DC/DC GEN3

Hardware and Installation

Manual
 DC/DC GEN3

Hardware and Installation

Manual

Edition: September 2024 – DCDCG3HW01FI Rev. F

HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

ABOUT THIS MANUAL

PURPOSE
This manual contains important instructions for the installation, configuration and use of
the product DC/DC GEN3 manufactured by Power Electronics. From now on, the term
“product” will be used to refer to the DC/DC GEN3.
Power Electronics reserves the right to modify product features.

TARGET AUDIENCE
This manual is intended for qualified personnel who will install, configure and operate the
product DC/DC GEN3 manufactured by Power Electronics.
Only authorized technical personnel approved by Power Electronics may install and
commission the products. The instructions assume that the installer is familiar with
electrical installation rules and regulations.

NOTICE
WARRANTY DISCLAIMER
The manufacturer is not liable for damages, losses, costs or expenses incurred by any
user of the product if such damages, losses, costs or expenses result from a failure to
comply with the applicable safety instructions or general instructions or operating
instructions given by the manufacturer in any of the documents and manuals of the
product, including, but not limited to hardware installation, programming and operation,
maintenance instructions, handling, or any other. Any damages, losses, costs or
expenses resulting from the improper handling, manipulation, modification or operation
of the product will be subject to the company’s warranty terms.

POWER ELECTRONICS CONTACT INFORMATION

Power Electronics USA Inc. Power Electronics España, S.L.
1510 N. Hobson Street, Gilbert, Polígono Industrial Carrases
Phoenix Ronda del Camp d’Aviació nº 4
AZ 85233 46160, Llíria (Valencia)
UNITED STATES OF AMERICA ESPAÑA
US Sales: 602-354-4890 / (480) 519-5977 Telephone: (+34) 96 136 65 57
Website: www.power-electronics.com

2 ABOUT THIS MANUAL

HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

REVISIONS CONTROL
DATE (DD / MM / YYYY) REVISION DESCRIPTION
21/09/2023 A First version.
05/04/2024 B HW1.0 update:
Acronyms, safety instructions, torque and screw sizing,
technical characteristics and dimensions and weight are
updated.
Extra information on handling and transport, standard
storage and extended storage is included.
Information about wiring access and connection, protections
and LEDs and controls are completed and updated to the
hardware of the product.
Misprints correction.
07/05/2024 C Update of warranty disclaimer.
17/07/2024 D Update of acronyms.
A warning is included in the safety instructions by referring to
the maintenance manual. Update of technical
characteristics.
The wiring access and connection section and the protection
section are updated.
The distribution of the neutral and the short-circuit power
supported in AC and DC are indicated.
24/09/2024 E Safe stop and start-up section is removed.
Update of Technical Characteristics.
Optional LVRT kit is removed.
Add cabinets distribution section.
Extra information on handling and transport, standard
storage, extended storage is included and unpacking.
26/09/2024 F Update information in the PPCU user panel section.

The products and technical documentation are periodically updated. Power Electronics reserves the right to modify all or part of the
contents of this manual without previous notice. The reproduction or distribution of the present manual is strictly forbidden unless
express authorization from Power Electronics.

3 REVISIONS CONTROL
HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

TABLE OF CONTENTS

ABOUT THIS MANUAL .............................................................................................. 2

ACRONYMS .............................................................................................................. 6

SAFETY SYMBOLS ................................................................................................... 9

IMPORTANT SAFETY INSTRUCTIONS ..................................................................... 10

TORQUE AND SCREW SIZING.................................................................................. 18

1. INTRODUCTION ................................................................................................. 19

1.1. Cabinets distribution .................................................................................................... 20

2. TECHNICAL CHARACTERISTICS ........................................................................ 21

2.1. FREEMAQ DC/DC ......................................................................................................... 21

3. DIMENSIONS AND WEIGHT ................................................................................ 22

3.1. Dimensions and center of gravity ................................................................................. 22

3.2. Weight .......................................................................................................................... 22

4. HANDLING, TRANSPORTATION AND INSTALLATION .......................................... 23

4.1. Delivery and storage ..................................................................................................... 23

4.2. Handling and transportation ........................................................................................ 23
4.3. Standard storage .......................................................................................................... 25
4.4. Extended storage ......................................................................................................... 26
4.5. Foundation considerations ........................................................................................... 27
4.6. Cooling system............................................................................................................. 31
4.7. Clearances.................................................................................................................... 31
4.8. Unpacking .................................................................................................................... 34
4.9. Anchoring requirements ............................................................................................... 38

5. WIRING ACCESS AND CONNECTION................................................................... 41

5.1. Wiring access ............................................................................................................... 41

5.2. Ground connection ....................................................................................................... 44
5.3. DC connections ............................................................................................................ 45
5.4. Auxiliary connections and communications ................................................................ 56
5.5. Neutral distribution ....................................................................................................... 60

6. PROTECTIONS ................................................................................................... 61

6.1. Front panel ................................................................................................................... 61

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6.2. Power supply system panel (PSA) ............................................................................... 63

6.3. Control panel (PCL) ...................................................................................................... 64
6.4. Main customer panel (PPCU) ....................................................................................... 65
6.5. DC and AC short-circuit withstand rating ..................................................................... 65
6.6. User power supply protections ..................................................................................... 66

7. LEDS AND CONTROLS ........................................................................................ 67

7.1. LEDS and controls ........................................................................................................ 67

8. COMMISSIONING ............................................................................................... 69

5 TABLE OF CONTENTS
HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

ACRONYMS

The terms commonly used in the documentation of Power Electronics’ products of the
Solar & Storage division are listed in the table below.

ACRONYM MEANING

AASS Auxiliary Services.

AC Alternating Current.

AI Analogue Input.

AO Analogue Output.

BESS Battery Energy Storage System.

BMS Battery Manager Solution.

CP Control Pilot.

CPU Central Processing Unit.

dBA Weighted decibel level.

DC Direct Current.

DCL Discharge Current Limit.

DI Digital Input.

DSP Digital Signal Processor.

DO Digital Output.

EMS Energy Management System.

FPGA Programmable device (Field-Programmable Gate Array).

FRU Field Replaceable Unit.

GFDI Ground Fault Detector Interrupter.

GPRS General Packet Radio Services, a data transmission system.

HVAC Heating, Ventilation, and Air Conditioning.

IGBT Insulated Gate Bipolar Transistor.

IMI Insulation monitoring device.

IK Degree of protection against mechanical impact.

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ACRONYM MEANING

IP Degree of protection against solid/fluid objects.

Grid system where the power supply is kept isolated and the electrical
IT
equipment system is grounded.
Locking, tagging and verification procedure (Lock Out – Tag Out – Try
LOTOTO
Out).

LVR Low Voltage Regulation.

MCB Miniature Circuit Breaker.

MCCB Moulded Case Circuit Breaker.

MPCS Multi Power Conversion System.

MID Measuring Instrument Directive.

MV Medium Voltage. This term is used to refer to high voltage in general.

PE Ground connection (Protective Earth).

PI Proportional and Integral.

PLC Programmable Logic Controller.

POI Point Of Interconnection.

PowerComms Configuration and monitoring interface developed by Power Electronics.

PPE Personal Protection Equipment.

PV Photovoltaic energy.

RAL Color code (Reichsausschuß für Lieferbedingungen und Gütesicherung).

RCD Residual Current Device.

RCM Residual Current Monitor.

RFID Radio Frequency Identification.

SOC State Of Charge – referred to battery.

State Of Health – referred to battery. It compares the actual state of the

SOH
battery to its initial conditions. It is measured in percentage.

