Bidirectional Optimizer for Storage Systems (BOSS)

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

330 Warminster Rd., Suite 380 | Hatboro, PA 19040 | USA
 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. 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 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. MM Content Review
Shivshankaran
2 8564 6/6/19 P. MM Additional Modifications
Shivshankaran
3 8564 6/7/19 O.Fishman PS Added BOSS Protections
4 8565 10/7/19 P. OSF Hardware + Installation +
Shivshankaran PODD
5 8566 10/22/19 P. OSF Added information about
Shivshankaran turn_On procedure + test
setups
6 8567 10/23/19 P.Shivshankaran OSF Ground leak Detection +
removal of excess PODD
details. Updated flow
diagram + addition of state
diagram
10 8568 12/13/19 Z. Dereli PS Certification Related
updates are made.

CEC/Peak Efficiency
Updated 12/20/2019
11 8569 1/30/2019 P.Shivshankaran PS Modbus map v.17 added
12 8570 2/3/2020 P.Shivshankaran PS Modbus Map Removed
13 8571 12/16/2020 J. Faber HF Updated with FEED info

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Contents
Contents ............................................................................................................................................. 2
General Information............................................................................................................................ 4
Purpose ..................................................................................................................................... 4
Glossary..................................................................................................................................... 4
Product Warranty ....................................................................................................................... 5
Technical Support and Assistance ............................................................................................. 6
Warnings, Cautions and Notes................................................................................................... 6
Packing List ............................................................................................................................... 7
Ordering Information .................................................................................................................. 7
IMPORTANT SAFETY INSTRUCTIONS ............................................................................................ 8
Introduction ...................................................................................................................................... 10
Energy Storage Systems Benefits ............................................................................................ 10
Energy Storage Systems Challenges ....................................................................................... 10
Potential Hazards..................................................................................................................... 10
State-of-Charge and State-of-Health ........................................................................................ 10
BOSS Features ................................................................................................................................ 11
BOSS- Bi-Directional Optimizer for Storage Systems............................................................... 11
Galvanic Isolation..................................................................................................................... 11
Ground Leak Detection ............................................................................................................ 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
Current Limit ........................................................................................................................ 16
Short Circuit Protection ........................................................................................................ 16
Battery Protection .................................................................................................................... 16
Under voltage....................................................................................................................... 16
Over current ......................................................................................................................... 16
Short Circuit Protection ........................................................................................................ 16
Ground Leak Protection ....................................................................................................... 16
Environmental Protection ......................................................................................................... 17
Temperature on Power Semiconductor ................................................................................ 17
Microcomputer Temperature ................................................................................................ 17
Control Board Temperature .................................................................................................. 17
Humidity ............................................................................................................................... 17
BOSS Installation ............................................................................................................................. 18
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

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Installation Criteria ................................................................................................................... 23

PODD Mounting ....................................................................................................................... 23
PODD Mounting Location ................................................................................................. 23
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 ........................................................................................................ 32
Testing the BOSS using a DC source and a DC Load.............................................................. 35
Testing the Bi-directional Functionality of the BOSS Using a Single DC Source ...................... 37
Testing the Charge-Discharge Functionality of the BOSS Using Battery Racks .................... 39
Further information....................................................................................................................... 40

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General 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.
Purpose
This manual provides information about installing, operating, maintaining, 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 product
- Commission the product
- Operate the product
- Maintain the product, if necessary

Glossary
Word(s)/Acronyms Definition
BOSS Bi-directional Optimizer for Storage Systems
SPOT String Power Optimizer and Transmitter
ACE Alencon Communication Environment – a communication system containing
hardware and software elements provided by Alencon to control power
conversion equipment.
HUB Alencon Communication, Monitoring and Control Software

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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.

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:

1. Collect all the information about the problem encountered. (For example, issues you are
encountering in your PV array or battery system) Note anything abnormal when the
problem occurs.
2. Call Alencon Systems or your licensed Alencon Systems dealer and describe the
problem. Please have your manual, product, and any helpful information readily available.
3. If your product is diagnosed as defective, obtain an RMA (return merchandise
authorization) number from your Alencon Systems. This allows us to process your return
more quickly.
4. 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.
5. Write the RMA number

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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. Please have the following
information ready before you call:
– Product name, LIN and serial number (see section 6.5 for more information the location
of the LIN and serial number)
– Description of your peripheral attachments including fusing and cables

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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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.

