Solar Stik 24VDC HyPR 3000, Operator And Maintenance Manual

Page 1: ... PRELIMINARY DRAFT 24VDC HyPR 3000 Operator and Maintenance Manual Operator and Maintenance Manual for the 24VDC HyPR 3000 Version 1 0 Updated 20210413 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited ...

Page 2: ...Requirements for Operation 15 Battery Low voltage Cut Off LVCO 15 Battery Current Requirements for HyPR AC Output 16 Temperature dependent Power Processing 16 Derating Specifications 16 How to Minimize Derating 17 Important Safety Information and Instructions 18 Safety Information Labels 18 Fire Hazard 19 Recommended Fire Extinguisher 19 Electric Shock Hazard 20 Environmental and Handling Precauti...

Page 3: ...hes Panel 35 AC Output Status LED 35 Connecting Generators to HyPR 36 Compatible Generator Options 36 HyPR GEN COMM Port Specificity 37 MPG Parallel Connections 39 Operator Instructions HyPR Setup and Operation 40 Navigating DC User Interface Menus 41 Programmable Parameters 42 Maintenance Preventive Maintenance Checks and Services PMCS 43 HyPR 3000 Air Intake Filter Cleaning 43 Water Intrusion Re...

Page 4: ...vents 30 Figure 18 24 VDC HyPR 3000 Faceplate 31 Figure 19 HyPR 3000 DC INTERFACE 33 Figure 22 AC Input Control dial 34 Figure 20 Generator mode control switches and LEDs 34 Figure 21 Generator Status LED blinking pattern 34 Figure 23 HyPR 3000 breakers 35 Figure 24 HyPR Inverter AC OUTPUT status LED 35 Figure 26 Connecting generators to HyPR 36 Figure 25 Compatible generator options 36 Figure 27 ...

Page 5: ...aneous AC and DC outputs Plug and play compatibility with the Solar Stik Inter Connect circuit Efficient management of available power to loads This manual provides operation and safety information for the HyPR 3000 The HyPR 3000 has been designed specifically to support Hybrid UPS Power Conditioning and Scavenging requirements When operating the HyPR within a system consult the I Plate and the Sy...

Page 6: ... power breaker switch is turned on The HyPR DC INTERFACE will power up and report DC bus voltage and amperage data on the home screen The inverter DC AC will be active but only operational once the HyPR AC OUTPUT breaker is engaged The converter AC DC will be active but only operational once the HyPR AC INPUT breaker is engaged The HyPR solar charge controller will be active but only able to proce...

Page 7: ...n of the HyPR 3000 internal circuits System voltage and net current can be monitored on the DC User Interface However it will report only a negative current value if no PV array is connected A schematized illustration of the DC bus and its relationship to internal components inputs and outputs is shown below The arrows indicate the flow of current in the circuits Solar DC Input AC Input 24 VDC bus...

Page 8: ...very from overdischarged batteries is possible using AC power or alternative 24 VDC power sources System recovery using PV power is not an option Inverter continuous AC power output fluctuates based on conditions such as temperature heat derating efficiency loss AC Functions The HyPR employs two 2 separate AC functions that operate on the DC bus Charging AC DC converter provides up to 100 A at 29 ...

Page 9: ... by voltage Prioritizing PV and scavenged DC power over AC power reduces reliance on fuel powered generators Solar Power The SOLAR INPUT port is the only port that may be used to connect PV power to the HyPR Connecting a PV array to any other input port will damage to the HyPR Any PV array input must meet the following specifications 400 W or less voltage between 30 and 57 VDC and a maximum curren...

Page 10: ...ply and the inverter self protect Auto Generator Start Stop The HyPR Auto Generator Start Stop AGS functions are controlled using the GENERATOR CONTROL switches on the Faceplate The ON position turns on a connected generator regardless of the DC bus voltage The AUTO setting automatically starts and stops a connected generator based on DC bus battery voltage The OFF setting stops the generator s if...

Page 11: ...power will be prioritized to the load reducing consumption of energy stored in the batteries thereby extending battery only runtime and the reducing need for AC power from a grid utility or generator source When operating a HyPR with a fuel driven generator s the AGS circuit can be used to start the generator s when the battery SOC is low Once the battery SOC reaches a user determined point the Hy...