STO Safe Torque Off.

SW Software.

THD Total Harmonic Distortion.

Grid system where the power supply is grounded, and the electrical
TN equipment system is brought to the same ground through the neutral
connector.

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ACRONYM MEANING

Grid system where both the power supply and the electrical devices are
TT
connected to the ground via separate connections.

UPS Uninterruptible Power Supply.

Vac Alternating current voltage.

Vdc Direct current voltage.

8 ACRONYMS
HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

SAFETY SYMBOLS

Always follow safety instructions to prevent accidents and potential hazards from
occurring.
In this manual, safety messages are classified as follows:

Identifies potentially hazardous situations where dangerous

voltage may be present, which if not avoided, could result in
WARNING minor personal injury, serious injury or death.

Be extremely careful and follow the instructions to avoid the

risk of electrical shocks.
Identifies potentially hazardous situations, which if not
avoided, could result in product damage, or minor or moderate
CAUTION personal injury.

Read the message and follow the instructions carefully.

NOTICE Identifies important measures to take in order to prevent

damages to the product.

Other symbols used in this manual for safety messages are:

Hot surface. Be careful and follow the instructions to avoid burns and
personal injuries.

Risk of fire. Be careful and follow the instructions to prevent causing an

unintentional fire.

Caution, risk of electric shock. Energy storage timed discharge. Wait for
the indicated time to avoid electrical hazards.

Caution, risk of hearing damage. Wear hearing protection.

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IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for DC/DC GEN3 converters that shall be
followed during installation and maintenance of the DC/DC converter.
Read carefully all documentation before manipulating the product and pay special
attention to safety recommendations to maximize the performance of this product and to
ensure its safe use and installation.
It is the installer’s responsibility to follow the instructions provided on this manual, to
follow good electrical practices and to identify all mentioned warnings and
recommendations before starting up and operating the DC/DC converter.

WARNING

If the instructions on this manual are not followed, the DC/DC converter system may
present a SHOCK HAZARD. Read and retain the Hardware and Installation Manual for
future reference. Before installing the product, read all instructions and cautionary
markings. Failure to follow the safety instructions could result in severe shock or even
death. Exercise extreme caution always to prevent possible accidents.
Ensure the product is completely disconnected from the power supply and connected
to ground before manipulating it or performing any maintenance tasks. Otherwise,
electric shock hazard exists.
To prevent electrical hazards, disconnect input supply, connect the product to ground,
remove all control voltages before carrying out any task and ensure busbars are
completely discharged.
Warning and safety labels must be properly placed in terminals, enclosures and control
panels according to local normative in force.
In addition to the recommendations on this manual, local and site-specific safety
procedures must be considered regarding electrical installation, buildings, fire and
other regulations or network requirements applicable to the installation and / or
product. Also, national and local electrical codes must be followed in order to avoid
personal injuries and / or product damage.
Failure to comply safety instructions and electrical codes may void the warranty.
When working in electrical installations always remember to apply the FIVE GOLDEN
RULES:
1. Visible cutout of all sources in voltage.
2. Mechanical locking of all cutting elements.
3. Check the absence of voltage.
4. Ground and short-circuit all possible voltage sources.
5. 5. Define and mark the work area.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

CAUTION

The DC/DC operates at a high voltage (up to 1500 Vdc). Do not touch the DC input
terminals or cables. Touching the DC terminals may result in personal injury or death.
The system has sufficient energy to sustain an arc flash. Always wear PPE while
maintaining product that is exposed and energized. Always follow proper LOTOTO
procedures. Adhere always to local site regulations. Operating or maintaining
energized product without appropriate PPE and insulated tools and without following
proper LOTOTO procedures may result in personal injury or death.
Regarding the handling and transport of the product, read the instructions carefully.
Failure to comply with any of the instructions may result in damage to the product or
serious injury to persons.
The relevant work safety regulations must be followed. Never position yourself
underneath the product to work, or in a radius that could allow the load to fall on the
operator.
Sudden movements must be avoided. When unloading the product, pause before
placing it on the ground and lower it slowly until it is fully supported, avoiding bumps.
The instructions in this manual do not replace or supersede local or national
regulations. It is the responsibility of the user to comply with all occupational safety
standards (risk assessment and work procedures) that apply at the installation site.
Possible risk of tipping over. Take precautions to avoid this.
Power Electronics assumes no liability for damage resulting from improper use of the
product or failure to comply with local or national regulations.

11 IMPORTANT SAFETY INSTRUCTIONS

HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

WARNING

Once LOTOTO procedures are complete, ensure batteries and AC are also cut off
before making any actions on the DC/DC converter. There could be hazardous
voltages present in the busbars and you may get an electric shock.
Do not remove the protective polycarbonates except for periodic inspections or
wiring, even if the input power is not applied.
Otherwise, you could make contact with the charged circuits and get an electric shock.
Do not connect any supply to the product while the doors are open.
Otherwise, you could get an electric shock.
Do not apply power to a damaged converter with missing parts even if the installation
is complete.
Otherwise, you could get an electric shock.
Keep all doors closed during product operation.
Otherwise, you could get an electric shock
Do not open the doors except for periodic inspections or wiring, even if the input
power is not applied. Otherwise, you could contact the charged circuits and get an
electric shock.
Always operate switches with dry hands and use personal protective product (PPE).
Otherwise, you could get an electric shock.
Any tasks performed in the product must be carried out with, at least, two operators.
The DC/DC Converter should never be operated by a single operator.
Do not use cables with damaged insulation. Do not subject the cables to abrasions,
excessive stress, heavy loads or pinching. Otherwise, you could get an electric shock.
Ensure compliance of all safety regulations for medium voltage operations that are
in force at the place where the DC/DC converter is installed. Otherwise, you could get
an electric shock.
In case the product stops due to a power loss, do not perform any works on it.
Automatic restart function might be enabled, and you could get an electric shock.
Always follow proper lockout / tagout procedures. For further information, refer to the
Maintenance Manual.

The device contains capacitors. The discharge time of the

capacitors is 5 minutes. Wait until the capacitors have been
5 min
discharged before carrying out any maintenance task.

Work at heights shall be carried out under the appropriate safety conditions and
product and always in accordance with the regulations of the country where the
operation is carried out.
In the cabinets where high voltage is present, the installer must add a warning signal
“DANGER – HIGH VOLTAGE”.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

NOTICE

SAFETY
− Before operating the DC/DC, read this manual thoroughly to gain an
understanding of the product. If there are any doubts, please contact Power
Electronics.
− Handle the DC/DC with care according to its weight.
− Install the DC/DC according to the instructions within this manual.
− Do not place heavy objects on the DC/DC.
− Ensure that the mounting orientation is correct.
− Do not drop the DC/DC or subject it to impact.
− The Freemaq converters contain static sensitive printed circuits boards. Use
static safety procedures when handling these boards.
− Avoid installing the DC/DC in conditions that differ from those described in the
Technical Characteristics section of this manual.
− The cabinet doors should only be opened for commissioning, maintenance,
troubleshooting, data query and parameter setting.
− The product is equipped with several fans for cooling. To perform any work on
the fans, switch off the product as explained in the correspondent section. This
procedure should be taken into account during commissioning, maintenance and
repair work.
− The product may create significant levels of operating noise. In addition, a fault
in the product can lead to very high sound levels. Power Electronics recommends
the use of ear protection while in the vicinity of the product for extended periods.
− Immediately after isolating the product, certain components can be very hot (i.e.,
fuses, transformer core, sine wave filter, heatsinks, etc.). Safety gloves should
always be worn when working near components that can be expected to be very
hot. Power Electronics recommends using personal protection equipment (PPE)
during all work on the DC/DC.
Consult LOTOTO procedure in the Safety Instructions for Operating, Troubleshooting and
Maintenance Manual.
The intervals and tasks required within the preventive maintenance plan of the product
are described in the relevant documentation. Please refer to the Maintenance Manual
of the product for further information.
This unit is not provided with a GFDI device. The inverter or charge controller must be
used with an external GFDI device as required by the Article 690 of the National
Electrical Code for the installation location.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