Figure 1: The BOSS unit

Ordering Information
Model Number Description

Model Number Description

BOSS-1000-X4 Bidirectional Optimizer for Storage Systems for 600 & 1000V PV
Systems
BOSS-1500-X4 Bidirectional Optimizer for Storage Systems for 1500 V Systems

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 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.
Use the Ground Lug shown in Figure 3 below on the BOSS to
ground the unit safely.

Figure 3: Ground Lug located on the BOSS Unit

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WARNING! A BATTERY CAN PRESENT A RISK OF ELECTRICAL SHOCK,

BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE OR
EXPLOSION FROM VENTED GASES. OBSERVE PROPER
PRECAUTIONS.

Figure 4: The graphic above indicates that the BOSS 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. Follow CSA
C22.1 when installed in Canada.

1. Before installing and using the BOSS, read all instructions presented in this manual and the
cautionary markings shown on the BOSS's enclosure.

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.

4. The metallic enclosure surface may become hot during certain operation circumstances.

5. The BOSS 600, 1000 and 1500 requires external fusing. This requirement is explained in
detail in Section 8.2 of this manual “Fusing for Input & Output Wiring”.

6. Test any wire or terminal for the voltage before touching them. Disconnect all input and
output terminals before performing any work on the equipment.

7. Use only accessories recommended or approved by the manufacturer.

8. Ensure that wiring is in good conditions and that all wiring is sized accordingly. Ignoring to do
so may result in a risk of fire.

9. PV modules produce electrical energy when exposed to light and thus can create an
electrical shock hazard. Wiring of the PV modules should only be performed by qualified
personnel.

10. Always have BOSS manual in hand.

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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 – a major shortcoming of solar and wind as sources of energy. With
ESS, solar power becomes available on demand, just the same as conventional generation
means such as coal and gas. Today, the majority of ESS deployed and being deployed utilize
Lithium Ion battery technology. The cost of batteries has significantly fallen in the past few years
while the need for energy storage capacity has increased due to the increased levels of
renewables on the Grid. These dynamics have made the case for ESS adoption very attractive.

Energy Storage Systems Challenges

Many megawatt-hours of alternative energy can be stored in large containers filled with Lithium
Ion batteries. Individual battery cells are assembled into modules, modules into racks (stacks)
and racks into containers. A large amount of energy is packed in one space and presents a
danger of a potential explosion if conditions of safe charge and discharge are violated or 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 terminals are connected together and all the negative terminals are
connected together then in the case of a short on one of the battery racks, the rest will rapidly
discharge their stored energy into a shorted component causing a huge current reaching tens of
thousands of amperes and risking an explosion. The isolation deterioration of the battery cells to
the grounded case is one of the major factors of fault in the battery rack that may cause fault
current.
State-of-Charge and State-of-Health
The capacity of lithium ion batteries to store and discharge electrical energy is measured in MWh
or KWh. The amount of releasable charge the battery contains at any given time relative to full
capacity of a battery is called State-of-Charge (SOC) and is measured in percentiles:

𝑆𝑂𝐶 = 100%

As batteries age over time as they experience a number of charge/discharge cycles. As such,
their capacity to hold charge diminishes. The degree of degradation of the battery measured as
a percentage of current full capacity to the initial rated capacity is called State-of-Health (SOH)
and is measured in percentiles:

𝑆𝑂𝐻 = 100%

To prevent overcharge of full discharge all battery racks should maintain the same SOC. This
means that charge/discharge current should be controlled according to their SOH.

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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). Each DC-DC converter
autonomously controls the charge and discharge current into a battery rack.

Galvanic Isolation
The main safety feature of the BOSS is the galvanic isolation incorporated in each DCDC. Due
to galvanic isolation each battery rack is isolated from the DC BUS, the common earth ground,
and from each other up to 2500 VDC potential. This means that in case of a fault in one rack,
the remainder stays completely isolated from the other racks preventing catastrophic fault
currents.

