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CUBE – Compact Universal
Bi-directional Efficient
DC/DC Converter
A Compact High Power Density BOOST or BUCK Converter
Installation, Operation and Maintenance Manual for use with the full
line of CUBE DCDC Converters
Alencon Systems – Passionate About Power
COPYRIGHT © 2020 ALENCON LLC, INC. | ALL RIGHTS RESERVED.
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Table of Contents
Summary of Contents for ALENCON CUBE-PV 1000 Volt Series
- Page 1 A Compact High Power Density BOOST or BUCK Converter Installation, Operation and Maintenance Manual for use with the full line of CUBE DCDC Converters Alencon Systems – Passionate About Power COPYRIGHT © 2020 ALENCON LLC, INC. | ALL RIGHTS RESERVED.
- Page 2 Alencon Systems LLC reserves the right to change details in this publication without notice.
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Page 3: Disclaimer
Readers are cautioned, however, that Alencon LLC reserves the right to make changes without notice and shall not be responsible for any damages, including indirect, incidental, or consequential damages, caused by reliance on the material presented, including, but not limited to, omissions, typographical errors, arithmetical errors or listing errors in the content material. -
Page 4: Table Of Contents
Alencon CUBE: Installation, Operation, and Maintenance Manual Contents Disclaimer ................................2 1 Table of Figures ............................... 6 2 General Information ............................7 2.1 Purpose ..............................7 2.2 Product Warranty ............................7 2.3 Warnings, Cautions and Notes ........................8 2.4 Packing List ............................... 9 2.5 Ordering Information .......................... - Page 5 Alencon CUBE: Installation, Operation, and Maintenance Manual 6.1.3 CUBE-PV in PV Centric DC Coupled Solar + Storage: ................. 17 6.1.4 Grounding of PV panels ........................17 6.2 CUBE-ES: Battery Energy Storage Systems ..................... 18 6.2.1 DC Coupled, Battery Centric Solar + Storage ................... 18 6.2.2 Standalone Battery Systems ......................
- Page 6 12.3 Modbus Definitions and Map ......................... 41 13 CUBE Communication ..........................42 13.1 PODD – Point of Data Distribution ......................42 13.2 Alencon Communication Environment (ACE) - System Overview ............42 13.3 CUBE User Interface (via PODD) ......................43 14 Maintenance and Servicing .......................... 44 14.1 General Maintenance ..........................
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Page 7: Table Of Figures
Alencon CUBE: Installation, Operation, and Maintenance Manual 1 Table of Figures 1: P CUBE ..........................9 IGURE ICTURE OF A UNIT 2: T CUBE ..........11 IGURE HE GRAPHIC ABOVE INDICATES THAT THE IS A GROUNDING CONDUCTOR 3: T CUBE .......... -
Page 8: General Information
• Maintain the product, if necessary 2.2 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 three 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 9: Warnings, Cautions And Notes
• Collect all the information about the problem encountered. (For example, issues you are encountering in your PV array) Note anything abnormal when the problem occurs. • Call Alencon Systems or your licensed Alencon Systems dealer and describe the problem. Please have your manual, product, and any helpful information readily available. -
Page 10: Packing List
Alencon CUBE: Installation, Operation, and Maintenance Manual 2.4 Packing List The CUBE is assembled and fully tested at the Alencon factory. Before installation, please ensure the following items have been shipped: • Commensurate # of CUBE Units specified for your project... -
Page 11: Ordering Information
Alencon CUBE: Installation, Operation, and Maintenance Manual 2.5 Ordering Information Model Number Description Max Rated Max Rated Application Voltage Modality* Model Number Voltage Power (directionality) 1 1500 V 430 KW Solar Non-Interleaved CUBE-15-PV-N (unidirectional) 2 1000 V 470 KW Solar... -
Page 12: Important Safety Instructions
1. Before installing and using the CUBE, read all instructions presented in this manual and the cautionary markings shown on the CUBE’s enclosure. 2. For service and maintenance of the CUBE contact Alencon Systems LLC or a certified Alencon Systems service center. Opening the device or attempting to perform a non- authorized repair will void the warranty. - Page 13 Alencon CUBE: Installation, Operation, and Maintenance Manual 5. Do not disconnect output (direction dependent) contactors or switches while equipment is operating. Shutdown the DCDC converter by sending “Shutdown” command using the controller (see Section 11.2). 6. Always use input disconnect switch to shut down the CUBE before disconnecting the output.