NOTICE

TRIAL RUN
Verify all parameters before operating the DC/DC.
Always apply voltage and current signals to each terminal that are within levels indicated
in this manual. Otherwise, it may result in damage to the DC/DC.
OPERATION PRECAUTIONS
Do not modify or alter anything within the DC/DC.
CYBER SECURITY DISCLAIMER
This product is designed to be connected to and to communicate information and data
via a network interface. The user is the sole responsible for providing and continuously
ensuring a secure connection between the product and user network or any other
network (as the case may be). User shall establish and maintain any appropriate
measures (such as but not limited to the installation of firewalls, application of
authentication measures, encryption of data, installation of antivirus programs, etc.) to
protect the product, the network, its system and the interface against any kind of security
breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or
information.
Power Electronics and its affiliates are not liable for damages and/or losses related to
such security breaches, any unauthorized access, interference, intrusion, leakage and/or
theft of data or information.

CAUTION

Install the product on a solid and levelled surface. Follow the recommendations on
how to build the foundation. Otherwise, there is a risk of malfunction and even
permanent damage.
Disconnect the input power in case the DC/DC converter gets damaged.
Otherwise, it could result in a secondary accident or a fire.
Do not allow lint, paper, wood chips, dust, metallic chips or other foreign
matter into the DC/DC Converter. Otherwise, a fire or an accident could
occur.
After the input power is applied or removed, the DC/DC converter will
remain hot for a few minutes. Touching internal hot parts could result in
skin burns.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

NOTICE

RECYCLING
Product packaging must be recycled. Separate all different materials (plastic,
paper, cardboard, wood…) and place them in the corresponding containers.
Ensure waste collection is properly managed with a Non-Hazardous Waste
Agent.
To guarantee health and natural environmental sources protection,
the European Union has adopted the WEEE directive concerning
discarded electric and electronic product (SEEA).
Waste of electrical and electronic product (WEEE) must be
collected selectively for proper environmental management.
Our products contain electronic cards, capacitors and other
electronic devices that should be separated when they are no longer
functional. These WEEEs should be managed accordingly with a
Hazardous Waste Agent.
Power Electronics promotes good environmental practices and recommends that all
its products sold outside of the European Union, once they reach the end of their life,
are separated and the WEEE managed according to the particular country applicable
legislation (especially electronic cards, capacitors and other electronic devices).

REQUIRED PERSONAL PROTECTION EQUIPMENT (PPE FROM NOW ON)

PPE is required according to standards for repairing and maintaining Freesun inverters.
Always Follow the site operative instructions to fulfil the compliance of national or local
normative.
In case of actions with voltage presence, it is compulsory to use an Arc Flash Safety Kit
(gloves, clothes and face shield).
A detailed example of PPE used will be shown below. User must specify in his safety
instructions (risk assessment and method statements) which are the PPE required and
when and how they should be used according to his electric arc studies, the
characteristics of site, inverters, installation and country.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

Power Electronics accepts no responsibility or liability for any damages resulting from
inappropriate use of the product or failure to comply national or local normative.
The following table includes just an example of commonly used PPE description. Always
follow local regulations / NFPA-70E standard about Safety and Health.

ÍTEM DESCRIPTION
Safety glasses Eye protection according EN 166.
Electric gloves Gloves with mechanical, dielectric and against
arc flash.
Class according to voltage.
EN 60903; ASTM D120 specifications and NFPA
70E standards.
Safety footwear S3 class complying with BS EN ISO 20345.
Insulation carpet Isolation carpet according to IEC 61111
Class according to voltage.
Safety kit arc flash Arc flash personal protective equipment kit
(including arc flash protective face shield & hard
hat), fire resistant 40 cal/cm2.
Lock Out / Tag Out elements Padlock and auxiliary elements set to lock out
set dangerous product.
HI-VIS vest Fr VIS vest 9 cal/cm2.

PPE FOR INSTALLATION

Mechanical
Safety boots Safety helmet Safety glasses
gloves
Additional PPE for commissioning and maintenance tasks

Safety clothes according to NFPA-70E and safety labels

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

The following table shows the protection class type, depending on the working voltage

ELECTRICAL INSULATED GLOVES

Clase AC (VAC) DC (VDC)
00 500 750
0 1000 1500
1 7500 11250
2 17000 25500
3 26500 39750
4 36000 54000

ELECTRICAL SAFETY MATTING

Clase AC (VAC) DC (VDC)
0 1000 1500
1 7500 11250
2 17000 25500
3 26500 39750
4 36000 54000

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

TORQUE AND SCREW SIZING

The following table shows the torque for both mechanical and electrical connections,
applicable to all cabinets [1, 2]:
SCREW SIZE TORQUE
Metric English ISO 8.8 QUALITY[a]
(mm) (in.) (Nm) (lb-ft)
M3 1/8 1,3 0.95
M4 5/32 3 2.21
M5 3/16 6 4.42
M6 1/4 8 5.9
M8 5/16 20 14.75
M10 7/16 40 29.5
M12 1/2 60 44.25
M14 9/16 120 88.5
M16 5/8 210 154.89

[a] For other qualities, follow the screw’s manufacturer guidelines.

NOTICE
Criteria for the use of the tightening torque:
1. Whenever a metric is indicated in any step, the applicable tightening torque will be
the one indicated in the general table unless another one is expressly indicated in
that step.
2. If no torque is indicated during the step, this means that the user must look at the
general table and use the torque indicated in the table for each bolt size.
3. When the screw or fastening means does not require torque, or can be fastened
by hand, it shall be expressly indicated.

1
Power Electronics recommends the use of Zinc Steel quality 8.8 bolts for internal connections
in general, DC and earth connections included.
2
Power Electronics recommends the use of A2-70 stainless bolts for external connections in
general, AC connections included.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

1. INTRODUCTION
Following the Power Electronics philosophy, the Freemaq DC/DC GEN3 is a modular
outdoor solution available from 1000kW to 1200kW, fully compatible with different battery
technologies and manufacturers, with a voltage range up to 1500Vdc and the highest
efficiency in the market. This product has been designed to be easily integrated with a
Freesun inverter in new or already installed PV power plants, being the most cost-
competitive solution for battery storage systems paired with PV installations.
By coupling the Power Electronics Freemaq DC/DC GEN3 converter with a Freesun solar
inverter, it is possible to perform functions such as: energy shifting, ramp control rate,
frequency response, and most importantly, clipping energy recovery, that will boost user
revenues.

DC/DC GEN3

19 INTRODUCTION
HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

1.1. Cabinets distribution

The following picture shows the standard cabinet layout of Freemaq DC/DC GEN3:

DC/DC GEN3 cabinets

REF. CABINET DETAIL

Control panel access cabinet and DC cable
1 Main cabinet
connection.
Access door to communication connections,
2 Cable cabinet interconnections with the inverter, DC auxiliary
power supply.
3 Power stage cabinet Access door to the power and ventilation stages.
4 Inductance cabinet Inductance access door.