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Ground Leak Detection

Many installed PV systems are negatively grounded at the suggestion of the PV panel
manufacturer (though some PV panels do require positive grounding). Additionally, guidance
from the National Electrical Code (NEC) and certain AHJ rulings also encourage PV arrays to be
grounded, as opposed to being allowed to “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.

By continuously monitoring the system's differential voltage, BOSS ground-fault detectors can
provide early indication of ground faults before leakage becomes prominent. Galvanic isolation
of each battery rack allows each DCDC to measure the isolation resistance from a positive
battery terminal (BAT 1) and negative battery terminal (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.

Communication
The DC units communicate among themselves and with the ESS controller via an industry
standard MODBUS RTU protocol. (An optional MODBUS TCP-IP is available via PODD
communication controller). The ESS controller collects the SOC and SOH information from the
BMS associated with batteries in the racks as well the power information from the inverter and
DC Bus. Based on this information ESS controller assigns the magnitude of the charge or
discharge current to each DCDC. The purpose is to keep the same SOC on each rack
regardless of its SOH. This way all battery racks can be fully charged and discharged at the
same time, thus assuring full utilization of battery capacity.

Parallel Operation
Each DCDC is designed for a specific maximum current. If a battery rack requires more current
than a DCDC can provide, two or more DCDC may be paralleled. Each DCDC should be
provided with a separate fuse and disconnect. The ESS controller should be programmed to
recognize BOSS configuration.

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Figure 6: Parallel connection of DCDC - 2 DCDC’s connected to a single battery rack.

BOSS Operation
The BOSS is packaged in to a 19” rack mounted enclosure for use inside a battery container or
in an 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.

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 Controls
Each DCDC included in the BOSS has an independent Sic MOSFET full bridge power
inverter/rectifier on the DC BUS side and another Sic MOSFET full bridge power inverter/rectifier
on the Battery side. Both power bridges are linked by a deployment specific, high frequency
transformer. The transformer provides the galvanic isolation as well as mapping of the bus and
battery voltages.

Both power bridges are fully microcomputer controlled. The microcomputer also monitors the
bus voltage and the battery voltage.

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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:

 INITIALIZE
 STANDBY
 STARTUP
 BOOTLOADER
 RUN

These states are explained in greater detail in Table 3 of section 7.4 below.

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Technical Specifications

Model BOSS 1000 BOSS 1500

Number of DCDCs 4 4
DC Bus Specifications
Max DC Bus Voltage 1000 V DC 1500 V DC
Minimum DC Bus Voltage 200 V DC 200 V DC
Battery Voltage Specifications
Operation Voltage Range - Configurable 360 - 1000 360 - 1500
Individual DC-DC Power and Current Specifications
Max Current per DCDC @ 25 Deg C Ambient 19.2 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%
Standards & Compliance
Certifications UL1741, IEC 62109-1, CSA C22.2
Environmental
Storage Temperature -40°C to 60°C
Cooling Forced Air
Humidity 0-95%
Operating Ambient Temp. -40°C to 50°C
Form Factor
Packaging Rack or Rail Mounted, Outdoor Rated
Dimensional Limitations (H x W x D) Rack Mount: 7U - 8U x 19” x 27”/Rail
Mount: 24.8” x 16.5” x 10.6”
Aux Power 24 V Available
Weight Rack Mount: 53 KG/Rail Mount: 51 KG
Communications Modbus RTU Standard/TCP IP optional

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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
 Environment

BUS Protection
Protection caused by conditions on any DC-to-DC converter’s unit. The conditions parameters
are configurable and are stored in the nonvolatile microcomputer memory
Under voltage
The input voltage is too low for normal operation. BOSS enters into STANDBY mode.
Current Limit
Current magnitude is requested by the ESS controller. Current limit is set in the
configuration file and overrides the ESS request.
Short 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 operation. This may prevent upstream equipment
to operate below its designed limit. BOSS enters into STANDBY mode

Over current
Current magnitude is requested by the ESS controller. Current limit is set in the
configuration file and overrides the ESS request.

Short Circuit Protection

When in Discharge mode, Rapid shut down of the DC-to-DC converters unit in case of
external short.

Ground Leak Protection

The BOSS monitors leakage to ground and shuts down if excessive ground leakage
current is detected.