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Page 14: Introduction
Operation, and Maintenance Manual 4 Introduction Alencon’s Combined Universal Buck-Boost Electronics (CUBE) for large scale DCDC power conversion, is a unique and cost-effective solution for optimizing the performance of large- scale PV plants, Battery energy storage systems (BESS), Fuel Cells, Hydrogen Electrolyzers and Fast EV charging installations. -
Page 15: Cube Features
Standby is an idle control mode, used when no power conversion is desired. 5.2.2 MANUAL Switching frequency is set directly through the controller. This control mode is used only for testing and troubleshooting by Alencon Systems personnel. 5.2.3 PV MPPT Autonomous control mode, where the DCDC maximizes power harvested from the connected PV array by modifying the voltage level. -
Page 16: Cube Protection Modes
Alencon CUBE: Installation, Operation, and Maintenance Manual 5.3 CUBE Protection Modes: Protective functions as triggered by measurements on the primary or secondary side of the DCDC converter. The trip conditions are configurable, project specific and pre-defined in the CUBE memory, they can be modified to some degree, if necessary, during deployment. -
Page 17: Cube Applications
Alencon CUBE: Installation, Operation, and Maintenance Manual 6 CUBE Applications The CUBE can be configured to serve two different broad use cases: CUBE PV and CUBE ES. 6.1 CUBE-PV: Photovoltaic Installations In PV installations the CUBE balances the PV voltage with the inverter DC bus voltage. It helps to harvest peak PV power by providing maximum power point tracking (MPPT). -
Page 18: Cube-Pv In Pv Centric Dc Coupled Solar + Storage
Alencon CUBE: Installation, Operation, and Maintenance Manual With one input switch With input combiner box 4: D CUBE IGURE IAGRAM OF DEPLOYED S IN A NEWLY CONSTRUCTED PLANT 6.1.3 CUBE-PV in PV Centric DC Coupled Solar + Storage: The CUBE is a unique solution for DC-coupling of PV and Storage. When deployed with battery energy storage systems, the DC bus, in some implementations, may be shared with the storage terminal as shown in Error! Reference source not found. -
Page 19: Cube-Es: Battery Energy Storage Systems
Alencon CUBE: Installation, Operation, and Maintenance Manual 6.2 CUBE-ES: Battery Energy Storage Systems In a BESS the CUBE is used to control charge and discharge of the batteries to a common DC bus. If BESS voltage is always lower or always higher than DC bus the N-series CUBE can be used. -
Page 20: Fast Automobile Charging Technology (Fact)
Alencon CUBE: Installation, Operation, and Maintenance Manual 6.5 Fast Automobile Charging Technology (FACT) In FACT the CUBE is used in conjunction with isolated DCDC converters to control charging of the internal BESS and supply voltage to the automobile charge dispensers. -
Page 21: Technical Specifications
0 – 95% Operating Ambient Temperature -5 C to 50 C Certifications UL1741, IEC 62109-1, CSA C22.2 Communications Modbus TCP/IP via Alencon Communications Environment (ACE) Form Factor Packaging Pad Mounted, Outdoor Rated Size (L x W x H) .76 x .67 x .72 M... -
Page 22: Mechanical Specifications
Alencon CUBE: Installation, Operation, and Maintenance Manual 7.2 Mechanical Specifications The precise dimensions of the CUBE device can be found in Figure 6 below. 6: M CUBE IGURE ECHANICAL IMENSIONS OF 21 | P a g e... -
Page 23: Cube Hardware
Alencon CUBE: Installation, Operation, and Maintenance Manual 8 CUBE Hardware This section provides information on how the CUBE is constructed and its principles of operation. The CUBE with can be configured to operate as: 1. Step-up DCDC converter (Boost) 2. Step-down DCDC converter (Buck) The CUBE construction is comprised of two main sections;... -
Page 24: Electrical Compartment
Alencon CUBE: Installation, Operation, and Maintenance Manual 8.1 Electrical Compartment The majority of HV and LV electronics are within the NEMA 3R rated compartment at the front of the CUBE device. 8: E IGURE LECTRICAL COMPARTMENT 8.2 Inductor Enclosure The CUBE’s inductor and water-cooling system are stored in the larger back part of the device. -
Page 25: Water-Cooling System
Alencon CUBE: Installation, Operation, and Maintenance Manual 8.2.1 Water-cooling System The CUBE is equipped with a pressurized, liquid cooling system. During normal operation, the pump will circulate the coolant (deionized water) through the system. A filter keeps the deionized water at low conductivity and a pressurized expansion tank keeps the incoming pressure above the pump’s cavitation point. -
Page 26: Isolators And Disconnects