Page 12: ...e s 2000 W AC Output for loads Modes of Operation UPS Mode The HyPR 3000 is capable of operating as an Uninterruptible Power Supply Source providing instantaneous emergency power to a load in the event that primary power source fails In this mode the HyPR 3000 will to provide power to the load until it can be turned off safely or until primary power is restored In this mode power duration is limit...

Page 13: ...ng Model With or without Energy Storage Loads AC 9 36 VDC Scavenge DC Scavenging Mode The HyPR 3000 provides an energy scavenging tool to harvest power from conventional and non conventional 9 to 36 volt power sources not integral to the Solar Stik family of products such as a random batteries or a 12 VDC vehicle accessory outlet The HyPR scavenging circuit automatically converts any power source ...

Page 14: ...ion to a vehicle NATO port is available Inverter Mode The HyPR 3000 may be used in inverter mode when no AC power generation sources are available This allows the combined total input of DC sources including ESMs to be dedicated to AC loads This mode may be used when ESMs Scavenge 9 36 VDC AC Power Limits 2000 W with ESMs connected Solar Vehicle Other Loads AC Figure 6 Using HyPR in Inverter Mode ...

Page 15: ...an active 24 VDC battery to operate There is a minimum energy storage capacity requirement for operation of the HyPR at it s full rated power Consult the I Plate and subsequent sections of this Manual for specific information regarding minimum capacity necessary for a particular application The HyPR is compatible with lead acid and lithium battery chemistries However battery chemistries should nev...

Page 16: ...at the temperature of the equipment will rise above ambient and STC in direct proportion to power being processed This too results in derating Internal thermostatic mechanisms are built into most equipment to reduce power processing in a heat dependent manner to lower heat and prevent damage Power processing vs heat curves vary widely They HyPR contains two 2 major subcomponents a charger and inve...

Page 17: ... process around 2000 W continuous for battery charging with no loads connected How to Minimize Derating Do not overload the HyPR Manage power processing demand by paying close attention to what is plugged in Prioritize critical loads Shade the HyPR 3000 to reduce solar loading Solar Stik data indicate that solar loading of a Pelican case can increase internal heat by 40 ºF 22 ºC above ambient Do n...

Page 18: ...esent Safety Information Labels Your safety and the safety of others is very important Many important safety messages have been provided in this manual and directly on the System components Always read and obey all safety messages This is the safety alert symbol This symbol is an alert to potential hazards that can cause death or injury All safety messages will follow the safety alert symbol and t...

Page 19: ...e 10 lb Carbon dioxide is a liquefied gas which is highly effective fighting class B and C fires These extinguishers are ideal for areas where contamination and or cleanup are a concern such as data processing centers labs and telecommunication rooms Using the Fire Extinguisher When using the extinguisher on a fire remember PASS Pull the pin Aim the nozzle or hose at the base of the fire from a sa...

Page 20: ...cal shock DON T LET THIS BE YOU HIGH VOLTAGE System components PV arrays and generators may produce lethal line voltages Extreme care should be taken to protect against electrocution Always work with another person in case an emergency occurs Disconnect power before performing maintenance Wear safety glasses whenever working on any part of a system that requires exposure to mechanical or direct el...

Page 21: ...ment weather Lids should be open only to access operator controls and closed at all other times Impact Equipment should not be dropped onto hard surfaces at a height greater than one foot when transporting or during operation Dust Foreign Object Intrusion Air intake filters should be cleaned once per month or more frequently when conditions warrant As a general rule minimize exposure to high level...

Page 22: ...the circuit It ensures the potential for a reverse polarity connection within the circuit is minimized If a problem occurs in a leg of the Inter Connect Circuit the affected leg will disconnect from the primary network leaving the other circuits functioning If a major failure occurs in the circuit then the entire network will shut down for System and Operator protection Operate with Voltage The In...

Page 23: ...ified in the field Inter Connect Cables for use with the Li Expander Pak 1300 have two types of plugs straight and angled The straight plug connects to the Expander Pak 1300 to facilitate stacking Figure 7 24VDC Linear Inter Connect Cable Straight Angled Figure 8 Inter Connect Plug The Standard Inter Connect Plug Polarized 200 A maximum current 24 VDC connection only Mechanically locks into place ...

Page 24: ...he system is operating or idle The HyPR 3000 provides important battery status information and therefore increased security for continuity of operations The following diagram illustrates an overview or where to connect power sources ESMs and loads to the HyPR 3000 Introduction 85 264 VAC Input 9 36 VDC Input 24VDC Input Output x2 120VAC loads 24VDC HyPR 3000 Generator Communications Figure 9 24 VD...