The Ground Leak Monitoring built into the BOSS is not a certified feature, therefore it
does not satisfy the GLDI requiremenets of the overall system. The system must have
an external GFDI device such as GARD (Alencon’s Ground Arc Rapid Disconnect) to
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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. Prevents our optimizer from
failure.
Microcomputer Temperature
Monitors the temperature on the Microcomputer. Prevents DC-to-DC converter from
failure.
Control Board Temperature
Monitors the temperature on the PCB. Prevents DC-to-DC converter from failure.
Humidity
Monitors the humidity inside sealed electronic compartment. Prevents DC-to-DC
converter from failure.

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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
 Cabinet
 Rail mounted Unit

8U Rack Mounted Unit Rail Mounted Unit

Cabinet Based Unit for Multiple BOSS units

Figure 7: Different form factors of the BOSS

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The most common form factor is the 8U rack mounted BOSS unit as shown below

Figure 8: 8U Rack-mounted BOSS UNIT

The unit has four cooling fans. Ensure that there is enough clearance for the fans to
have sufficient air flow. 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.
These are hardware elements that will have to be purchase separately from Alencon .

The basic external hardware provided to the customer is –

 4 AWG Single Wire Grounding Mechanical Lug
 Mounting Plate – if BOSS is going to be hung outside or on a Unistrut
 Termination Terminal Block – optional termination scheme
 H4/MC4 Solar Connectors – default termination scheme

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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.

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 power flow, please make sure that
input and output cables are connected to their commensurate terminal blocks. Any
interchange will cause a short and possible damage

H4/MC4 Termination:
The termination requires an H4/MC4 crimping tool to mate the connectors

Figure 9: H4/MC4 Crimping

Tool

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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.

Communication Ports
Each BOSS unit consists of 2 x RJ45, shielded Ethernet jacks. BOSS’s are generally co-
located and easily daisy chained to a PODD. The BOSS System architecture using a
Single PODD configuration is shown below –

Terminate with 120K

Figure 11: BOSS System Schematic with PODD
resistor between Rx +
& TX +

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Fusing for Input and Output Wiring

The BOSS input and output wires need to be fused as per BOSS specification. The fusing on the
input and output of the BOSS is critical for two reasons –
 Overcurrent Protection/Short Circuit Protection
 Safe Disconnect during Maintenance
 The recommended current rating of the fuses and disconnects is 1.5 times the rated
current of the BOSS per channel.
o For 20 Amp rated input use 20 x 1.5 = 30 Amp rated fuse and disconnect per
channel.

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 FEEDTM (Fused Electrical Disconnect), see Error! Reference source not found.,
provides a configurable add-on device to BOSS primary and secondary ports. Mounted directly
onto the BOSS unit, the FEED is used to add disconnects and over-current protection via fuses
to inputs and outputs connected to the BOSS. As well, FEED offers multiple input and output
connection options for varying BOSS applications.

See more about FEED options in FEED Manual.

Figure 12: Alencon BOSS with Fused Electrical Disconnect

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Alencon Communication Environment (ACE) Setup

The ACE is a communication system containing hardware, and software elements provided by
Alencon to control power conversion equipment.
 Hardware Element – PODD
 Software Element – HUB

PODD Installation
Installation Options
Single PODD
A single PODD is installed at one end of a daisy chained RS-422 network. The total length
of the RS-422 network should not exceed 100 meters. An antenna will be included for each
PODD if wireless package is purchased.

Multi PODD
The centralized PODD will be stand-alone and installed in a central location. The PODD is
powered through the 120VAC to 24VDC power supply and POE injector included in the Wi-
Fi access point kit. Each distributed PODD will be installed at one end of a daisy chained
RS-422 network using an STP CAT5e cable. 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 a Wi-Fi access
point will be used for the centralized PODD.

Installation Criteria
The following information should be considered when selecting the topology and the locations for
installation of PODDs:
 Field Size
 Application

Technical support will be provided when purchasing the ACE system to ensure the best PODD
configuration is selected for your application.

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. The attached hook shaped bracket allows for the PODD to be easily hung
on the unistrut and then fastened using a Hex head screw. More details on mounting the
PODD can be found in the PODD user manual.
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PODD Setup
PODDs are accessed remotely over your local server using IP addresses. For the initial
setup, download a network IP scanner of your choice. A recommended IP scanner is
Angry IP Scanner which can be downloaded from https://angryip.org/download/. Once
installed and opened, your local IP Range should automatically be set. Hit the start button
to scan your local network for 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 address of
that PODD and type the IP address followed by: 8888 (ex. 123.456.789.012:8888)
; 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.

