ALENCON CUBE-PV 1000 Volt Series User manual

Alencon Systems –Passionate About Power
COPYRIGHT © 2020 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 for use with the full
line of CUBE DCDC Converters

Alencon CUBE: Installation,
Operation, and Maintenance Manual
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This Document is the confidential and proprietary information of Alencon Systems LLC. No
part of this document may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photographic, magnetic or otherwise, without
prior written permission. Alencon Systems LLC reserves the right to change details in this
publication without notice.
Copyright 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 of their respective owners.
Publication Number: PM004 Revision 04
REVISION LOG:
Revision
ECO
Date
Author
Approval
Comment
00
8451
4/21/2021
O. Fishman
ZD
Original Release
01
8452
6/9/2021
O. Fishman
MM
Added W/C system
02
8453
4/1/2022
Z. Dereli
OSF
Additional changes on new version
03
8454
9/21/2022
O. Fishman
ZD
Added more information on
applications, N and I series
04
8455
2022
J. Faber
HF
Reformatting, operation
instructions, and commissioning
instructions.

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Disclaimer
Alencon LLC makes no representations, express or implied, with respect to this documentation
or any of the equipment and/or software it may describe, including (with no limitation) any
implied warranties of utility, merchantability, or fitness for any particular purpose. All such
warranties are expressly disclaimed. Alencon 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 complete, accurate and up to date. 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.

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Contents
Disclaimer ..........................................................................................................................................................2
1 Table of Figures ...............................................................................................................................................6
2General 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 .............................................................................................................................. 10
3 Important Safety Instructions ........................................................................................................................ 11
4 Introduction................................................................................................................................................... 13
5 CUBE Features............................................................................................................................................... 14
5.1 CUBE Hardware Modalities...................................................................................................................... 14
5.1.1 Non-Interleaved Modality –N-Series ............................................................................................... 14
5.1.2 Interleaved Modality –I-Series......................................................................................................... 14
5.2 Available Control Modes.......................................................................................................................... 14
5.2.1 STANDBY ........................................................................................................................................ 14
5.2.2 MANUAL ......................................................................................................................................... 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 SECONDARY POWER CONTROL .................................................................................................... 14
5.3 CUBE Protection Modes: ......................................................................................................................... 15
5.3.1 Primary/Secondary overvoltage (P-OVP, S-OVP) ............................................................................. 15
5.3.2 Primary/Secondary undervoltage (P-UVP, S-UVP) ........................................................................... 15
5.3.5 Primary/Secondary Overcurrent (P-OCP, S-OCP)............................................................................. 15
5.4 Environmental Protection........................................................................................................................ 15
5.4.7 Power Semiconductors Over temperature (S-OT)............................................................................ 15
5.4.8 Control PCB Overtemperature (C-OT) ............................................................................................. 15
5.4.9 MCU Overtemperature (M-OT)........................................................................................................ 15
6 CUBE Applications......................................................................................................................................... 16
6.1 CUBE-PV: Photovoltaic Installations........................................................................................................ 16
6.1.1 CUBE-PV Applications ..................................................................................................................... 16
6.1.2 CUBE-PV in New PV Plants .............................................................................................................. 16

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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 ........................................................................................................... 18
6.3 Fuel Cell Integration (FC) ......................................................................................................................... 18
6.4 Hydrogen Electrolyzing Installations (HEI)............................................................................................... 18
6.5 Fast Automobile Charging Technology (FACT). ....................................................................................... 19
7 Technical Specifications ................................................................................................................................. 20
7.1 Electrical Specifications ........................................................................................................................... 20
7.2 Mechanical Specifications........................................................................................................................ 21
8 CUBE Hardware............................................................................................................................................. 22
8.1 Electrical Compartment........................................................................................................................... 23
8.2 Inductor Enclosure................................................................................................................................... 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
10.2 Install procedure ....................................................................................................................................26
10.3 System Layout Schematic and/or Installation Drawing .......................................................................... 27
10.4 Mechanical Install .................................................................................................................................. 28
10.4.1 Selecting Location ......................................................................................................................... 28
10.4.1 CUBE Placement............................................................................................................................ 29
10.5 CUBE Grounding Requirements ............................................................................................................. 30
10.6 Connecting the CUBE Primary and Secondary to Source/Load Cables ................................................... 31
10.7 Connecting Comms Cables between CUBE and a PODD ........................................................................ 32
11 Turning ON and OFF the CUBE .................................................................................................................... 33
11.1 Steps to turn ON the CUBE: ................................................................................................................... 33
11.2 Steps to turn OFF the CUBE: .................................................................................................................. 33
11.3 Commissioning your CUBE Device ......................................................................................................... 34
12 CUBE Operation........................................................................................................................................... 35
12.1 CUBE State Machine .............................................................................................................................. 36
12.1.1 States..............................................................................................................................................37
12.1.2 Commands..................................................................................................................................... 39
12.1.3 Conditions......................................................................................................................................40