20 INTRODUCTION
HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

2. TECHNICAL CHARACTERISTICS

2.1. FREEMAQ DC/DC

REFERENCES FD1200
DC Rated Power (kW) @ 30 ºC 1200
DC Rated Power (kW) @ 40 ºC 1120
DC Rated Power (kW) @ 50 ºC 1040
Max. DC Output Current (A) @ 30 °C 1200
Max. DC Output Current (A) @ 40 ºC 1120
Max. DC Output Current (A) @ 50 °C 1040
DC INPUT & DC PV Voltage Range (Vdc) [1] 850 – 1500
OUTPUT DC BESS Voltage Range (Vdc) [1] 850 – 1500
Maximum DC PV Input Voltage (Vdc) 1500
DC Voltage Ripple <3%
Max. DC Short Circuit Current PV (kA) 14
Max. DC Short Circuit Current BESS (kA) 250 kA with a time constant of 3ms
Compatible with all battery
Battery Technology
technologies
EFFICIENCY Efficiency (Max) 98,9 % (preliminary)
Dimensions [WxDxH] (ft) 3.94 x 5.9 x 7.56
Dimensions [WxDxH] (m) 1,20 x 1,80 x 2,30
CABINET
Cooling Forced air
Enclosure Protection Degree NEMA 3R / IP54
CONNECTIONS Number of PV connections 4 negative / 4 positive
-25ºC to +60ºC, >50ºC / Active
Operating temperature Range [2]
Power derating
Storage temperature rating -40ºC to +60ºC (-40ºF to +140ºF).
ENVIRONMENT Relative Humidity From 4% to 100% non-condensing
Max. Altitude (above sea level) 4000m (>2000m power derating)
Location Suitable for wet locations
Pollution degree Type III
Emergency stop pushbutton and
CONTROL Interfaces
indicator lights
INTERFACE
Communications Protocol Modbus TCP
Inverter side [3] Motorized DC disconnect switch
Motorized DC disconnect switch
BESS side [4]
and ultra-fast fuses
PROTECTIONS
Overvoltage category II
Surge Protection Device (SPD) -
Overvoltage protection
Type I+II
CERTIFICATIONS Safety UL1741, IEC 62109

Notes:
[1] Consult Power Electronics for derating curves.
[2] Consult Power Electronics for temperatures below -25ºC.
[3] In case of augmentation application, ultra-fast fuses are included on the inverter side.
[4] Battery short circuit disconnection must be done on the battery side.

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

3. DIMENSIONS AND WEIGHT

3.1. Dimensions and center of gravity

The following image shows the dimensions and center of gravity of DC/DC GEN3
converters.

DC/DC GEN3 dimensions

GENERAL DIMENSIONS
A B C D E F G H I J K
mm 1200 1408 2306 2285 2266 1833 1334,9 369 96 369 155
in. 47.24 55.43 90.79 89.96 89.21 72.16 52.55 14.52 3.78 14.52 6.10

GENERAL DIMENSIONS
L M N O P Q
mm 340 132 760 100 141 924
in. 13.38 5.2 29.92 3.94 5.55 36.38

GENERAL DIMENSIONS
x y z
mm 616,5 814 600
in. 24.27 32.05 23.62

3.2. Weight
Total weight of the product is approximately 1850kg (4078.55lb).

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HW AND INSTALLATION MANUAL – DC/DC GEN3 POWER ELECTRONICS

4. HANDLING, TRANSPORTATION AND

INSTALLATION

4.1. Delivery and storage

Power Electronics’ DC/DC Converter are carefully tested and packed for shipment. In
the event of damage to the unit during transportation, notify the transport agency and
Power Electronics (International +34 96 136 65 57, US +1-415-874-3668), or your nearest
agent, within 24 hours from receipt of the goods.

Make sure the model and serial number of the DC/DC Converter match the information
on the delivery packing list.

The DC/DC Converter should be stored in a location that is protected from direct sun
and moisture excess. The storage temperature rating for the DC/DC Converter is -40ºC
to +60ºC (-40ºF to +140ºF).

4.2. Handling and transportation

The instructions to be followed during handling and transport of the product are
indicated throughout this section. The use of any other method of handling not
described in this document may damage the product. The transport and handling
requirements for the product are as follows.

1. During transport and handling, the product must not be exposed to moisture, placed
upside down, tilted or damaged.

2. The product may only be transported and protected in its packaging.

3. The lifting angle, for products that require lifting by machinery, must be less than 90º.

4. Avoid sudden movements and jolts during lifting. When unloading the product, define
its location and lower it slowly until it is completely supported. Avoid knocks.

5. The lifting elements selected must be in accordance with the lifting system of each
piece of product. For the selection of loading/processing tools and machinery,
consult the technical standards of reference for loads as an indispensable technical
criterion in the determination of safety procedures and processes.

6. Guarantee the stability of the product in the movement operations.

7. Loading and/or unloading must be carried out in accordance with the lifting plan in
accordance with the occupational safety standards applicable at the place of
installation, considering the health and safety measures, as well as assessing the
necessary auxiliary means in accordance with the regulations in force in that country.

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8. Prior to unloading operations, ensure the optimum conditions of any element

involved in this process. In the event of identifying any type of damage, defect or
problem in the lifting elements, as well as their accessories, these must be replaced
by similar or equivalent ones in accordance with the regulations in force in each
country. Do not use damaged or defective slings.

9. Power Electronics does not provide additional material for the transport and handling
of the product.

The location of the anchorage points of the lifting gear (M16 rotating eyebolts) to the
converter is shown in the following picture:

DC/DC GEN3 anchorage points

A B C
mm 1126 2300 1639
in. 44.33 90.55 64.53

The product has a self-supporting steel base with access (marked in red in the picture)
for lifting machinery such as a pallet truck or forklift truck. The weight, load distribution
and centre of gravity must be taken into account, in accordance with account the
occupational safety standards applicable at the installation site, as well as health and
safety measures. The necessary aids must also be assessed in accordance with the
regulations in force in that country.

To lift the converter, use a lifting system according to the applicable occupational safety
standards and health and safety measures at the installation site. The following image
shows an example of the lifting of the product hooked to its four eyes at the top:

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DC/DC GEN3 lifting

CAUTION

Possible risk of tipping over. Take precautions to avoid this.

Do not remove the lifting elements until it is secured that the product is correctly
installed and fixed in its final location.

Under no circumstances should the operator position himself under the product or
within a radius where the load can fall. Maintain a distance radius proportional in 1.5
m to the height of the equipment.

4.3. Standard storage

Standard storage is defined as the expected period of time from the time the product
arrives at its location until its commissioning occurs. It is assumed that this period is
less than 6 months. This period is variable according to the weather conditions of the
site. The storage temperature and humidity range of the product is indicated in section
“Technical characteristics”.

User is responsible of deciding if the DC/DC converter is installed within the standard
period or otherwise, the installation date is to be defined. In this case, user must take
the appropriate measures.

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If it is necessary to store the product, keep it in its original packaging, indoor and under
cover. Follow the points below to ensure correct condition and installation.

• The storage must be indoors and under cover, in a place protected against
harmful elements such as animals, excessive humidity, exposure to extreme
temperatures, direct exposure to sunlight, contact with chemicals and
corrosive gases, among others.

• Store the product on a flat, level surface. Never rest the product on wooden
beams.

• Store the product away from walkways where it may be damaged.

• Store the product away from flood zones, as no part of the equipment should
be submerged.

• Keep the product covered during storage.

• Keep the product packed until the moment of installation.

4.4. Extended storage

If the product is stored for a prolonged period of time (3 months or more), further
considerations must be considered, in addition to the recommendations listed in the
previous section.