For further information regarding PODD installation, mounting and wiring, please refer
Alencon’s PODD manual.

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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.

HUB Features
The HUB has 6 tabs –

 Alencon Devices
 Config Update
 Firmware Update
 Maintenance Changes made to these pages would
require Alencon Supervision/Training
 Factory test
 Settings

Alencon Devices Tab

The current version of the HUB provides DCDC information that can be accessed using the
commensurate GUID associated with the board. Each BOSS contains 4 DCDC’s each with a
separate GUID.

Figure 14: HUB Webpage

Device Commands

 Provides granular control of DCDC’s within a BOSS

 Commands can be sent to a single DCDC or the whole installation of BOSS units.

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 BOSS – Installation, Operation and Maintenance Manual

Device Target Selection

Select the DCDC/BOSS to command. The targets available are:

1. DCDC GUID’s: Send a command to the individual DCDCs within a BOSS

2. Field Broadcast: Broadcast the command to all the BOSSs in the list i.e. all the GUID’s
will receive the command

Figure 15: Different targets that can be selected

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 –

1. System Reset - Restarts the BOSS and enables Run if in the
Shutdown state.

Note: BOSS will not transition to start or soft pre-charge

without receiving the power direction and the current set
point

2. Shutdown – Disables power production. The BOSS or DCDC

must receive a System Reset command to enable Run.

3. Clear Fault - This command clears all error flags on the target
selected.

Note: It is not necessary to clear faults for the BOSS to

run.

Figure 16: Different Commands for

the BOSS

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4. Set BOSS Direction – This command will decide if the BOSS is going to RUN from BATT to
BUS or from BUS to BATT.

Note: BOSS Default Setup considers the BUS as input and BATT as Output

5. Current Set-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 customer would then have to re-define the Modbus
addresses of each DCDC using the “metadata” file available in the HUB 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.

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Config Tab

Figure 18: Configuration Tab

The Config Tab allows the user to update the configuration on the BOSS. BOSS configuration is
provided to the user in a .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.

Figure 19: Configuration factory file to be uploaded to BOSS

The BOSSs are selected by GUID (The BOSS LIN can be found the BOSSs tab). Configuration
can be sent to the whole field or a single DCDC:

 BOSSCOM and All DCDCs: Configures all

DCDCs and communication on the selected
BOSS

 BOSSCOM: Configures communication on the

selected BOSS

 DCDC 1 - 4: Configures the individual DCDC

on the selected BOSS

 All BOSSs (BOSSCOM and DCDCs):

Configures all DCDCs and communication in the Figure 20: Available DCDC targets
entire field

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 BOSS – Installation, Operation and Maintenance Manual

Steps to send a configuration file to the BOSS

Step 1: Choose the file you would like to send to the BOSS. This file has a ‘.factory’ extension.
Note: The factory file is a standard json object 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.

Figure 22: Configuration page upload steps

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

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 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.

Powering the BOSS

There are two ways to power ON the BOSS –
 24 V External Connector – panel mounted connector on the 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 large, the BOSS will function in either direction
without interruption. In the event, the Battery is allowed to discharge below the 200V limit; the
BOSS will turn OFF.

If voltage on the Battery is low, the customer will have to power the board via an external 24V
power supply. As soon as the Battery is charged to > 200V, the auxiliary will kick in and provide
the necessary current required to keep the board ON.

As soon as you power the BOSS ON, you can access the HUB using the PODD. The two files
necessary to ensure communication with the board is –
 metadata File
 Hub_Config File

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 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.

Each board will be in the shutdown state as soon it is powered on

Figure 25: Populated HUB page

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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. Bus 
BATT or BATT BUS. Applied voltage will show
up on the HUB in the commensurate field.