Operation, and Maintenance Manual 9 Isolators and Disconnects Alencon requires using disconnects (or contactors) to enable an electrical cut-off of the CUBE from its primary and secondary power sources/loads. Prior to disconnecting the CUBE primary and secondary terminals, the device should be shutdown (see Section 11.2). -
Page 27: Cube Installation
The CUBE has been designed to be quickly deployed in the field. Much of the system configuration is done at Alencon’s factory prior to shipping to decrease the amount of time needed for install and commissioning the system in the field. -
Page 28: System Layout Schematic And/Or Installation Drawing
Alencon CUBE: Installation, Operation, and Maintenance Manual 10.3 System Layout Schematic and/or Installation Drawing System installers and/or integrators should supply installation drawings showing the location of where the CUBE is to be installed. As well, the single line diagram should show electrical interconnections. -
Page 29: Mechanical Install
Alencon CUBE: Installation, Operation, and Maintenance Manual 10.4 Mechanical Install 10.4.1 Selecting Location The following considerations should be made when selecting the CUBE location. Indoor/Outdoor: The CUBE is NEMA 3R rated and can be safely deployed indoors or outdoors without additional weather protection. -
Page 30: Cube Placement
Alencon CUBE: Installation, Operation, and Maintenance Manual 10.4.1 CUBE Placement To place the CUBE in its designated location: 1. The CUBE can be transported into location by forklift truck or by crane, see Figure 13. 2. Convenient removable I-hooks are provided, that can be used on the 4 corners of the CUBE top surface to lift and place the CUBE in desired location. -
Page 31: Cube Grounding Requirements
Alencon CUBE: Installation, Operation, and Maintenance Manual 10.5 CUBE Grounding Requirements PV Grounding CUBE supports positive, negative, and floating grounding schemes. The chassis of the CUBE must be connected to main earth ground. Not properly grounding the CUBE enclosure can be dangerous for operators and maintenance personnel. -
Page 32: Connecting The Cube Primary And Secondary To Source/Load Cables
Alencon CUBE: Installation, Operation, and Maintenance Manual 10.6 Connecting the CUBE Primary and Secondary to Source/Load Cables Ensure the sources are off (disconnects are in OPEN positions), before making connections to the CUBE primary or secondary. Fire Hazard: Wiring should not be undersized. The size of the wires must be selected based on the maximum short circuit current in the node. -
Page 33: Connecting Comms Cables Between Cube And A Podd
Operation, and Maintenance Manual 10.7 Connecting Comms Cables between CUBE and a PODD CUBE units require a connection to the Alencon PODD device to establish communications and be controlled. Alencon specifies the use of: • CAT5e or better STP cable •... -
Page 34: Turning On And Off The Cube
CUBE is isolated from both primary and secondary. 4. Measure the primary and secondary DC currents using a clamp and verify no current flows to or from the CUBE. If current is still present, contact Alencon technical support directly. -
Page 35: Commissioning Your Cube Device
7. Implementing final configuration changes (with assistance from Alencon technical support) 8. Controlling and operating the system (Section 12) Alencon offers live commissioning support for all system deployments using the CUBE device. Please discuss this with your Alencon Systems representative if interested. 34 |... -
Page 36: Cube Operation
Alencon CUBE: Installation, Operation, and Maintenance Manual 12 CUBE Operation This section explains the operation of a CUBE, distinguishing between typical and atypical operation is key when troubleshooting your system. When running the CUBE as a boost converter, power flows from primary to secondary. When running the CUBE as a buck converter, power flows from secondary to primary. -
Page 37: Cube State Machine
PODD. Main states may have lower-level state machines incorporated within. Arrows indicate the conditions of transfer from state to state. Commands can be issued from the Alencon PODD UI or the system controller via Modbus at any time. -
Page 38: States
If operating conditions return to standard run limits, the CUBE will return to RUN status. For more information see the Alencon Whitepaper on DCDC curtailment. 37 | P a g e... - Page 39 Alencon CUBE: Installation, Operation, and Maintenance Manual Output Voltage Current Curtailment I_START=15A V_START=1050A V_END=1500V I_LIMIT 1000 1200 Output Voltage 22: E CUBE IGURE XAMPLE OF CURTAILMENT TRIPPED – Contactor is open If, while in RUN or LIMIT_ON status, voltage, current or temperature exceed the pre- configured limits on the CUBE (i.e., hit a trip condition) it will enter TRIPPED state and move...