• The product should be protected indoor, by an external protector or by a method

adapted to local conditions that prevents condensation and humidity inside the
product.

• Consult Power Electronics for the need to include corrosion inhibition and
protection systems inside the product to prevent moisture damage to the
electronic components, depending on the particular conditions of each case.

• Clearance must be provided around the product for inspection purposes.

• If periodic inspections of the product are necessary, access to the interior of the
product for such inspections must be arranged with Power Electronics.

The above recommendations are standard and are not applicable to all weather
conditions. In extreme weather conditions, these requirements should be adjusted on a
case-by-case basis, as well as the maximum storage time for these conditions. Consult
with Power Electronis about the applicable protection, packaging and inspection
measures that are particular to each case.

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4.5. Foundation considerations

NOTICE
The instructions on this section do not replace the internal regulations of each
country.
Prior to installation, a geotechnical study of the terrain where the DC/DC Converter
will be installed must be carried out, in order to determine its characteristics and
decide the most suitable type of foundation.
It is the responsibility of the user to design and build the foundation.

4.5.1. Soil
The soil should have the following characteristics:
• It must be dry, compacted, stable and homogeneous.

• It must be gravel, ballast or pebble.

• It must have hard or medium harshness characteristics.

• The calculation of the maximum permissible pressure on the ground must

comply with local and national standards, as well as with any other requirements
regarding natural disasters (hurricanes, earthquakes, etc.) that may apply to the
place of installation.

• Do not install on floodable grounds.

• The soil must be provided with drainage systems, especially in high water table
and / or heavy precipitation sites.

• It is recommended that the ground does not exceed the level of the foundation.

• The minimum soil compaction degree is 98 %.

• Maximum slope is 0,25 %.

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4.5.2. Concrete slab

A layer of lean concrete can be laid between the slab and the ground. The slab must
comply with the following characteristics:
• Dimensioning must be appropriate to the weight of the product.

• It must have trenches wide enough to guarantee proper cable passing.

• The slab must comply with minimum working clearance around the product for
its safe and correct operation. These clearances are shown below.

• Thick enough to support the product and avoiding floodable foundations.

The following figure shows the DC/DC converter once placed in the foundation slab.
Please notice this foundation is only for DC/DC converter.

DC/DC GEN3 foundation

REF. DESCRIPTION
1 Soil.
2 Lean concrete.
3 Foundation slab.
4 Trenches for cable access.

To guarantee proper cable access and battery connection – for those connections
that enter from the bottom – the slab must have a trench (number 4 in the figure
above). This trench must be drilled by the user.

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CAUTION

For proper electrical installation, it is very important to meet the cable curvature radius.
For this purpose, the dimensions of the trench must be calculated by the user taking
into account the characteristics of the selected cable, this choice being the user's
responsibility. For a correct selection of wires consult section “Wiring access and
connection”.
The user must consider that it is recommended that the cables enter the product
perpendicularly and must verify that the separation between them is adequate. The
connection terminals should not be over-tightened.
All cable openings on the concrete slab must be adequately covered to avoid creating
a fall or trip hazard.

The following figure (footprint view) shows the size of the bottom plate, which are
necessary to determine the dimensions for the trench, in mm and inches.

DC/DC GEN3 bottom plate

A B C D E F G H I J K
mm 1200 1085 57,5 1833 141 340 132 760 924 1085 100
in. 47.24 42.72 2.26 72.17 5.55 13.39 5.2 29.92 36.38 42.72 3.94

L M Ø
mm 18,5 1763 17
in. 0.73 69.41 0.67

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In case there is any specification regarding variable actions such as snow, wind or
earthquake, the slab must also meet the following requirements:
• Ability to withstand compressive forces of 25 N/mm2.

• Steel frame with capacity to withstand traction forces of 500 N/mm2.

• Considering severe wind conditions (greater than 60 m/s) dimensions would be:

o The longitudinal side of the frame must be able to withstand forces up to

80 kN.

o The transverse side of the frame must be able to withstand forces up to

10 kN.

Please notice that thickness of the slab must be determined based on the results of
the geotechnical study.

4.5.3. Pillars
In case of installing the product on pillars, the converter is verified for moderate and
high seismic zone (according to IEEE693), as long as the product is anchored with the
high-strength expansion bolts.
The minimum footprint of the structure that must be on pillars is the one shown in the
following picture (grey zone).

DC/DC GEN3 footprint

For further details about the anchorage dimensions, see section “Anchoring
requirements”.

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4.6. Cooling system

The product has two air inlets located at the top and one outlet at the bottom.

DC/DC GEN3 air inlets

4.7. Clearances

CAUTION

Observe all minimum clearance requirements for electrical code, thermal and safety
requirements. Refer to NEC 110.34 for additional clearance requirements for product
above 600 Volts.

The product is designed with thermal insulated cabinet doors to ensure the optimum
outdoor performance. For an adequate inspection, cooling, operation and heavy vehicles
with crane passing, it is important to leave a walkway around the product. The following
figure shows the recommended clearances.

DC/DC GEN3 clearances

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A B
m 2 1
ft 6.56 3.28

In case of installing several DCDC GEN3, there should be a separation between them to
allow a proper operation and heavy vehicles with crane passing. The minimum distance
with outlets facing each other must be greater than or equal to C = 4m (13,12ft).

There is no minimum lateral distance required between product being up to four. The
following figures shows the recommended clearances.

NOTICE

The inverter supports up to a maximum of 4 connected product.

Distances between DC/DC GEN3

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When inverters and DCDCs are installed with air outlets facing each other, the distance
between them must be D = 6m (19.67ft) in front or E = 3m (9.8ft) on the sides to ensure
optimum cooling system performance. The following figures show the product footprint
view with the minimum distances.

Distances between equipments

D E
m 6 3
ft 19.67 9.8

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4.8. Unpacking
During unpacking, carefully remove the packaging (do not use sharp tools). Once the
packaging has been removed, check the materials inside. If it is received spare parts
with the product, separate them and store them in a safe place.

The unpacking steps are as follows:

1. In case of air transport, the equipment is fixed on a pallet. Unscrew and remove
all set of M10 nuts and screws that fixing the equipment to the lower pallet feet on
both sides.

Follow the recommendations indicated in “Handling and transportation” section to

lift and position the equipment on a flat and level floor surface for continue
unpacking.
1.

2. Remove the adjustable film from the 3. Remove the U-shaped cardboard
contour of the product. corner pieces located on the short
sides of the product.

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4. In case of maritime transport, remove the corrosion protection bag (VCI) from the
product.

5. Carefully remove the adjustable film that wraps around the filter located in the
upper grids of the equipment. Do not use sharp tools that could damage the filter.
Return the filter to its original position.

Once unpacked, user must install the ventilation visors, anchor profiles, polycarbonates,
and the transport eyebolts. These elements are packed and stored inside the product.

NOTICE

Waste disposal is user's responsibility, and it is not within Power Electronics' scope.
The polycabonates are installed at the same time as the converter is wired, so keep
them in a safe place until wiring. For more information, see the "DC power connections"
section.

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4.8.1. Ventilation visors

Qualified personnel must install the two visors with anti-insects grids in the ventilation
grids of the product. This material is delivered inside the product to avoid damages
during transport. The visors and anti-insects grids must be installed on the air inlets,
one at the front and one at the back of the product using six M6 screws.

DC/DC GEN3 visors

4.8.2. Anchor profiles

Qualified personnel must install the two anchoring profiles of the product to the floor.
This material is delivered inside the product to avoid damages during transport. The
anchoring profiles must be installed on the lower front and back part of the product
using four M8 screws. The following picture show the anchor profiles.
In case of air transport, they are not included as they are used to fix the equipment to
the pallet which facilitates its transport.