 When the BUS is the source, the

“Input_Voltage” header will display the
commensurate source voltage applied

 When the BATT is the source, the

“Output_Voltage” will display the
commensurate source voltage applied

Figure 26: HUB BOSS data

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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” Command –

Choose the appropriate direction
 Bus to Battery or
 Battery to Bus

Figure 28: Direction Command for

BOSS ONLY
“Current Set Point” Command –
This command sets the current required to be drawn from the source

Figure 29: Current Set-Point Command

Once the two parameters are set, the capacitors will begin to precharge at a rate set in
configuration.

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Reset Command –
This command puts the BOSS in startup allowing it to pre-
charge the capacitors connected on the output.

**Note: The BOSS will not pre-charge or startup without

providing the above two parameters.
Figure 30: Reset Command
After pre-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 to rise. This continues until
frequency limits are approached.

**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
this is the case you will have to manually swap input and output cables

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Testing the BOSS using a DC source and a DC Load

To test the BOSS using a DC source and load, power flow must be unidirectional, if source
cannot behave as a load. The default direction of flow is BUS to BATT with BUS connected
to the source while BATT connected to the load. If direction needs to be changed, connect
the 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. BUS side is connected to the DC source

Figure 33: Basic setup for testing the BOSS with a DC voltage source and a variable
voltage DC load. BATT side is connected to the DC source.

Please follow the below sequence of instructions to interact with the BOSS

 Read Alencon’s documentation.

o Establish communication the PODD – refer PODD setup instructions
 Power ON the BOSS – refer section 10.1
o Battery side Auxiliary
o 24 V External Power Supply
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 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

 Apply Input Voltage from the DC Source

 Set the voltage level on the variable voltage 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 current flowing at a specified set point.
 Make small changes to the voltage on the source to simulate DC Bus voltage
fluctuations. Observe the current of the BOSS and confirm that it follows the set
point.
 Make small changes to the voltage on the load to simulate battery charge and
discharge behavior. Observe the current of the BOSS and confirm that it follows
the set point.

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o Provide different current set point and observe the current flowing through the BOSS.
Confirm that the actual current follows the set point.
o Once the test is complete, shutdown the BOSS using the shutdown command.
o Discharge/Shutdown then disconnects the load.

Testing the Bi-directional Functionality of the BOSS Using a Single DC

Source
This test known as re-circulation allows the test personnel to use a single source to test the
BOSS in a bi-directional way. The test setup allows testing personnel to –
o Perform high power tests for long duration.
o Test how the BOSS follows the 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 side.
o 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.

BOSS
DC Voltage Source
BUS BATT
with a current limit
V

Comms
Figure 35: Basic setup for testing the BOSS in a bi-directional way.
Please follow the below sequence of instructions to interact with the BOSS

 Read Alencon’s documentation.

o Establish communication the PODD – refer PODD setup instructions

 Power ON the BOSS – refer section 10.1

o Battery side Auxiliary
o 24 V External Power Supply

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 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

 Apply Input Voltage from the DC Source
o Ensure input and 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 current flowing at a specified set point.
 Change the current set point and observe the actual current flowing at the
specified set point.
 Change the direction of the current and give a new current set point. Observe
the actual amount of current and its direction.
o Provide different current set points and observe the current flowing through the BOSS.
Ensure that the actual current follows the set point.
o Once the test is complete, shutdown the BOSS using the shutdown command.
o Turn off the DC Power Source.

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Testing the Charge-Discharge Functionality of the BOSS Using Battery

Racks

This test setup can be used to charge and discharge battery racks at a specific current set point.
As the current flows from the BUS to the BATT terminals the battery rack voltage on the BUS
side will decrease and the voltage of the battery rack on the BATT side will increase.

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

 Connect the batteries to the both sides of the BOSS shown in Figure 36.
o Ensure input and 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 current flowing at the specified set point.
 Change the current set point and observe the actual current flowing at the
specified set point.
 Change the direction of the current and give a new current set point. Observe
the actual amount of current and its direction.
o Observe the voltages on the both sides as the batteries’ state of charge change.
 The voltage of the battery which provides current will drop.
 The voltage of the battery which takes current will rise.
 As the voltages on both batteries change due to their state of charge, the
current through the BOSS will stay constant at a specified set point. Observe
the actual amount of current and confirm that it stays at the specified set point.
o Once test is complete, shutdown the BOSS using the shutdown command.
o Disconnect the batteries.

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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: [email protected] or call +1 (215) 816-3366

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