ALENCON CUBE-10-ES-I Installation, Operation And Maintenance Manual Download Page 1

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Alencon Systems

–

Passionate About Power

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

Summary of Contents for CUBE-10-ES-I

Page 1: ...0 ALENCON LLC INC ALL RIGHTS RESERVED CUBE Compact Universal Bi directional Efficient DC DC Converter A Compact High Power Density BOOST or BUCK Converter Installation Operation and Maintenance Manual...

Page 2: ...yright Information Any product names listed in this manual that are not registered trademarks of Alencon Systems LLC and or organization names mentioned may be trademarks and or registered trademarks...

Page 3: ...on LLC shall not be liable for any incidental or consequential damages under any circumstances Specifications are subject to change without notice Every attempt has been made to make this document com...

Page 4: ...NUAL 14 5 2 3 PV MPPT 14 5 2 4 PRIMARY VOLTAGE CONTROL 14 5 2 5 SECONDARY VOLTAGE CONTROL 14 5 2 6 PRIMARY CURRENT CONTROL 14 5 2 7 SECONDARY CURRENT CONTROL 14 5 2 8 PRIMARY POWER CONTROL 14 5 2 9 SE...

Page 5: ...nclosure 23 8 2 1 Water cooling System 24 9 Isolators and Disconnects 25 9 1 Built in Disconnects 25 9 2 Combiner Box and Third Party Disconnects 25 10 CUBE Installation 26 10 1 Install criteria 26 10...

Page 6: ...ter 45 14 4 Refilling the Coolant 45 14 5 Further Service and Repair 45 Appendix A Safety Precautions 46 A 1 Degree of Danger Symbols 46 A 2 Electrical hazards 46 A 2 1 Electric shock from live voltag...

Page 7: ...MPLE OF A SINGLE LINE DIAGRAM SLD INCLUDING CUBE 27 FIGURE 12 CUBE SN LABEL 27 FIGURE 13 MOVING THE CUBE 29 FIGURE 14 CUBE ADJUSTABLE LEGS AND MOUNTING BRACKETS 29 FIGURE 15 CUBE GROUND LUG LOCATION E...

Page 8: ...ly to any products which have been repaired or altered by persons other than repair personnel authorized by Alencon System or which have been subject to misuse abuse accident or improper installation...

Page 9: ...thorization number from Alencon Systems Thisallowsusto process your return more quickly Carefully pack the defective product preferably in the original packaging material it was shipped in a fully com...

Page 10: ...anual 9 P a g e 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 specif...

Page 11: ...430 KW Energy Storage bidirectional Non Interleaved CUBE 15 ES N 4 1000 V 470 KW Energy Storage bidirectional Non Interleaved CUBE 10 ES N 5 1500 V 430 KW Solar unidirectional Interleaved CUBE 15 PV I...

Page 12: ...CUBE ACTS AS A DIRECT CURRENT SUPPLY Installation of this equipment must be performed by an authorized electrician in accordance with the local and NEC ANSI NFPA 70 and OSHA requirements 1 Before inst...

Page 13: ...the NEC or other relevant electrical code 9 Exposed PV strings to sunlight represent a shock hazard at the wires and exposed terminals Disconnect CUBE primary and secondary switches or contactors perf...

Page 14: ...ower density of other non isolated DCDC conversion units The CUBE achieves its unrivaled power density by using a silicon carbide based power train instead of bulky traditional silicon insulated gate...

Page 15: ...n the other side of the converter i e the voltages are interleaved The CUBE I series is slated for availability in the second half of 2023 5 2 Available Control Modes 5 2 1 STANDBY Standby is an idle...

Page 16: ...P OCP S OCP Operational current magnitude is limited to protect from hardware damage If limit is exceeded CUBE will TRIP and enter STANDBY mode 5 4 Environmental Protection The CUBE has software func...

Page 17: ...lates the PV from the DC bus At sunrise the CUBE PV automatically wakes up and begins to supply harvested PV energy to the DC bus 6 1 1 CUBE PV Applications In new PV construction or in repowering to...

Page 18: ...the storage terminal as shown in Error Reference source not found 5 In this case the inverter operates in a constant voltage mode The CUBEwillmatch the PV voltage tothe batteryvoltage and provide gran...

Page 19: ...pling lower voltage batteries to higher voltage inverters As battery energy storage technology evolves many novel battery chemistries are coming on the market that operate at voltages that may not be...

Page 20: ...rnal BESS and supply voltage to the automobile charge dispensers CUBE ES will serve the EV market DC Fast Charging stations and offer impressive cost reduction The power electronic equipment that will...

Page 21: ...lation Non Isolated Buck Boost Topology Operating Information Peak CEC Weighted Efficiency 99 5 98 5 Storage Temperature 40 C to 85 C Cooling Internal closed loop water cooling Environmental Rating NE...

Page 22: ...n CUBE Installation Operation and Maintenance Manual 21 P a g e 7 2 Mechanical Specifications The precise dimensions of the CUBE device can be found in Figure 6 below FIGURE 6 MECHANICAL DIMENSIONS OF...