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DC/DC GEN3 anchor profiles

4.8.3. Transport eyebolts

In order to be transported, the product is sent to the field with the lifting eyebolts in
place. During the installation of the product in the field, it is necessary to replace the
four M16 rotating eyebolts of the upper side of the equipment by the screws that will
be packed inside the product. This replacement is the responsibility of the qualified
personnel assigned to this task.
The images below show the location of the eyebolts and replacement screws.

DC/DC GEN3 transport eyebolts

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4.8.4. Protective elements: VCI foams

The product is fitted with corrosion protection foams (250x250mm). These must be
removed, as a last resort, before commissioning the converter. The location of the
foams is as follows:

ZONE QUANTITY
A 1
B 2

DC/DC GEN3 VCI foams

4.9. Anchoring requirements

NOTICE

It is recommended to drill the anchorage holes before placing the converter in its
final location.
Anchoring must always be done with screws. They should not be welded to prevent
corrosion problems and, specially, power electronics problems. Any other anchoring
system different from the one mentioned on this manual is not allowed and, in that
case, the warranty will be voided.

The location and dimensions of the anchor (footprint view) are shown below.

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DC/DC GEN3 dimensions of the anchor

A B C D E F
mm 57,5 1085 1763 18,5 141 17
in. 2.26 42.72 69.41 0.73 5.55 0.67

In case of moderate and high seismic zone, the minimum area that must be in contact
with the ground is as follows. All loads indicated are exclusively relative to the weight of
the product.

DC/DC GEN3 loads of the anchor

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DIMENSIONS MINIMUM AREA IN CONTAC

REACTIONS OF ANCHOR POINTS
WITH THE GROUND (GREY AREA)
A B C D E F G H
mm 115 970 150 1533 kN 5,01 5,38 3,96 5,09
in. 4.5 38.2 5.9 60.4 lbf 1126.29 1209.47 890.24 1144.28

To anchor the product in concrete slab, it is recommended to use M16 (5/8”) A4-70
stainless screws for high load solicitations, being accepted both expansive anchor bolts
and chemical.

In the case of anchoring the product to a metal structure, the use of M16 (5/8") A4-70
stainless screws is recommended.

In case of installing the product on pillars, it is recommended to use M16 (5/8”) high
load expansive anchor bolts, made of stainless steel A4-70 or high corrosion resistant
steel. The tightening torque is 110 Nm.

Please, secure them applying the recommended torque for mechanical connections
(see section “Torque and screw sizing”).

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5. WIRING ACCESS AND CONNECTION

5.1. Wiring access

The following figure (bottom view) shows the location of DC and auxiliary accesses for
DC/DC converter.

DC/DC GEN3 wiring access

A B C D E F G H I J
mm 340 132 760 100 141 924 369 96 155 369
in. 13.38 5.2 29.92 3.94 5.55 36.38 14.53 3.78 6.10 14.53

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DC Power, auxiliary power and communication cables must be connected by the user.
The access can be either through the lower or laterals gland plates. All cable must entry
through the cable gland.

CAUTION

For a correct electrical installation, it is very important to respect the bending radius
of the cable. It is essential that the trenches are deep enough. It is recommended that
the cables enter straight, and that the bending radius is outside the product so as not
to force the connection terminals.

In case the curvature radius is inside the product, it is necessary to consider that the
wire bending space is 579 mm.

The removable gland plates are NOT pre-drilled or pre-marked. The user is
responsible to install the proper knockouts and watertight fittings in the gland plates
before inserting the cables. Once this step is done, it is important to check again the
tightness of the product to avoid dirt and humidity problems. See the images of the
table below for a correct installation.

CORRECT INSTALLATION INCORRECT INSTALLATION

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CORRECT INSTALLATION INCORRECT INSTALLATION

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5.2. Ground connection

The product has a common ground to which the user must connect the ground busbar
located in the cable cabinet. The following images show the location of the ground
busbar:

DC/DC GEN3 ground connection

A
mm 13
ft. 0.51

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The ground plate has 13 through holes of diameter 13 mm (0.51 in.) as shown in the
following image.

DC/DC GEN3 ground plate

NOTICE

This unit is not provided with a GFDI device. The inverter or charge controller must
be used with an external GFDI device as required by the Article 690 of the National
Electrical Code for the installation location.

5.3. DC connections
Before connecting the power cables to the input terminals, the following assembly
sequence of the different elements that affect the cable cabinet must be followed:

• Connection of the DC+ / DC- power cables.

• Installation of polycarbonates.

The power connections must be carried out in conjunction with the installation of
polycabonates as they are installed between the different polarities of the cable cabinet
connection plates.

It is necessary to consider their location before wiring the product. See the section
"Installation of polycarbonates" for more information.

NOTICE

Follow the National Electrical Code, ANSI/NFPA 70 wiring instructions.

The compression lugs shall be sized to accommodate the minimum wire sizes as
required per the National Electrical Code ANSI/NFPA 70.

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To reduce the risk of fire, connect only to a circuit provided the maximum current
established by the branch circuit overcurrent protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

WARNING

The DC/DC converter is designed for use in floating or grounded PV installations.

Consult the BESS manufacturer in order to know if the batteries are compatible with
either floating or grounded PV installations.
Paralleled conductors (DC input, neutral (if used), grounded circuit conductor, product
grounding conductor, or product bonding jumper) shall comply with all the following:
• Cables must be the same length.
• Cables must be used with the same material.
• Cables must be the same size in terms of circular mil area.
• Cables must have the same insulation type.
• Cables must be terminated in the same manner.

The power cables, both those coming from the BESS system and those going to the PV
inverter, will be connected to the plates on the front of the product. The cable entry can
be done from the lower part or from the side through the covers provided for this
purpose, as shown in the following picture. The product must be made watertight again
to avoid problems of dirt, humidity and corrosion.

DC/DC GEN3 power cables access

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The front plates will be the positive pole and the rear plates the negative pole. Both are
separated by a polycarbonate and will also be identified on the product with stickers
with the names BESS and PV.

BESS PV FIELD

DC/DC GEN3 power cables connection

The part corresponding to the DC connections in the electrical schematic is shown in

the following figures:

DC Input 1 (+) to power stage 1

DC connection from BESS system to input busbars 50x10mm2 1500Vdc

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DC Input 1 (-) to power stage 1

DC connection from BESS system to input busbars 50x10mm2 1500Vdc

DC Input 2 (+) to power stage 2

DC connection from PV system to input busbars 50x10mm2 1500Vdc

DC Input 2 (-) to power stage 2

DC connection from PV system to input busbars 50x10mm2 1500Vdc

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The cable cabinet distances are shown below.

DC/DC GEN3 distances cable cabinet

A B C D E F G H I J K
mm 743,7 699,2 364 364 52 52 315 315 45 45 294,6
in. 29.28 27.52 15.43 15.43 2.2 2.2 12.4 12.4 1.77 1.77 11.59

L (ᶲ) M (ᶲ) N O P Q
mm 14 13 463,4 50 138 125,5
in. 0.55 0.51 18.24 1.97 5.43 4.74

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NOTICE

The recommended cable section for DC connections is 240mm² and the maximum
cable section is 400mm². The product is designed for installation of a maximum of 4
x 400mm² cables per pole (one per plate). The user must calculate the power wiring
section considering the max. DC output current of the DC/DC and all the
characteristics of the installation.
Fastening hardware is not provided by Power Electronics. The following table
summarizes the recommended fastening hardware.

