintenance Manual Packing List Before installation, please ensure the following items have been shipped:  Correct # of BOSS Units specified for your PV System with appropriate mounting hardware  1 x Warranty Card Bi-Directional Optimizer for Storage Systems This unit provides a maximum of 4 inputs and 4 outputs.
Page 9: Important Safety Instructions
BOSS – Installation, Operation and Maintenance Manual IMPORTANT SAFETY INSTRUCTIONS WARNING! SAVE THESE INSTRUCTIONS– This manual contains important instructions for use with the BOSS 600, 1000 and 1500 that shall be followed during installation and maintenance of these devices. Figure 2: The graphic above indicates that the BOSS is a grounding conductor. WARNING! Always ground the BOSS enclosure before energizing the unit.
Page 10 2. The BOSS contains no user-serviceable parts. For service and maintenance, the BOSS should be returned to Alencon Systems LLC or a certified Alencon Systems service center. 3. During operation, hazardous voltages and currents may be present. Only authorized and qualified personnel should perform servicing/installation.
Page 11: Introduction
BOSS – Installation, Operation and Maintenance Manual Introduction Energy Storage Systems Benefits Energy Storage Systems (ESS) is actively advancing into the portfolio of equipment being offered by the Renewable Energy Industry. In both new and existing PV installations, ESS helps to overcome intermittency –...
Page 12: Boss Features
BOSS – Installation, Operation and Maintenance Manual BOSS Features BOSS- Bi-Directional Optimizer for Storage Systems Alencon’s BOSS is an integral part of multi-rack Electrical Storage System (ESS) that increases the utilization of the battery, extends battery life and improves safety. Figure 5: ESS with BOSS The BOSS is comprised of several DC-to-DC converter units (DCDC) that are connected between a common DC BUS and each individual battery string (rack).
Page 13: Ground Leak Detection
“float.” By contrast, today’s large-scale battery energy storage systems are generally “floating” or ungrounded. Alencon’s BOSS leverages the inherent properties of galvanic isolation to provide the customers with a “Ground leak Detection” feature.
Page 14: Boss Operation
IP65 extruded aluminum enclosure for outdoor use. It comprises of four DCDC converter units, each with its own input and output connections. Alencon provides two types of DCDC converters: BOSS-1000 rated at 1000 VDC max and BOSS-1500 rated at 1500 VDC max.
Page 15: State Machine
BOSS – Installation, Operation and Maintenance Manual The BOSS receives commands like current direction (charge/discharge) and current magnitude from ESS controller. It DCDC communicates with the ESS controller via MODBUS-RTU. STATE Machine DCDC controls operate as a state machine with states: ...
Page 16: Technical Specifications
BOSS – Installation, Operation and Maintenance Manual Technical Specifications Model BOSS 1000 BOSS 1500 Number of DCDCs DC Bus Specifications 1500 V DC Max DC Bus Voltage 1000 V DC 200 V DC Minimum DC Bus Voltage 200 V DC...
Page 17: Communication
BOSS – Installation, Operation and Maintenance Manual Communication The communication with the BOSS is carried out via MODBUS RTU. Please contact Alencon for Modbus map information. BOSS Protection The BOSS’s protection functions are grouped into three classes:  BUS  Battery ...
Page 18: Environmental Protection
BOSS – Installation, Operation and Maintenance Manual meet the ground fault detection/protection requirements. Please see Alencon’s GARD for additional information. Environmental Protection The BOSS mechanicals are designed to protect it from extreme external conditions of high temperature and moisture. Temperature on Power Semiconductor Monitors the temperature of the Power Semiconductors.
Page 19: Boss Installation
BOSS – Installation, Operation and Maintenance Manual BOSS Installation Understanding BOSS Hardware The BOSS unit has many different form factors. The form factor is completely dependent on the application and customer requirement. The possible form factors are –  Rack Mounted ...
Page 20 Follow BOSS Mounting instructions for more info. To cater to the many different form factors of the BOSS, Alencon offers a few customizable hardware solutions that will help our customers with installation and integration of the BOSS.
Page 21: Bus & Battery Cable Termination
BOSS – Installation, Operation and Maintenance Manual BUS & Battery Cable Termination The BOSS input and output cables have been labelled as BUS and BATT. There are 4 DCDC’s within each BOSS labelled serially as A, B, C, and D. Each DCDC contains a single input and single output channel.
Page 22: Communication Ports
BOSS – Installation, Operation and Maintenance Manual Figure 10: H4/MC4 Termination The wires from the cable gland are routed to the H4/MC4 connectors via cable ducts. This is a fairly straight method of terminating the input and output cables without having to deal with DIN rail mounted terminal blocks.
Page 23: Fusing For Input And Output Wiring
There are several options available to protect the device. Alencon recommends using –  Appropriately rated DC disconnects offered by Alencon Systems  Appropriately rated DC disconnects offered by External Supplier  Alencon’s Ground Arc Rapid Disconnect (GARD)  Alencon’s Fused Electrical Disconnect (FEED) Alencon Fused Electrical Disconnect (FEED) Alencon’s FEED...
