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June 2020
Solar Stik® Inc.
OPERATOR AND MAINTENANCE
MANUAL
FOR THE
24VDC LI EXPANDER PAK 1300
Updated: 20200611
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.Version 1.0
P/N 21-0202316
Page 1: ...2020 Solar Stik Inc OPERATOR AND MAINTENANCE MANUAL FOR THE 24VDC LI EXPANDER PAK 1300 Updated 20200611 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited Version 1 0 P N 21 0202316 ...
Page 2: ...ct Cable 11 Optimizing the Battery Configuration 12 Determining Proper Battery Capacity for a System 12 Scaling Methods 13 Keys to Expander Pak Performance 14 EQUIPMENT DESCRIPTION External Features 15 24VDC Li Expander Pak 1300 Inter Connect Cable 15 Data Plate D Plate 16 OPERATOR INSTRUCTIONS Connect Expander Paks to Inter Connect Strip 17 Connect Expander Paks to Power Management 18 Alternative...
Page 3: ... stacking multiple Expander Paks 17 Figure 6 Connecting Inter Connect Cable to Expander Pak 17 Figure 8 Connecting Expander Paks to Solar Stik power management 18 Figure 9 24VDC Li Battery Maintainer with Inter Connect Plug 18 List of Tables Table 1 In storage Preventive Maintenance Checks and Services 20 Section Page s Description Date First published March 2019 All Most Update Expander Pak 1300 ...
Page 4: ...teries are consumable parts of the HPS While the role ESMs serve can be widely varied their function is quite simple ESMs discharge and recharge over time this is known as cycling Batteries are designed with a finite cycle life expectancy and several factors will determine how many cycles a battery can endure before it is depleted 1 Cell chemistry 2 Operational environments and conditions 3 Chargi...
Page 5: ...ion Labels Your safety and the safety of others is very important Always read and obey all safety messages This is the safety alert symbol This symbol alerts you to potential hazards that can kill you or hurt you and others All safety messages will follow the safety alert symbol and the word DANGER WARNING or CAUTION These words are defined as DANGER Indicates a hazardous situation which if not av...
Page 6: ...ch as data processing centers labs and telecommunication rooms Use Sweeping Motion WARNING Only CO2 carbon dioxide fire extinguishers should be used with Solar Stik equipment These additional cautionary steps will ensure your safety System components should not be operated in standing water System cables should not be routed through standing water Cable connections should remain dry Unused ports o...
Page 7: ...ct 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 electrical contacts WARNING The Expander Pak is NOT GFCI protected WARNING Standing water around the electrical equipment and or intrusion of water into the Sys...
Page 8: ...during outdoor operation and or storage Impact The Expander Pak should not be dropped onto hard surfaces at a height greater than one foot when transporting or during operation Dust As a general rule minimize exposure to high levels of particulates by exercising common sense placement Heat Heat and solar loading reduce efficiency and life expectancy Shade the Expander Pak to prevent the negative e...
Page 9: ...us when 100 discharged Ruggedized for extreme conditions Designed to MIL STD 810G GVT Safety Confirmation for worldwide deployment Transportable by land sea and cargo air Adherence to operation and safety protocols will yield optimal performance from the Li Expander Pak for many years Procedures for operation preventive care and maintenance are in this manual Please read this manual thoroughly bef...
Page 10: ...sures 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 Inter Connect Circu...
Page 11: ...Mechanically locks into place Rotate knob clockwise to lock counterclockwise to release Can be repaired or modified 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 1 24VDC Linear Inter Connect Cable Straight Angled ...
Page 12: ...cuit breaker that will limit the amount of current available from the individual batteries In most System configurations where Expander Paks are used the combined values of the Expander Pak circuit breakers must be greater than the rated demand of the connected power management distribution equipment Connecting an insufficient number of Expander Paks energy storage modules will result in a situati...
Page 13: ...e resources to other locations then Li Expander Paks can be removed from service in accordance with reductions in runtime requirements Figure 2 Connecting Li Expander Paks using Inter Connect Strips and Inter Connect Cables Inter Connect Strip 7 Power Hub PRO Verter Power Hub Inter Connect Strip 7 Inter Connect Cable Basic Expanded Solar Stik power management components have minimum battery capaci...
Page 14: ...nuals when putting Expander Paks into service in a bank system Expander Paks prefer to be charged using a PRO Verter or Power Hub If any other charging device is used it must be rated for the Expander Pak s storage capacity voltage and current limit see Alternative Charging Methods Accurate monitoring current voltage SOC cycles etc of a bank of Expander Paks should be obtained from the system s PR...
Page 15: ...nformation Figure 3 External features of the Expander Pak EQUIPMENT DESCRIPTION Inter Connect Cables for use with the Li Expander Pak 1300 have two types of plugs straight and angled Figure 4 The straight plug connects to the Expander Pak 1300 to facilitate stacking Figure 7 24VDC Li Expander Pak 1300 Inter Connect Cable Figure 4 Li Expander Pak 1300 Inter Connect Cable plugs External Features Lin...
