ALENCON BOSS 1000 Installation, Operation And Maintenance Manual Download

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idirectional

ptimizer

for

torage

ystems

(BOSS)

A unique DC-DC Optimizer to help medium and large
Energy Storage Systems (ESS)

NSTALLATION

PERATION AND

AINTENANCE

ANUAL FOR

USE WITH THE

BOSS

1000

AND

1500

PM003 Revision 12

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

Summary of Contents for BOSS 1000

Page 1: ...S A unique DC DC Optimizer to help medium and large Energy Storage Systems ESS INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR USE WITH THE BOSS 1000 AND 1500 PM003 Revision 12 Alencon Systems LLC 3...

Page 2: ...ed trademarks of their respective companies Publication Number PM003 Date and Revision Revision ECO Date Author Approval Comment 0 8562 5 29 2019 O Fishman MM Original Release 1 8563 5 31 2019 P Shivs...

Page 3: ...tion 12 Communication 12 Parallel Operation 12 BOSS Operation 13 BOSS Controls 13 STATE Machine 14 Technical Specifications 15 Communication 16 BOSS Protection 16 BUS Protection 16 Under voltage 16 Cu...

Page 4: ...on 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 32 Testing the BOSS using a DC...

Page 5: ...ining and troubleshooting the Alencon s BOSS PV Harvesting System Who Should Read this Manual This manual should be read by anyone who needs to Understand the product Plan the installation Install the...

Page 6: ...se of Alencon Systems high quality control standards and rigorous testing most of our customers never need to use our warranty service If an Alencon Systems product is defective it will be repaired or...

Page 7: ...r technical support if you need additional assistance Please have the following information ready before you call Product name LIN and serial number see section 6 5 for more information the location o...

Page 8: ...ur 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 Figure 1 The BOSS unit Ordering In...

Page 9: ...uctions 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...

Page 10: ...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 4 The meta...

Page 11: ...general deterioration of battery condition is not detected Potential Hazards Each high voltage battery rack has a positive and negative terminal isolated from the battery case If all the positive ter...

Page 12: ...nverter units DCDC that are connected between a common DC BUS and each individual battery string rack Each DC DC converter autonomously controls the charge and discharge current into a battery rack Ga...

Page 13: ...minal BAT2 to the earthed chasses and compute the leakage current from these terminals If the leakage current becomes excessive the ESS may disconnect the DCDC and associated rack from the system Comm...

Page 14: ...and BOSS 1500 rated at 1500 VDC max Each DCDC generates charge current from BUS to BATTERY or discharge current from BATTERY to BUS according to commands it receives from the ESS controller BOSS Contr...

Page 15: ...ke 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...

Page 16: ...2 A 14 A Max Power 25 Deg C Ambient 19 2 KW 15 4 KW Max Current per DCDC 50 Deg C Ambient 15 A 10 A Max Power 50 Deg C Ambient 15 KW 11 KW Efficiency Peak Efficiency 98 CEC Weighted Efficiency 97 5 S...

Page 17: ...hort Circuit Protection When in Discharge mode Rapid shut down of the DC to DC converters unit in case of external short Battery Protection Under voltage The output voltage is too low for normal opera...

Page 18: ...nal conditions of high temperature and moisture Temperature on Power Semiconductor Monitors the temperature of the Power Semiconductors Prevents our optimizer from failure Microcomputer Temperature Mo...

Page 19: ...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 Cabinet Rail mount...

Page 20: ...or 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 The...

Page 21: ...ingle input and single output channel Since the BOSS is a bi directional optimizer that can work in both directions the connection scheme is flexible i e Safety Note After you decide the direction of...

Page 22: ...raight method of terminating the input and output cables without having to deal with DIN rail mounted terminal blocks Communication Ports Each BOSS unit consists of 2 x RJ45 shielded Ethernet jacks BO...

Page 23: ...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 Dis...

Page 24: ...For a wired network all distributed PODDs will be daisy chained together ending with the centralized PODD If the wireless package is purchased an antenna will be provided for each distributed PODD and...

Page 25: ...PODDs Figure 13 Angry IP Scanner Interface When a PODD is found it will appear under the Hostname column as PODD xxxx where the xxxx will be the last four digits of its serial number Locate the IP ad...

Page 26: ...HUB has 6 tabs Alencon Devices Config Update Firmware Update Maintenance Factory test Settings Alencon Devices Tab The current version of the HUB provides DCDC information that can be accessed using t...

Page 27: ...tional 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 1 Syst...

Page 28: ...t Point this command sets the current required to be drawn from the source 6 Reset Modbus address to 247 Default This command resets the Modbus address of the BOSS within a page to default The custome...

Page 29: ...n personal Failure to follow these instructions may damage the BOSS and will void your warranty Figure 19 Configuration factory file to be uploaded to BOSS The BOSSs are selected by GUID The BOSS LIN...

Page 30: ...t that is viewable with any text editor Figure 21 Folder containing factory files for Alencon products Step 2 Select the GUID of the target BOSS The LIN to GUID mapping can be found on the BOSSs Tab F...

Page 31: ...e end cap Applying 200V to the BOSS Auxiliary The auxiliary of the BOSS is powered by the Battery The minimum voltage required to power the board is 200V As long as the battery voltage is sufficiently...

Page 32: ...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 com...

Page 33: ...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 Bus BATT or BATT BUS Applied voltag...

Page 34: ...re available within the command window seen in figure Set Direction Command Choose the appropriate direction Bus to Battery or Battery to Bus Current Set Point Command This command sets the current re...

Page 35: ...charging the capacitors to the desired output voltage the DCDC s transition to RUN adjusting the frequency to obtain the desired current set point As the frequency goes down the current drawn begins t...

Page 36: ...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 volt...

Page 37: ...DC load o Hit Reset command wait for BOSS to transition to standby o Establish Power Flow Direction i e BUS BAT when DC Source connected to the BUS terminals o Provide Current Set Point Observe the cu...

Page 38: ...e current set point o Change the direction of the current flow on the fly On the other hand since the input is connected to the output o The voltages always will be the same on the BUS and the BATT si...

Page 39: ...r BOSS to transition to standby o Establish Power Flow Direction i e BUS BAT o Provide Current Set Point Observe the current flowing at a specified set point Change the current set point and observe t...

Page 40: ...nd output cables are connected to the terminal block o Hit Reset command wait for BOSS to transition to standby o Establish Power Flow Direction i e BUS BAT o Provide Current Set Point Observe the cur...

Page 41: ...m s L L C P a g e 40 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 techni...

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