Page 25: ...I Plate is an application specific part of the HyPR It provides condensed instructions for deploying and operating a System that includes a HyPR as manager of power within the System Detailed information about deployment of a specific System including a HyPR is found in System Setup and Operation Manuals The HyPR 3000 I Plate ...

Page 26: ...ed ESMs Specifications for the solar charge controller and compatible PV arrays are on the HyPR 3000 Faceplate Functioning PV arrays must be connected for the DC INTERFACE to calculate and report ESM state of charge SOC Pins A and C are the current conductors pin B is unused Connect AC power sources to the 120 230VAC INPUT port The HyPR 3000 accepts universal 85 264 V power Power via this connecti...

Page 27: ...in bayonet connector Power between these voltages is converted to 28 3 VDC and applied to the DC bus to charge batteries or support small loads Power input is limited to 150 W Power output is limited to 100 W Custom cables may be required Pins A and C are the current conductors pins B D are unused 9 36VDC Input Limit 150 W max A Neg C Pos Figure 12 HyPR 3000 DC power scavenging port ...

Page 28: ...d to the HyPR 3000 EXPANDER PAK ONLY port A single battery is enough to power up the HyPR 3000 internal circuits and user interface as well as to support small loads However additional batteries must be connected for the HyPR to operate at its full rated capacity see Battery Requirements for Operation Note The total Ah capacity of all connected ESMs must be programmed into the HyPR using the DC in...

Page 29: ...4000 W are tolerated These four 4 ports are cumulatively breaker limited to 20 A The Inter Connect Port is a direct connection to the HyPR DC bus This port is not metered may be used to parallel HyPRs or to connect additional power management components The NATO port is a direct connection to the HyPR DC bus This port is not metered and may conduct current into or out of the HyPR This connection i...

Page 30: ...environments Left side Back Front Air intake vents with air filters Exhaust vents Figure 16 HyPR 3000 cooling vents GEN COMM Ports These connectors provide a communication link between the HyPR and auto start stop capable generators GEN COMM 1 and GEN COMM 2 communicate with 1 kW and 2 kW generators GEN COMM 1 communicates with TQGs Figure 17 Expander Pak generator communications ports Note The Hy...

Page 31: ...scharge current inverter low voltage disconnect and more It contains a microprocessor that allows it to learn the battery s behavior over time increasing accuracy of reported metrics GENERATOR TYPE selection switch Choose Ranger Defender if the HyPR is connected to Novatio 1 kW or 2 kW gensets Choose TQG if connected to auto start stop equipped gensets i e MEP 802A or MEP 831A GENERATOR CONTROL sw...

Page 32: ...ation is required USB CHARGING Ports The USB ports are for charging only no data are transmitted via these ports Breakers Switches The breakers serve as switches to activate circuits and to deactivate circuits not in use Circuit breakers protect against overcurrent conditions in dedicated circuits If too much amperage flows due to short circuit inadequate or improper loading or component failure t...

Page 33: ...charge and at a rate that usually does not exceed 25 of the battery s amp hour capacity This is also known as the constant current phase Acceptance Charge In this stage the charge current gradually decreases as the batteries obtain full charge It is also known as the constant voltage phase With the Li ESM 1300 the acceptance charge phase is not necessary Float Charge This final stage compensates f...

Page 34: ...actor Figure 22 AC Input Control dial 1 kW generator grid power source 2 kW generator grid power source 3 kW generator grid power source Generator Control Switches Figure 20 Generator mode control switches and LEDs Figure 21 Generator Status LED blinking pattern Generator operating status is reported by the LEDs above the GENERATOR CONTROL switches Figure 20 arrows The blinking pattern of the LED ...

Page 35: ...ch for the circuit Power Switch 100 A Limits flow to and from batteries to 100 ADC Breakers Switches Panel Figure 23 HyPR 3000 breakers The HyPR can be configured into a System in many ways Understanding the function of each breaker and its associated circuit is critical to proper operation Circuit breaker panel is only for IN OUT circuit limit protections AC Output Status LED The LED on the Facep...

Page 36: ...start stop TQGs that have been modified with a Solar Stik Remote start Enabling Kit RsEK and the 1 kW and 2 kW Man Portable Generators MPGs Figure 25 Figure 25 Compatible generator options MEP 802A 5 kW TQG MEP 831A 3 kW TQG Ranger 2 kW MPG Defender 1 kW MPG Note The TQGs above must have a Solar Stik RsEK installed to be compatible with the HyPR Tactical Quiet Generators TQG Man Portable Generator...