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12.2 Running two CUBEs in series ................................................................................................................. 41
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............................................................................................................................. 44
14.2 Replacement of the air filter .................................................................................................................. 44
14.3 Replacement of Deionized water filter ................................................................................................... 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 voltage ....................................................................................................... 46
A.2.2 Danger due to Battery Voltage........................................................................................................ 47
A.2.3 Electric shock caused by ground fault .............................................................................................. 47
A.2.4 Electric shock due to damaged equipment ...................................................................................... 47
A.3 Environmental hazards ........................................................................................................................... 47
A.3.1 Danger to life due to blocked escape routes..................................................................................... 47
A.3.2 Damage to the equipment caused by dust or moisture penetration................................................. 48
A.3.3 Danger to life due to electric shock when the equipment is unlocked............................................... 48
Appendix B –Glossary ......................................................................................................................................49
Appendix C –Technical Support and Assistance ............................................................................................... 50

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1 Table of Figures
FIGURE 1: PICTURE OF A CUBE UNIT.............................................................................................................................9
FIGURE 2: THE GRAPHIC ABOVE INDICATES THAT THE CUBE IS A GROUNDING CONDUCTOR ................................................. 11
FIGURE 3: THE GRAPHIC ABOVE INDICATES THAT THE CUBE ACTS AS A DIRECT CURRENT SUPPLY.......................................... 11
FIGURE 4: DIAGRAM OF DEPLOYED CUBES IN A NEWLY CONSTRUCTED PV PLANT. .............................................................17
FIGURE 5: DIAGRAM OF A DC-COUPLED SOLAR +STORAGE SYSTEM USING THE CUBE........................................................17
FIGURE 6: MECHANICAL DIMENSIONS OF CUBE........................................................................................................... 21
FIGURE 7: CUBE –TWO SECTIONS ............................................................................................................................ 22
FIGURE 8: ELECTRICAL COMPARTMENT ....................................................................................................................... 23
FIGURE 9: MAIN ENCLOSURE,LIQUID COOLING SYSTEM ................................................................................................. 23
FIGURE 10: REFILING LIQUID COOLING SYSTEM............................................................................................................. 24
FIGURE 11: SAMPLE 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 EXAMPLE (IN ORANGE)............................................................................... 30
FIGURE 16: CUSTOMER SHOULD SUPPLY WATERTIGHT CONDUIT IN THE PROVIDED 2INCH KNOCKOUTS ................................ 31
FIGURE 17: HIGH VOLTAGE TERMINATIONS................................................................................................................. 31
FIGURE 18: COMMS PORTS ON THE CUBE TO CONNECT TO THE PODD OR EXTERNAL SCADA ........................................... 32
FIGURE 19: MULTIPLE CUBES CAN BE DAISY CHAINED TO A SINGLE PODD ...................................................................... 32
FIGURE 20: HIGH LEVEL CIRCUIT DIAGRAM OF CUBE.................................................................................................... 35
FIGURE 21: HIGH LEVEL STATE MACHINE DIAGRAM OF CUBE........................................................................................ 36
FIGURE 22: EXAMPLE OF CUBE CURTAILMENT............................................................................................................. 38
FIGURE 23: CONNECTING TWO CUBES IN SERIES,BACK-TO-BACK OPERATION ................................................................ 41
FIGURE 24: PODD .................................................................................................................................................. 42
FIGURE 25: CUBE DEVICE TELEMETRY ON THE PODD UI ............................................................................................. 43
FIGURE 26: CUBE FILTER REPLACEMENT .................................................................................................................... 44
FIGURE 27: DEIONIZED WATER FILTER........................................................................................................................ 45

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2General Information
All efforts have been made to ensure the accuracy of material provided in this document at the
time of release. Items are subject to continuous development and improvements. All
specifications and descriptions are subject to change without notice.
2.1 Purpose
This manual provides information about installing, operating, maintaining, and troubleshooting
the Alencon CUBE DCDC Converter.
Who Should Read this Manual?
This manual should be read by anyone who needs to:
•Understand the product
•Plan the installation
•Install the product
•Commission the product
•Operate the product
•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.
This warranty does not apply 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. This warranty does not cover the repair or
replacement of any goods which fail as a result of damage in transit, misuse, neglect, accident,
Act of God, abuse, improper handling, misapplication, modification, improper storage,
excessive stress, faulty or improper installation, testing or repair, negligent maintenance, or
failure to comply with the written instructions for installation, testing, use or maintenance (if
any) provided by Alencon Systems. Alencon Systems assumes no liability under the terms of this
warranty as a consequence of such events.
Because 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 replaced at no charge during the warranty period. For out-of-warranty repairs,
you will be billed according to the cost of replacement materials, service time and freight. Please
consult Alencon Systems for more details. If you think you have a defective product, follow these
steps:

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•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.
•If your product is diagnosed as defective, obtain an RMA (return merchandise
authorization) number from Alencon Systems. This allows us to process your return more
quickly.
•Carefully pack the defective product (preferably in the original packaging material it was
shipped in), a fully completed Repair and Replacement Order Card and a photocopy
proof of purchase date (such as your sales receipt) in a shippable container. A product
returned without proof of the purchase date is not eligible for warranty service.
2.3 Warnings, Cautions and Notes
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.
Note!
Notes provide optional additional information.

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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
FIGURE 1: PICTURE OF A CUBE UNIT