Solar Stik USAF G-BOSS, Setup And Operation

Page 1: ...c PRELIMINARY DRAFT SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEMS Version 1 0 Updated 20201209 DISTRIBUTION STATEMENT A Approved for public rele...

Page 2: ...c Functions 13 Load Support Automatic Functions 13 Peak Power Delivery Manual Functions 13 UPS Automatic Functions 14 The HPS Architecture Function and Operation 14 Energy Storage The Foundation of th...

Page 3: ...s FAVS 3 38 e Set up generator 38 f Calibrate the System 38 3 PDM 3000 PDU and or Tower Operation 39 4 System Deactivation 39 Modes of Operation 39 Hybrid Mode 39 Invert Mode optional 39 System Breakd...

Page 4: ...p 58 High Volts AC 58 Overcurrent 59 Overtemp 59 Stuck Relay 59 Tfmr Overtemp 59 Unknown Fault 60 PRO Verter Internal Fault Messages 60 Internal Bridge 60 Internal Charger 60 Internal NTC 60 Internal...

Page 5: ...ttery Monitor BMK Data Meter 05 71 BMK Status 71 Battery SOC 71 DC Volts BMK 71 DC Amps BMK 71 AH In Out 71 Reset AH Out 71 Total AH Out 72 Minimum VDC 72 Maximum VDC 72 Days Since 100 SOC 72 Generato...

Page 6: ...igure 13 PRO Verter 5000 120 AGS left exterior 26 Figure 14 PRO Verter 5000 120 AGS right exterior 27 Figure 15 PRO Verter 5000 120 AGS back exterior 27 Figure 16 PRO Verter I Plate 28 Figure 17 PRO V...

Page 7: ...k Inc SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRELIMINARY DRAFT Revision History Section Page s Description Date First released as a PRELIM...

Page 8: ...the battery and ensure uninterrupted power to the loads The battery becomes the foundation of the HPS and the architecture is opened to allow multiple technologies to operate in concert Generator Load...

Page 9: ...n snow moisture or liquids Close and latch and or lock the cases when the components are unattended Exercise caution when handling or operating the System Live power may be present Safety Information...

Page 10: ...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 b...

Page 11: ...e earth ground at the main breaker panel of the grid power Any generator connected to the System must have a neutral to ground bond Grounding the System PRO Verter Grounding Lug Figure 1 PRO Verter gr...

Page 12: ...ht especially during inclement 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...

Page 13: ...enerator grid AC power to maintain the load The batteries will cycle regularly to mitigate generator runtime and logistical support often associated with operation in remote locations Hybrid systems a...

Page 14: ...and provide uninterrupted pure sine wave AC and DC power to the loads It is a powerful solution for the following conditions 1 The generator requires protection from adverse operating conditions 2 Gr...

Page 15: ...For this reason multiple Expander Paks must be connected to a PRO Verter for the System to function at its rated power The combined values of the Expander Pak circuit breakers must be greater than th...

Page 16: ...charging the connected batteries once the load is fully supported by the generator Real time Load Management When connected to an active AC source the PRO Verter can automatically adjust in real time...

Page 17: ...Model 2 Peak Power Model Load Support is an automatic function of the PRO Verter that combines power from a generator grid AC source with the inverter s AC output to briefly support high AC loads that...

Page 18: ...nd a sudden AC surge is demanded by the load Since the PRO Verter can t determine in advance how much power will be demanded at the time of the surge it can only react to the surge condition It may ta...

Page 19: ...advanced power distribution and management modules stacking of generators with PRO Verters Power Hubs and more can be added or removed Consult the individual product manuals for additional informatio...

Page 20: ...Example Plug Play architecture allows expansion or contraction of battery capacity when conditions warrant Use Inter Connect Strips and Inter Connect Cables to create a bank of Li Expander Paks Figur...

Page 21: ...s strategically placed throughout 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 a...

Page 22: ...EDIUM AND HEAVY HYBRID POWER SYSTEM PRELIMINARY DRAFT Figure 6 Inter Connect plug The Standard Inter Connect Plug Polarized 200 A maximum current 24 VDC connection only Mechanically locks into place R...

Page 23: ...raws power from the HPS 24 VDC bus and converts it to stable regulated 28 VDC output The PDM protects equipment sensitive to voltage fluctuations 24VDC NATO Figure 7 PDM 3000 front side Figure 8 PDM 3...