Page 16: ...24VDC Li Expander Pak 1300 Operator Manual June 2020 Solar Stik Inc 16 Data Plate D Plate Figure 5 24VDC Li Expander Pak 1300 D Plate ...
Page 17: ...cket are polarized Figure 6A and can be connected only in the proper orientation 2 After inserting the plug into the socket Figure 6B twist the knob to lock the connection Note The red wire cover denotes the positive terminal and green or black denotes the negative terminal A B Figure 6 Connecting Inter Connect Cable to Expander Pak Figure 7 Connecting and stacking multiple Expander Paks Connect E...
Page 18: ...ks to Power Management Alternative Methods of Recharging the Expander Pak Alternative methods of recharging should be performed using only regulated charging sources appropriate for 24 VDC LiFePO4 batteries such as the 24VDC Li Battery Maintainer shown in Figure 9 Figure 9 24VDC Li Battery Maintainer with Inter Connect Plug Recharging Voltage Do not connect an external charging source that exceeds...
Page 19: ...tored at temperatures above 91 ºF 33 ºC then the time between maintenance checks and or charges must be reduced to three 3 months In Storage Charging Procedures Charge one charge all It is important to maintain an equal level of health between all Expander Paks in a System If one 1 Expander Pak in a System needs to be charged during storage it is likely that any all others will also need to be cha...
Page 20: ...rage Temp Interval at 77 90 ºF 25 32 ºC Storage Temp Procedures Non mission Capable 1 Visual inspection of 24VDC Li Expander Pak 1300 M1 Q2 1 Inspect case for visible damage and missing items 2 Clean excessive dust or dirt accumulation from the exterior and ports 3 Close all unused port covers If the case is broken or split or if the port is damaged contact Solar Stik Technical Support 2 In storag...
Page 21: ...pper Ground Li Expander Pak Transport The following information is a summary of the conditions that apply to the 24VDC Li Expander Pak 1300 for air transport Dangerous Goods Training The international and U S transportation regulations require personnel involved in shipping the 24VDC Li Expander Pak 1300 to complete the appropriate level of HAZMAT training Classification The 24VDC Li Expander Pak ...
Page 22: ...aste Storage Area HWSA Defense Reutilization and Marketing Office DRMO or other local authorities for the standard operating procedure for packaging quantity labeling shipping and tracking requirements If an HWSA or DRMO is not available or does not accept the Li Expander Pak contact the servicing environmental compliance organization Solar Stik is also able to handle disposal of the Li Expander P...
Page 23: ...n battery Forbidden from transport on passenger aircraft Certification s IP67 intrusion protection UN 38 3 Warranty 1 year materials and workmanship Weights and Dimensions L x W x H Weight 34 lb 15 42 kg Dimensions 17 55 x 17 25 x 4 06 in 44 58 x 43 82 x 10 31 cm Environmental Operating Temperature 26 F to 149 F 32 C to 65 C Storage Temperature 4 F to 113 F 20 C to 50 C Connections Input s Output ...
Page 24: ...as lead acid Other than passenger aircraft transport regulations are the same as for lead acid The cycle life of LiFePO4 is generally advertised as 3000 cycles but it may be affected by adverse operating temperature conditions extreme heat and cold and high C rates rate of current charge and discharge Batteries must not be stored in a discharged state or they may become permanently damaged The pri...
Page 25: ...n internal protection circuit However just as with lead acid batteries irreversible damage can occur to a lithium cell when it is discharged below a certain voltage Li Expander Pak is 2 5 V cell for an extended period of time Solar Stik Li Expander Paks contain eight 8 LiFePO4 supercells These cells require a complex BMS which manages the supercells and their protection circuits The BMS is solely ...
Page 26: ...r Charging mechanisms used with ANY Li Expander Pak do not have the ability to recognize when a cell in a battery module has failed or by extension when a battery has removed itself from service In any lithium battery that is made of multiple cells that is the exclusive role of the BMS External charging sources such as solar vehicular and the AC circuit will continue to attempt to charge at their ...
Page 27: ...l drop in voltage very quickly when they have reached low SOC The BMS will disconnect the terminals to prevent further discharge by an external component but the BMS itself requires power to operate THE BMS WILL CONTINUE TO USE POWER FROM THE CELLS TO PERFORM ITS PRIMARY FUNCTIONS even if the battery has disconnected itself from service The cells will continue to discharge internally in support of...
Page 28: ...senses the cell voltage is too low to discharge further time is of the essence to place the batteries on charge Failure to do this may cause a fatal error known as bricking Once the batteries reach their internal disconnect voltage the voltage can fall very rapidly in the internal cells causing the battery to brick This means that the battery cells are non recoverable and the battery module must b...
Page 29: ... small scale renewable energy power generation 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...