TERMINAL LUG 2-HOLE NEMA PAD COPPER, COPPER-CLAD

MATERIAL ALUMINUM OR ALUMINUM.
Terminal lug diameter 13mm/0.5’’.
Ground connection
Bolts and nuts metric M12 x 50mm (1/2”) ASTM A325 type 1.
2-hole NEMA pad Copper, Copper-Clad Aluminum
Terminal lug material
or Aluminum.
DC connection
Terminal lug diameter 13mm/0.5’’.
Bolts and nuts metric M12 x 50mm (1/2”) ASTM A325 type 1.

DC and ground busbar is made of tinned aluminum. Connection should be done

considering the following recommendations:

• The DC and ground cable must enter in the converter through the removable
metal plate located in the bottom of the cabinet and be connected to the main
ground busbar. The cable must be routed in the converter only with conduit hubs
or fittings rated as 3, 3S, 4, 4X, 6 or 6P1 to ensure the appropriate IP rating of the
product.

• Before connecting the cables, clean the contact surfaces with a clean cloth and
ethanol cleaner.

• Apply conductive paste between the terminals and the plates to improve and
protect any electrical contact Al - Al, Al - Cu and Cu - Cu exposed outdoors,
allowing the reduction of electrical resistance and the sealing of the contact
parts to avoid corrosion. The working temperature range of this paste should be
between -40ºC and 150ºC (-40ºF to 302ºF).

1
Applies for both UL and IEC normatives.

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REF. ELEMENT
1 M12 screw (1/2")
2 Spring washer
3 Flat washer
4 Plate
5 Connection terminal
6 Flat washer
7 M12 nut (1/2")

Application of conductive paste between terminals and the plates of DC/DC GEN3

• It is recommended to use copper, aluminum or copper-clad aluminum terminal

lugs for M12 (1/2”) bolts with a maximum width of 45mm / 1-3/4”.

• Use M12 (1/2”) bolts and nuts and apply the recommended torque according to
the quality (See “Torque and screw sizing”).

• Use a spring washer and a fender washer between the nuts or bolts head and
the busbar or terminal lug.

5.3.1. Installation of polycarbonates

As mentioned before, the insulation (polycarbonate) must be installed in field
between the different polarities of the user connection plates. This material is
delivered inside the product to avoid damages during transport. The installation of
the polycarbonate is the responsibility of the user. The following picture shows the
polycarbonate.

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DC/DC GEN3 polycarbonate

The correct instructions for installing the polycarbonate in the product are detailed
below.

Previous considerations
The insulating panel will be installed in the cable cabinet, where power connections
are located, which will have the function of separating the positive and negative
plates.
Note that the polycarbonate is installed at the same time as the product is wired, so
reserve the polycarbonate in a safe place until wiring.
The following picture show the side view the location of the polycarbonate inside the
DC/DC Converter between the positives and negatives plates.

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Frontal access

Polycarbonate DC/DC GEN3 location

Note that the polycarbonate to be installed has holes to introduce testing lances and
make possible measurements in the field.

The following picture shows the access holes for both the positive and negative
plates. The plates are distributed in rows according to their polarity (positive or
negative).

Access holes to the negative plates

of the second row.

NOTICE

For this procedure it is necessary to have a 10mm extension socket with a minimum
length of 26cm to reach the screws of the polycarbonate.

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POLYCARBONATE INSTALLATION STEPS

1. Use the key to open the door at the bottom front of the product to access the power
connections where the polycarbonate is to be installed.

2. Before installing the polycarbonate, connect the negative cables on the second
row located inside the cable cabinet.

Frontal access to the product

For correct wiring, please refer to section “Wiring access and connection”.
3. Place the polycarbonate between the first and second row of plates and tighten
the two screws M6 included in the kit. Use the following pictures as a guide.

Frontal access to the product

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POLYCARBONATE INSTALLATION STEPS

4. Connect the positive cables on the first row located inside the cable cabinet.

Frontal access to the product.

For correct wiring, please refer to section “Wiring access and connection”.
5. Close the door at the bottom front of the product with the key.

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5.4. Auxiliary connections and communications

Due to the product's design, all connections required for AC auxiliary power,
manoeuvring, and communications are conveniently situated and centralized in the
same panel. This panel is known as main user panel (PPCU).
The precise placement and purpose of each component within the panel are depicted
in the following image.
Further elucidation on the functionality of these elements will be provided in
subsequent sections. Additionally, all cables will be routed through the lateral clamps
so that the wiring remains tidy in the installation.

PPCU componentes

ID ELEMENT DESCRIPTION

1 Q10 AC Auxiliary power supply (3P+PE).

Connection Interconnection of safety signals
2 X02
between DCDC and inverter.
3 U02 Ethernet connection. DC communications.

4 XC01.1
Optical fiber connections. DC communications.
5 XC02.1

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5.4.1. AC Auxiliary power supply

For the AC auxiliary power supply of the autotransformer (T01) incorporated in the
product, the user must provide an auxiliary power supply with the following
characteristics according to the corresponding standards:

IEC 400VAC 50 / 60Hz 3P + PE

208VAC
UL 60Hz 3P + PE
480VAC

The following schematic shows the connections for phases (L1, L2 and L3) and
ground (PE).

Q10 connection diagram

The autotransformer has several input taps, one for each type of supply voltage, and
two common output taps: the first one at 430VAC three-phase for the power supply of
the ventilation system with a power of 5kVA and the second tap of 1kVA at 93VAC for
the power supply system.
The supply must be connected directly to the AC input protection at the bottom of
Q10 and the ground wire must be connected to the terminal provided for this function.
This device incorporates a locking mechanism for safe stop.
The minimum cable section is 6 mm² and maximum 10 mm² (1kV) (in the case of a
single conductor per pole). A 4G6 mm² section hose with 1kV insulation may also be
used. It is the user's responsibility to select the number of cables and sections.

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5.4.2. DC/DC – Inverter interconnections

The X02 terminal block is used to interchange of safety manoeuvre signals between
DC/DC and the inverter. For the correct operation of the system, the X02 terminal
block must be wired according to the following diagram and pin table where the inputs
and outputs are detailed.

DC/DC – Inverter connection diagram

TERMINALS CONNECTION DESCRIPTION

X02:1 This is a voltage-free "NC" contact so that it can
Emergency stop of the DC/DC to
be interleave in the safety manoeuvre of the
X02:2 installation.
installation.
X02:3 Emergency Stop of installation to The voltage-free ''NC'' contact required from the
X02:4 DC/DC. inverter or/and installation will be connected.
X02:5 A potential-free ''NC'' contact is required on these
External fault to DC/DC. terminals, as the return will go to a digital input of
X02:6 the system.
X02:7 In order for the inverter or/and installation to
X02:8 DC/DC failure to installation. receive the correct electrical polarity, a voltage-
X02:9 free switch contact must be provided.

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NOTICE

The terminals X02:3-X02:4 and X02:5-X02:6 are bridged, before connecting the
signals, please remove them.
Only connect the signals to be used.

The minimum cable section is 2,5 mm² and depends on the distance between the
DC/DC and the installation. The maximum cable section is 4 mm².

5.4.3. Communication connections

On the right side of the main user panel are located the RJ45 connector and fiber optic
cable glands that communicate with the DCDC. The following diagram shows the
correct wiring of the communications connections.

Communication connections diagram

For the communication with DC/DC switch, the user can connect by Ethernet or
Optical fiber using the RJ45 port or introducing the optical fiber cable through the
gland.
• Recommended Ethernet cable: Ethernet CAT 6 - RJ45 connector.
• Required optical fiber cable: Duplex multi – mode OM3 (50 / 125 micron)
SC/SC connectors.