Page 24: ...r in the right side of the PDM 3000 provides regulated 28 0 VDC power to the G BOSS Power Distribution Unit PDU The 100 A breakers on the right side also serve as power switches for engaging and disen...

Page 25: ...er 2020 Solar Stik Inc SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRELIMINARY DRAFT PDM 3000 I Plate Figure 11 PDM 3000 top Faceplate specs an...

Page 26: ...r Connect Port 24 VDC 200 B Power Switch C AMMPS Comm Port MS3452W14S 28 D TQG Comm Port Amphenol HA100001 02 36 E Tech Port Ethernet RJF21B F Air Intake A A B Description Connector Voltage Amps A Inp...

Page 27: ...RO Verter 5000 120AGS right exterior Description Connector Voltage Amps A 120 VAC Output HBL61CM65 120 VAC 20 B DC load Power Hub Connection Inter Connect Port 24 VDC 200 C 120 VAC Output HBL2610 SW 1...

Page 28: ...late I Plate provides concise but abbreviated information for setting up and running a System All System components should be connected as shown in the diagram on the I Plate The diagram illustrates c...

Page 29: ...rator is starting For an AMMPS generator these LEDs are active but do not report the status of the generator Auto Generator Start AGS Alarm ON OFF Switch In the ON position an alarm will sound as warn...

Page 30: ...upply power to the RMK if present The LED associated with the breaker is green when the circuit is operating normally Remote Monitoring Kit RMK This optional sold separately device reports records and...

Page 31: ...Components A Optional AC Load Load Unregulated DC Load Tower G Regulated DC Load PDU F Inter Connect Strip 7 Li ESM 2000 x6 24VDC PRO Verter 5000 Power Generation Power Management Energy Storage 3 kW...

Page 32: ...iew Use the Generator AC Power Cable Heavy 50 Medium 10 to connect the generator to the 120VAC 50A INPUT port on the left side of the PRO Verter 5000 A custom cable or adaptor may be required to conne...

Page 33: ...Verter and the AUTO GENERATOR CONTROL port on the TQG using the TQG GEN COMM Cable Heavy 50 Medium 10 c Connect PRO Verter Generator Comms Cables Figure 20 MEP 831A and MEP 802A Generator Communicatio...

Page 34: ...on the front of the PRO Verter and the NETWORK port on the AMMPS using the AMMPS GEN COMM Cable Contact Solar Stik for information on this cable Figure 21 MEP 1030 AMMPS 5 kW Generator Communication...

Page 35: ...PRELIMINARY DRAFT d Connect PRO Verter 5000 to PDM 3000 Use a 24VDC Inter Connect cable Heavy Medium 12 0 AWG to connect the 24VDC PDM 3000 the PRO Verter There is a single Inter Connect port on the P...

Page 36: ...O Verter 5000 to Data Distribution Unit Optional Use an Ethernet cable to connect the PRO Verter to the Data Distribution Unit DDU The TECH PORT provides access to System level operation data The PRO...

Page 37: ...ches to prevent power draw during System setup Figure 24 PRO Verter 5000 AC power output ports 120 VAC 20 A Note The PRO Verter inverter may be turned off during programming at Solar Stik per customer...

Page 38: ...to a generator Alarm will last 10 seconds before generator engine start ii Once generator is running verify the LED over the AC IN 50 AMP MAX breaker is illuminated and User Interface displays Charge...

Page 39: ...CTRL button 2 Scroll to 03 Gen Control Press SELECT 3 Rotate SELECT dial until Generator AUTO appears on the LCD Press SELECT Invert Mode optional Supports AC loads from energy stored in the ESMs whe...

Page 40: ...ACLD Meters 07 PT Meters SETUP Button 01 System Setup 01A Set Clock 01B Screen Setup 01C Temp Display 01D Max Charge 02 Inverter Setup 02A Search Watts 02B LBCO Setting 02C AC In Time 02D AC In VDC 0...

Page 41: ...y PRO Verter 5000 METER Status 01 DC Meters Status 02 AC Meters Status 04 AGS Meters 01A DC Volts 26 2 VDC 02A Output Volts 120 VAC 60 0 Hz 01B DC Amps 0 Amps 02E Input AC1 120 Volts AC 02B Load Amps...

Page 42: ...up Start SOC Fault Gen Run Fault Topoff Manual Run Start Temp Fault MaxRn Fault VDC No Comm Start Test Fault SOC Fault 100 SOC No AGS present Start Time Off Start Topoff Quiet Time Start VDC Ready St...