Page 37: ...802A Gen Comm Cable connections HyPR GEN COMM Port Specificity The two 2 GEN COMM ports are not equivalent Their specificity is as follows Defender or Ranger single operation Connect to Gen Comm 1 or 2 port Defender Ranger MPG tandem operation Connect to Gen Comm 1 and 2 ports Use 120 VAC Parallel Power Cable Tactical Quiet Generator TQG Connect ONLY to Gen Comm 1 port The Gen Comm Cables for thes...

Page 38: ...ger 2 kW MPGs Connect to Gen Comm ports 1 and or 2 on the front of the HyPR to the DC OUT AUTOSTART port on the generator using a Ranger Defender Gen Comm Cable Figure 28 Defender 1 kW and Ranger 2 kW Gen Comm Cable connections Gen Comm Ports Generator Type Selection Switch HyPR 3000 Defender 1 kW MPG Ranger 2 kW MPG ...

Page 39: ...the left side of the HyPR Figure 12 The mode of each generator is controlled independently and each has its own communication cable to the HyPR The LED over each Generator Control Switch HyPR Faceplate blinks slowly when functioning in Auto mode more rapidly when manual On mode and very rapidly when there is a generator fault The LED does not blink when the switch is in the Off position To HyPR AC...

Page 40: ...power requirements must not exceed rated output of their respective connections 3 Toggle HyPR POWER SWITCH to ON This switch located on the front exterior of the HyPR allows current to flow from connected batteries into the HyPR energizing the internal DC bus Figure 1 on page 7 At this point the DC Interface will power up 4 Check Confirm Program total Ah capacity in HyPR DC User Interface typicall...

Page 41: ...repeatedly To move to the next menu press and hold SELECT for 4 seconds To change settings parameters in the Operation Setup and Battery Charger Parameter Setup menus move forward through the menus using the steps above to the menu window that contains the desired parameter Then do the following Press and hold SELECT for 4 seconds SETTING blinks Change the value To increase a value press NEXT The ...

Page 42: ... Additional Menu Options Additional Men u Options Additional Men u Options Additional Menu Options XXX AH 27 2 V 25 0 VDC 25 5 VDC 29 0 V Programmable Parameters Parameters that may need to be set or confirmed are orange outline windows SET BAT AMP HRS The value in this window should be the cumulative Ah capacity of the battery bank connected to the HyPR SET AUX OUT OFF ON The OFF value is the bat...

Page 43: ...install 3 If the filter is damaged or cannot be cleaned replace it If the filter cannot be cleaned is too damaged to function properly and a replacement is not immediately available the unit is partially mission capable Replace the filter as soon as possible to restore the unit to fully mission capable Preventive Maintenance Checks and Services PMCS HyPR 3000 Air Intake Filter Cleaning There are t...

Page 44: ...g it with water to remove the particulate matter then dry it Replace the filter if it is crushed rotted or cracked as illustrated in the left column of Figure 33 Spare filters may be stored behind the HyPR I Plate 3 Reinstall the clean dry filter or install the new filter Secure the vent shroud with the four 4 fasteners Figure 33 Replacing HyPR air intake filter left cleaning a HyPR air intake fil...

Page 45: ...00 in the most dry environment possible for a time long enough that any remaining moisture inside will dry When it is dry reintegrate the HyPR 3000 to the System and test it to determine if it is still functional Figure 34 Drain plug screw located under the TECH PORT Water Intrusion Remediation If water intrusion is suspected and the System is still functional disconnect power sources entering the...

Page 46: ...e 25 29 VDC Charging Stages CC CV Continuous Output Current 100 ADC Charging Efficiency 87 Transfer Time None AC Output Specifications 77 F 25 C AC Output Frequency 60 Hz AC Output Voltage 120 2 VAC Continuous Output Current 16 7 A 2000 W 3 Second surge capacity 4000 W Inverter Efficiency 87 Transfer Time None Operating outside of range will accelerate the battery aging process Prolonged exposure ...

Page 47: ...eration systems with detailed explanation of system components Advanced configuration options with hands on deployment of actual systems will enhance student understanding Solar Stik New Equipment Training on site teaches Hybrid System configuration options with hands on deployment of actual systems to enhance student understanding Solar Stik Training Courses are tailored to the specific needs of ...