Note: The user must be connecting the optical fiber in O.F.1 port.

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Fiber 1 connection

The second optical fiber has the function of communicating directly from the inverter
and controlling the product. This fiber goes directly to the module control PCB located
at the rear of the converter and will always be installed as standard.
Required Optical fiber cable: Duplex multi – mode OM3 (50 / 125 micron) SC/SC
connectors.

Fiber 2 connection

5.5. Neutral distribution

The converter requires a three-phase connection without neutral and a grounding
conductor to feed the auxiliary services autotransformer.

This generates the neutral required only for the single-phase resistors of the heating kit.
For all these reasons, the system installed is IT2 in this part.

2
An IT system has all active parts isolated from earth or a point connected to earth through an
impedance, the accessible conductive parts of the installation are connected to earth
independently or collectively to the earthing system (IEC 60364-1).

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6. PROTECTIONS
Power Electronics DC/DC converters are equipped with several hardware protections that
complete the software protections.

6.1. Front panel

The product includes two DC switch disconnectors to protect each power stages.

Rated current Rated voltage Breaking

Type
(In) (Un) capacity (kA)
DC power supply
4 poles 1600A 1500Vdc 10*In
protection (SI01)

The product includes two fuses to protect the product against a short circuit of the BESS
system. If the product includes the optional Augmentation, there are two additional
fuses for the PV system part.

RATED CURRENT (IN) RATED VOLTAGE (UN)

BESS DC fuse protection (F101,
1100A 1500Vdc
F102)
PV DC fuse protection (optional) 1100A 1500Vdc

The product includes a fuse to protect the surge protection device system.

RATED CURRENT (IN) RATED VOLTAGE (UN)

Fuse of surge protection
200A 1500Vdc
device (F103)

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The following image shows the protections location.

BESS power stage PV power stage

protection protection

Surge protection device

BESS protection PV protection

Front panel protections diagram

If the product is equipped with the optional heating kit, three 150W ventilated resistors
will be integrated, which will raise the temperature before start-up in extreme
temperature zones, below - 25ºC.

These resistors are each protected by a 1P/C6 magnetothermal protection which

protects the resistor and withstands the start-up peak at the initial moment.

This option does not imply any manipulation or connection by the user.

Resistors protection

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6.2. Power supply system panel (PSA)

The auxiliary power supply panel that integrates the product, located on the
right side, is equipped with the following protections:

Includes a fuse to protect the product from the initial start-up peak.

RATED RATED
CURRENT (IN) VOLTAGE (UN)
Start-up fuse protection
60A 60V
(F01)

Start-up fuse

PSA panel protections diagram

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6.3. Control panel (PCL)

The control panel integrates the main control of the system as well as various system
protections.

The ventilation system is protected by a three magneto-thermal protection (Q01-Q03),

The 24 Vdc output of each power supply is also protected by a magneto-thermal

protection (Q05).

RATED
TYPE
CURRENT (IN)
Ventilation protection circuit breakers (Q01,
3 poles 6A
Q02, Q03) - UL
Auxiliaries’ protection circuit breakers (Q05) 1 pole 4A

The product includes 4 fuses that protect the shunt coming from BESS and PV to obtain
voltage measurements and system signalling.

RATED RATED
CURRENT (IN) VOLTAGE (UN)
Shunt protection fuses (F11, F12, F13, F14) 4A 1500Vdc

Auxiliaries’
protection
circuit breakers

Ventilation Shunt protection fuses

protection circuit
breakers

PCL panel protections diagram

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6.4. Main customer panel (PPCU)

The rated breaking capacity of Q10 is shown in the following table:

RATED OPERATIONAL 220 VAC 400 VAC

CURRENT (IE) (UL) (IEC)
Q10 20-25 A 50 kA 50 kA

AC Auxiliary power
supply (3P+PE), Q10.

PPCU panel protections diagram

6.5. DC and AC short-circuit withstand rating

The input fuses on the battery side have a breaking capacity of 250kA in DC. On the
output side to the inverter, there will be no fuses as they are integrated in the DC cabinet
of the inverter itself. In case it has the optional "Augmentation", this output will also have
fuses with 250kA breaking capacity. Input protection to the auxiliary services
autotransformer is 100kA in AC.

DC and AC protections diagram

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6.6. User power supply protections

The user connections do not require any particular protection for the correct protection
of the converter beyond the protection of the line/power supply that the user installs to
protect the wiring.

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7. LEDS AND CONTROLS

7.1. LEDS and controls

The following control elements and indicator LEDs can be found on the main cabinet.

REF. DESCRIPTION
1 DC Disconnector (S01).
2 Emergency stop (S02).
ON / OFF switch key
3
(S03).
BESS voltage presence
4
(H01).
5 Run (H02).
1 2 3 4 5 6 7 8 9 6 Fault (H03).
PV voltage presence
7
(H04).
Ethernet RJ45 port
8
(U03).
9 Display USB port (U04).

Leds and controls

• ON/OFF switch key: Allows turning OFF and ON the product.

• DC Disconnect: Disconnector. Allows performing the LOTOTO.

• Emergency stop: Pushbutton. Allows stopping and isolate the converter in case
of an emergency situation. Auxiliaries are not isolated with this pushbutton.

• IMPORTANT: Do not use the emergency pushbutton to perform regular stops on

the product. It should only be used when an emergency occurs. Otherwise,
longevity of the main components could be shortened and result in product
damage. The DC disconnect switch should only be used for LOTOTO procedures.
Furthermore, switch key must be turned on OFF first.

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• LEDs: Show the operation status of the product, according to the following table:

COLOR LED ON LED OFF

DC Voltage presence No BESS voltage
White BESS Voltage presence [1]
BESS presence
Run Green Product ON Product OFF
Fault: LED fixed.
Fault Red Warning: LED flashing No faults
every 1s.
DC Voltage presence
White PV Voltage presence [2] No PV voltage presence
PV

[1] As long as there is voltage on the DC power side BESS.

[2] As long as there is voltage on the DC power side PV.

• ETHERNET: RJ45 port. Allows connecting an Ethernet cable.

• DISPLAY: USB port. Allows connecting the display unit to the main cabinet door.
Only authorized PE staff may have access.

CAUTION

Only use the display port to connect the display unit. Do not connect other USB
devices. Otherwise, the port may get permanently damaged, and you may cause
product malfunctioning.

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8. COMMISSIONING

CAUTION

Commissioning must only be performed by qualified personnel approved by Power

Electronics. Read carefully these instructions and all safety recommendations.
Otherwise, product may get damaged and personnel seriously injured.
Ensure no voltage is present in power terminals and supply cannot be connected
unexpectedly.
The instructions on this manual do not override nor replace local or national
regulations. It is the user’s responsibility to comply all safety standards that apply in
the site of installation.

NOTICE

For the commissioning of the product, the batteries must be charged.

The following steps describe the basic procedure to be followed for commissioning and
first start-up of the product.
1. Visual inspection: ensure all components are in good conditions and have not
suffered any damage during transportation.
2. Connect ground cable and input cables without voltage. Ensure connections and
tightening torque are appropriate.
3. Verify DC input power is compatible with the product DC voltage range.
4. Ensure all doors are properly closed and locked.
5. Connect AC power supply input.
6. Verify that AC voltage at the auxiliary supply circuit is compatible with the product
AC voltage range.
7. If all previous steps are successful, start-up the product.

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Polígono Industrial Pla de Carrases,

CV-35, Salida 30, 46160 Llíria,

Valencia