Page 43: ...wr Save 15 min 02 Invert Setup 02A Search Watts OFF 02B LBCO Setting Volts 24 0 02C AC In Time 6 00A to 6 00P 02D AC In VDC Range 22 0 28 0 VDC Set Search Watts Range OFF 5 50 Set LowBatCutOut Volts 1...

Page 44: ...ime Hold CV Chg Amps Set Max CC CV Time 0 1 25 5 Hrs off Set Recharge Volts 24 32 Range 0 0 to 25 5 Hrs Range Float Silent Multi 03F Max Charge CC CV Controlled 03G Final Charge CC CV Controlled Set M...

Page 45: ...00 00A Set Start Gen AM PM 00 00A Default OFF Set Stop Gen Hour 1 00P Set Stop Gen Minute 00 45P Set Stop Gen AM PM 00 00P Set Stop Gen Hour 12 00P Set Stop Gen Minute 00 00P Set Stop Gen AM PM 00 00P...

Page 46: ...nute 00 45P Set Start Quiet AM PM 0 00P 04G Quiet Time OFF Set Quiet Time ON Set Start Quiet Hour 1 00 12 00PM Set Start Quiet Minute 0 00P Set Start Quiet AM PM 0 00A Default OFF Set Stop Quiet Hour...

Page 47: ...Set 100 SOC Run AM PM 0 00A Default Off Range Off 1 255 continued SETUP 05 BMK Setup 05A Charge Eff Auto 05B AmpHour Size 420 AH 05A Charge Eff Range Auto 50 99 05B AmpHour Size Range 200 2500 Defaul...

Page 48: ...eratures Inv BTS F Read only Displays Remote 4 0 AGS BMK Router ACLD PT Read only Displays Read only Displays Status VDC ADC BTS F Tfmer F FETs F Specific fault listed if no fault No Fault History dis...

Page 49: ...irst Click the fault name to link to a detailed explanation of the reason s why the fault occurred and solutions to correct the fault The full list of all faults and statuses is on the following page...

Page 50: ...to Statuses Faults and Resolutions This guide is interactive if used on a computer or handheld device Each of the faults in the lists below is touch linked to an explanation of the fault and a soluti...

Page 51: ...es No crossover cable or incorrect cable installed between the two ports on the RMK See PRO Verter Remote Monitoring Kit RMK LAN Operator Manual Display shows unrecognized letters or symbols Static el...

Page 52: ...ing it through to the load The inverter function is active but the transfer switch has it in Standby until the external source is disconnected No Inverter Comm The LCD User Interface is not receiving...

Page 53: ...current determined by the SETUP 03E Max Charge Rate setting to the batteries The charger remains in Bulk charge until the absorb voltage determined by the SETUP 03C Battery Type setting or the 03F Max...

Page 54: ...SETUP 03G Final Charge Stage menu In Silent mode the charger is not actively charging but does monitor the battery voltage When the battery voltage reaches the Set Rebulk Voltage setting from 03G Fin...

Page 55: ...charge rates are not obtained in Charging mode Full charge rates will occur only after this mode changes to Bulk charging Absorb charging or Float charging modes Charger not charging even though Char...

Page 56: ...is fault message displays when the AC load on the PRO Verter output has exceeded the inverter s AC current protection limits This fault may occur because the connected AC loads are larger than the inv...

Page 57: ...the generator Solution 1 Check the DC voltage at any of the PRO Verter s DC terminals Inter Connect ports and compare it with the DC voltage at the battery bank These two voltages should be very close...

Page 58: ...a very high voltage 300 VAC has been detected on the AC input Solution Remove all AC power from the PRO Verter AC input for at least 15 minutes to clear this fault Ensure only 230 VAC power is connec...

Page 59: ...from exposure to direct sunlight Solar loading is a major source of heat buildup inside the PRO Verter Stuck Relay This fault message displays when the inverter is inverting but the internal AC pass...

Page 60: ...large but unexpected temperature change Internal Relay This fault message displays when the internal AC transfer relay is not closed while charging Solution If one of these internal faults occurs the...

Page 61: ...line displays the current status of the AGS An AGS status of Off or Ready indicates the User Interface and the inverter is communicating with the AGS If the AGS status is not Off or Ready then refer t...