Page 24: Alencon Communication Environment (Ace) Setup
PODD Mounting Each PODD will be shipped with the mounting bracket already installed. PODD Mounting Location The distributed PODDs will be mounted near the Alencon devices while the central PODD will be mounted close to the inverter. Mounting Parts The PODD can be easily mounted using standard Unistrut© along with spring loaded channel nuts.
Page 25: Podd Setup
; Into the URL bar of your favorite web browser. The PODD setup should then be completed and the HUB should start running. For questions regarding the HUB, please refer to the Alencon HUB manual. NOTE: All PODDs must be powered during setup and the Centralized PODD must be set up first.
Page 26: Communication Interface - "The Hub
BOSS – Installation, Operation and Maintenance Manual Communication Interface – “The HUB” Alencon Systems offers a piece of software called the Harvesting Unit Block (HUB) that two- way communication between the ACE hardware i.e. PODD and Alencon’s DC_DC optimizers and DC Interrupters.
Page 27 Device Command Selection The HUB provides a broad set of operational and diagnostic commands. Do not use unlisted commands unless instructed to do so by Alencon personnel. Failure to do so may damage the BOSS and void the warranty. Customer specific commands –...
Page 28 DCDC using the “metadata” file available in the folder. The file must be edited using Notepad++ or any other text editors (contact Alencon for training on this). Figure 17: Metadata File containing comm. details - Modbus address, GUID etc.
Page 29: Config Tab
.factory file as seen below. This file contains specific parameters for your customized BOSSs. Do not edit these parameters unless asked to do so by Alencon personal. Failure to follow these instructions may damage the BOSS and will void your warranty.
Page 30 Step 3: Once you load the “Config” file, you will have the option to modify the parameters without editing the file if necessary. Only do this if instructed to do so by Alencon. Figure 233: Loaded Configuration can be modified directly on the HUB...
Page 31: Interfacing With The Boss
BOSS – Installation, Operation and Maintenance Manual Step 4: The final step is to send the loaded configuration BOSS. Click “Write Config” button. Figure 24: Write configuration sends it to the commensurate product being used Interfacing with the BOSS Please refer to sections 8 & 9 before interacting with the BOSS. This section covers BOSS operating procedure and the various test procedures while interfacing with the BOSS.
Page 32 BOSS – Installation, Operation and Maintenance Manual Both these files would be pre-loaded onto the PODD or be provided to you by Alencon via secure file transfer. Once the PODD is setup, applying minimum voltage or external 24 V will turn ON the BOSS boards, allowing two way communications with the HUB.
Page 33: Soft Pre-Charge Of Boss
BOSS – Installation, Operation and Maintenance Manual Soft Pre-Charge of BOSS Since, the BOSS is a bi-directional optimizer it can pre-charge the output using the BUS side or the BATT side. Note: BUS and BATT used throughout the document are nomenclatures that are interchangeable based on the direction of power flow To pre-charge the load, you will need to first establish the direction of power flow i.e.
Page 34 BOSS – Installation, Operation and Maintenance Manual Before starting the BOSS, we need to provide the power flow “Set Direction” and the “Current Setpoint” expected from the BOSS. Both these features are available within the command window seen in figure. Figure 27: HUB Commands “Set Direction”...
Page 35 **NOTE: Frequency Range - BOSS: 60 ≤ f (KHz) ≤ 160 Figure 31: Alencon’s HMI – The HUB ** NOTE: Do not change direction of power flow if your DC source cannot act as a load. If...
Page 36: Testing The Boss Using A Dc Source And A Dc Load
DC source to the BATT side and the load to the BUS side, Fig.31, and follow the same procedure outlined below. Alencon performs this test using Magna Power Supplies and Alencon’s very own variable voltage DC load. Figure 32: Basic setup for testing the BOSS with a DC voltage source and a variable voltage DC load.
Page 37 BOSS – Installation, Operation and Maintenance Manual  Verify the BOSS DCDC’s communicate via the HUB o Check all 4 DCDC’s and their GUID’s show up o Clear any or all existing faults using the clear command Figure 34: HUB display of the 4 DCDC's ...
Page 38: Testing The Bi-Directional Functionality Of The Boss Using A Single Dc Source
The test can be performed only when the BOSS is designed for a system where the BUS and the BATT nominal voltages are relatively the same (I.e. 1:1 ratio). Alencon performs this test using Magna Power Supplies. Below diagram shows the basic test setup for bi-directional testing of the BOSS.
Page 39 BOSS – Installation, Operation and Maintenance Manual  Verify the BOSS DCDC’s communicate via the HUB o Check all 4 DCDC’s and their GUID’s show up o Clear any or all existing faults using the clear command Figure 36: HUB display of the 4 DCDC's ...
Page 40: Testing The Charge-Discharge Functionality Of The Boss Using Battery Racks
See the diagram in Figure 36 for a basic setup and follow the instructions below for the test. Currently Alencon does not have the setup yet to perform battery charge-discharge test. Figure 37: Charging and discharging of two battery racks using the BOSS ...
Page 41: Further Information
BOSS – Installation, Operation and Maintenance Manual Further information For more information on DC-Coupled products and solutions, please visit https://alenconsystems.com/ Contact us @ https://alenconsystems.com/alencon-and-you/ For technical support please email: support@alenconsystems.com or call +1 (215) 816-3366 A l e n c o n S y s t e m s L L C - P a g e...

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