Page 23: ...s 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 mai...

Page 24: ...e NEMA 3R rated compartment at the front of the CUBE device FIGURE 8 ELECTRICAL COMPARTMENT 8 2 Inductor Enclosure The CUBE s inductor and water cooling system are stored in the larger back part of th...

Page 25: ...mal 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...

Page 26: ...y rated disconnect to isolate CUBE from input power source direction dependent before disconnecting the output You may select from one of two options 1 Built in disconnects on integrated power equipme...

Page 27: ...hing them The primary or secondary voltage at the CUBE converter must never exceed its rated voltage i e 1000V for the CUBE 1000 Exposure to voltage higher than that may cause damage to the CUBE and w...

Page 28: ...a SLD is provided below FIGURE 11 SAMPLE OF A SINGLE LINE DIAGRAM SLD INCLUDING CUBE The installation drawing indicates the location of each CUBE and shows its Local Identification Numbers LIN Prior t...

Page 29: ...his will likely depend on hurricane regulations by location Temperature The CUBE can be stored in any location where ambient temperature ranges from 40 to 85 C The CUBE should be operated only when am...

Page 30: ...e 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 3 The CUBE comes with four adjustable legs The...

Page 31: ...ally based on the size of the largest conductor in the DC system Shock hazard All power terminals are considered to have a high voltage potential to ground To reduce the risk of shock during installat...

Page 32: ...urrent in the node Ensure wiring is in accordance with the NEC or applicable code The electrical compartment has 3 landing points for power cables up to 500 KCMIL in size and 2 conduit knockouts for t...

Page 33: ...s type B crimping 22 AWG conductors preferred 24 AWG are acceptable Note CAT cabling should be rated for outdoor use if the cable run is not indoors or enclosed within conduit FIGURE 18 COMMS PORTS ON...

Page 34: ...ntroller to check telemetry data for expected voltage measurements on both Primary and Secondary 6 CUBE is on and ready for active control see Section 12 11 2 Steps to turn OFF the CUBE In the event o...

Page 35: ...Installing any additional safety hardware as required Section 9 3 Electrically connecting to Primary and Secondary Section 10 6 4 Connecting comms cables between CUBE unit s and the PODD Section 10 7...

Page 36: ...ation 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 p...

Page 37: ...e Alencon PODD UI or the system controller via Modbus at any time FIGURE 21 HIGH LEVEL STATE MACHINE DIAGRAM OF CUBE Converter State Contactor State Power Conversion Expected Commands Shutdown Open No...

Page 38: ...d or control mode has not been set STARTUP Contactor is closed Current or voltage setpoint is already received In the STARTUP state the DCDC prepares the load for the RUN state When run limits are sat...

Page 39: ...or temperature exceed the pre configured limits on the CUBE i e hit a trip condition it will enter TRIPPED state and move automatically to STANDBY state When the TRIPPED state is entered the DCDC sto...

Page 40: ...and setpoint timeout o Options for control mode include STANDBY idle state with no power conversion Constant power requires actively choosing the primary or secondary power setpoint Constant current r...

Page 41: ...are in the permissible startup range as defined in the config file On board temperature Transistor temperature Primary and Secondary Voltages Voltages currents temps within RUN range Run limits Tests...

Page 42: ...from Secondary V_High to Primary V_Low Direction must be set Secondary to Primary CUBE Boost can pre charge its capacitor to the same voltage as the DC Bus 1 through its charge resistor MC 1 can be c...

Page 43: ...oint of Data Distribution The PODD communicates with CUBEs via MODBUS RTU External SCADA systems communicate with the PODD via MODBUS TCP IP A single PODD can collect the operation data from up to 16...

Page 44: ...communication of the CUBE with the PODD two files are required 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...

Page 45: ...off Section 11 2 fuse replaced and then CUBE can be turned back on Section 11 1 Use the controller to send a Shutdown command followed by a System Reset command give the CUBE a few minutes to restart...

Page 46: ...he pump motor by connecting to an external 24 volt power supply Air in the system will build up in the top of the water filter the red button can be used to open the bleeder valve and release that air...

Page 47: ...messages may lead to severe or lethal injuries due to electric shock To avoid electric shock from live voltage Wear class 2 personal protective equipment Always perform work in compliance with the re...

Page 48: ...ic shock due to damaged equipment Operating damaged equipment can lead to hazardous situations that may result in serious or lethal injuries caused by electric shock To avoid electric shock from damag...

Page 49: ...Perform maintenance on the CUBE only when the environment is dry and free of dust Always close the electrical compartment door before energizing the CUBE A 3 3 Danger to life due to electric shock wh...

Page 50: ...ional Efficient DCDC Converter DC Direct Current ESD Electrostatic Discharge ESS Energy Storage System FEED Fused Electrical Disconnect GARD Ground and Arc fault Rapid Disconnect GFDI Ground Fault Det...

Page 51: ...onsystems 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 ha...

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