Page 62: ...stem The Statuses in the gray box would appear only if the PRO Verter were programmed differently They are shown only as a reference Start Amp Generator has autostarted based on the SETUP 04C Gen Run...

Page 63: ...4I Gen Warm up Time menu Once the AGS status indicates Warm up the PRO Verter s AC input ignores any incoming AC power This prevents the PRO Verter from loading the generator during warm up Once the A...

Page 64: ...t Gen Run Symptoms Generator is overloading and shutting down the generator successfully started and ran for more than two 2 minutes but the generator unexpectedly stopped before the active AGS autost...

Page 65: ...he System and start it using the generator native controls If the generator does not start check the generator for fault codes adequate fuel and refer to the generator Operator and Maintenance Manual...

Page 66: ...ing in the inability to charge the Expander Paks to the voltage required to stop the generator Shade the PRO Verter to reduce solar loading and keep the air intake filters clean to promote more effici...

Page 67: ...ed the batteries need to be fully charged i e SOC 100 to establish a SOC reference point The batteries are fully charged the display has changed from Think n to 100 and is ready to provide accurate SO...

Page 68: ...TECH 04 Fault History 04D Clear Faults menu See the diagram below Rotate the SELECT dial to display the second and third screens for the particular fault shown on the first screen After viewing all sc...

Page 69: ...r 05 BMK Meters is displayed AGS and BMK Meters represent the only data sets for the generator or the battery system that is cumulative The DC and AC meters indicate current status information only In...

Page 70: ...when trying to determine how long the generator has been running in the auto mode This meter does not replace the hour meter for total hours the generator has run AGS Temp This feature is not enabled...

Page 71: ...ed DC Volts BMK This meter displays the DC volts at the Inter Connect bus The range is from 07 00 to 70 00 volts 0 02 DC Amps BMK This meter displays the real time charge current amps into battery or...

Page 72: ...hree 3 seconds while the Minimum VDC display is shown After this value has been reset the display will begin monitoring and showing new minimum DC input values If the battery monitor is not connected...

Page 73: ...y 30 60 seconds before automatically turning off Generator Having Difficulty Starting Causes Generator starter battery voltage too low Low fuel Fuel Air filters clogged Solution 1 Charge the generator...

Page 74: ...S will automatically start the generator to ensure continuity of operations The AGS will stop the generator after temperatures have cooled Generator Fails to Stop See also Max Gen Run fault section Ca...

Page 75: ...op Battery Circuit breaker tripping System crashes Expander Paks will maintain parity close to 100 SOC on a regular basis if the PRO Verter AGS is in AUTO mode using VOLTS to start stop the generator...

Page 76: ...save the values best suited for your application into each of the fields Start with the frequency e g every seven days and duration e g 12 hours as shown 4 Confirm that the SOC of the System battery...

Page 77: ...n No Comm Internal Fault Power up Fault or Unknown Fault are not valid SOC numbers Once the BMK s METER 05B Battery SOC displays 100 the AGS stops the generator and the BMK s METER 05J Days Since 100...

Page 78: ...elected power generation sources at regular intervals It will ensure there is enough energy to power the intended load between charges The best measure of a properly sized battery in a cycling applica...

Page 79: ...ick See 24VDC Expander Pak 2400 Manual Discharging the Expander Pak Battery to EMPTY For longest service life Expander Paks should only be discharged to 80 depth of discharge DOD This means that 80 of...

Page 80: ...ir intake vents once a month or more frequently as warranted to minimize the accumulation of internal heat Follow the generator maintenance procedures listed in the generator operator and maintenance...

Page 81: ...intake filters 2 Wash with water and dry the filter Reinstall 3 If the filter is damaged or cannot be cleaned replace If the filter cannot be cleaned is too damaged to function properly and a replacem...

Page 82: ...Figure 28 If the filter is in good shape clean it by rinsing it with water to remove the particulate matter and dry it Replace the filter if it is crushed rotted or cracked as illustrated in the left...

Page 83: ...e Power Hub 2400 Each component of the System is either sealed e g the Li Expander Paks or can be secured with a padlock to deter tampering Two or more latches allow the cases to be sealed to prevent...

Page 84: ...December 2020 Solar Stik Inc 84 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRELIMINARY DRAFT...

Page 85: ...e design and support of small scale renewable energy power generation systems with detailed explanation of system components Advanced configuration options with hands on deployment of actual systems w...