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Page 40: Commands
CUBE from the PODD UI or external controller via Modbus. For full details on available Modbus commands and registers, please request Modbus Maps from Alencon Systems. • Clear Error – remove error code flags from the UI, by resetting error code register. This has no effect on the state machine/operational flow of the CUBE. -
Page 41: Conditions
Alencon CUBE: Installation, Operation, and Maintenance Manual 12.1.3 Conditions Bootup in shutdown If evaluated as true, CUBE goes automatically to SHUTDOWN state when turned on. By default, the CUBE will be configured to evaluate as true, but this can be changed if necessary. -
Page 42: Running Two Cubes In Series
S IN ERIES PERATION For more information on how to start and operate Two CUBEs in series, contact Alencon Technical Support. 12.3 Modbus Definitions and Map A set Modbus register map and definitions document for the CUBE can be provided separately from this manual. -
Page 43: Cube Communication
Alencon’s PODD device. The PODD can be used with other Alencon products including the CUBE, SPOT, GARD, and BOSS. The PODD acts as a gateway to integrate Alencon’s power electronics with your plant level control systems or as a standalone controller and troubleshooting device. -
Page 44: Cube User Interface (Via Podd)
• metadata File • config File Both these files would be pre-loaded onto the PODD or be provided by Alencon via secure file transfer. Open the PODD UI through a networked computer, to upload these files, read live telemetry data from the connected CUBE, and control the operation of the CUBE. -
Page 45: Maintenance And Servicing
• Use the primary disconnect switch to turn off and on the CUBE. If the CUBE has an external 24V connection, that can be used to power cycle and reboot the device. If CUBE still does not operate as expected, please contact Alencon Systems technical support for assistance with troubleshooting (see Appendix C). -
Page 46: Replacement Of Deionized Water Filter
If the CUBE requires further servicing, disconnect it following the turn off procedure (Section 11.2) and contact Alencon Systems technical support, to assist with troubleshooting. The damaged CUBE may need to be returned to Alencon Systems or an authorized Alencon service agent. -
Page 47: Appendix A - Safety Precautions
Alencon CUBE: Installation, Operation, and Maintenance Manual Appendix A - Safety Precautions A.1 Degree of Danger Symbols Warning! Warnings indicate conditions, which if not observed, can cause personal injury! Caution! Cautions are included to help you avoid damaging hardware or losing data. -
Page 48: Danger Due To Battery Voltage
Alencon CUBE: Installation, Operation, and Maintenance Manual A.2.2 Danger due to Battery Voltage CUBE may be connected to high voltage batteries on both primary and secondary sides of the equipment. Before beginning to work on the CUBE, disconnect the power sources on both primary and secondary sides. -
Page 49: Damage To The Equipment Caused By Dust Or Moisture Penetration
Alencon CUBE: Installation, Operation, and Maintenance Manual A.3.2 Damage to the equipment caused by dust or moisture penetration Dust intrusion or moisture penetration can damage and impair the functionality of the equipment. To avoid damage from dust or moisture penetration: •... -
Page 50: Appendix B - Glossary
Alencon CUBE: Installation, Operation, and Maintenance Manual Appendix B – Glossary Word(s)/Acronyms Definition Alencon Communication Environment – a communication system containing hardware and software elements provided by Alencon to control power conversion equipment. ALENCON Systems, LLC BOSS Bidirectional Optimizer for Storage Systems... -
Page 51: Appendix C - Technical Support And Assistance
User Interface Appendix C – Technical Support and Assistance Visit the Alencon Systems web site at www.alenconsystems.com where you can find the latest information about the product. Contact your distributor, sales representative, or Alencon Systems’ technical support if you need additional assistance. Please have the following information ready before you call: •...
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