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February 2020

|

Solar Stik

®

, Inc.

30

|

System Setup and Operation Manual for ATSC MS3 L0

Gen Comm Cable:

“GEN COMM” port on the 24VDC PRO-Verter 5000 and “GEN COMM” port on

the generator using gray-to-gray connection

Power Cable:

AC power out on the generator to the “120 VAC INPUT” port on the left-hand side of

the PRO-Verter 5000 using blue-to-blue connection

b Connect PRO-Verter to generator

Make power and communications connections between the generator and PRO-Verter according to
Figure 13:

PRO-Verter

left side view

Yanmar YDG 5500

5.5 kW generator

Control Panel

Gen Comm Cable

AC Input Power Cable

Figure 13. PRO-Verter to generator connections

PRO-Verter

front view

GROUND

GEN COMM

5 Connect System components

Make connections between the System components that are to remain on the trailer according to the
diagram on the PRO-Verter I-Plate and in this manual. The lines connecting the components indicate
the colors of the connections to be made.

a Connect PRO-Verter to Expander Paks

Connect five (5) Expander Paks to the Inter-Connect Strip 7 with five (5) 5’ Inter-Connect Cables.
Connect the Inter-Connect Strip to the PRO-Verter with two (2) 10’ Inter-Connect Cables. All of these
are red-to-red connections.

Figure 14. PRO-Verter to Expander Pak connections

24VDC PRO-Verter

5000-220

Inter-Connect

Strip 7

24VDC Li Expander Pak 2400 (x5)

5’ Inter-Connect

Cables (x5)

10’ Inter-Connect

Cables (x2)

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Содержание ATSC MS3 L0

Страница 1: ...1 February 2020 Solar Stik Inc SYSTEM SETUP AND OPERATION MANUAL FOR ATSC MS3 L0 Version 1 0 Updated 20200214 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited...

Страница 2: ...ntrusion 14 Heat 14 THEORY OF OPERATION Models of Operation 15 DC only Inverter Automatic Functions 15 Hybrid Automatic Functions 15 Load Support Automatic Functions 15 Peak Power Delivery manual func...

Страница 3: ...34 C System Initialization and Calibration 35 D Order of Operations Activation and Deactivation of the System 36 L0 Isolation of Operations 36 L0 architecture Deactivation Sequence 36 Steps to power...

Страница 4: ...ons 61 Clearing Faults 61 AC Overload 61 Breaker Tripped 61 Dead Batt Charge 62 FET Overload 62 High Battery 63 High Batt Temp 63 High Volts AC 63 Overcurrent 64 Overtemp 64 Stuck Relay 64 Tfmr Overte...

Страница 5: ...e Gen Run 75 Days Since 100 SOC 75 Battery Monitor BMK Data Meter 05 76 BMK Status 76 Battery SOC 76 DC Volts BMK 76 DC Amps BMK 76 AH In Out 76 Reset AH Out 76 Total AH Out 77 Minimum VDC 77 Maximum...

Страница 6: ...Cases to Prevent Tampering 90 SOC Disparity Among Expander Paks 91 Restoring SOC Parity 91 Method to Restore Expander Pak SOC Parity 91 Maintaining SOC Parity 92 Method to Maintain Expander Pak SOC Pa...

Страница 7: ...of the cables as shown 31 Figure 17 Solar Array to Power Hub connections 32 Figure 19 PRO Verter to Power Hub connection 32 Figure 18 Power Hub air intake port and vent filter 32 Figure 20 RMK extern...

Страница 8: ...7 Nov 2019 List of Tables Table 1 Charge Status Indicator LED Status 47 Table 2 List of Faults and Source s of Problem 54 Table 3 Troubleshooting the User Interface LCD Screen 56 Table 4 Symptoms and...

Страница 9: ...ttery bank supports the load The power for the load is drawn from the batteries only as needed Multiple sources of power generation can be used simultaneously to support the battery and ensure uninter...

Страница 10: ...be used exclusively when performing this step The generator should not be used Once the mast and payload are fully deployed the remaining L0 systems and payloads can be activated and the system can be...

Страница 11: ...nd 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 Labels Your safety and the safety...

Страница 12: ...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 safe distan...

Страница 13: ...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 2 PRO Verter grounding lug Electric Shock Hazard W...

Страница 14: ...er 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 d...

Страница 15: ...ybrid Model the batteries will cycle regularly to mitigate generator runtime and logistical support often associated with operation in remote locations Hybrid systems also provide the operator with a...

Страница 16: ...C and DC power to the loads The HPS is a powerful solution for the following conditions 1 The generator requires protection from adverse operating conditions 2 Grid or generator AC power sources are n...

Страница 17: ...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 the rated inverter charger current requir...

Страница 18: ...nly after 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 its battery charging rate to...

Страница 19: ...is an automatic function of the PRO Verter that combines power from a generator or grid AC source with the inverter s AC output to briefly support high AC loads that exceeds the AC source s or the PRO...

Страница 20: ...ed 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 take up to 1 full second for the...

Страница 21: ...power distribution and management modules stacking of generators with PRO Verters Power Hubs and more Consult the individual product manuals for additional information about scaling and stacking Note...

Страница 22: ...y 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 Figure 6 Note Do not m...

Страница 23: ...he 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 th...

Страница 24: ...al for ATSC MS3 L0 Figure 7 Inter Connect Plug The Standard Inter Connect Plug Polarized 200 A maximum current 24 VDC connection only Mechanically locks into place Rotate knob clockwise to lock counte...

Страница 25: ...r coded Connections Cables and ports are color coded based on their function Figure 8 System connection color coding Orange Solar Circuit Connection Red DC Circuit Connection Example Ports Cable Color...

Страница 26: ...0 220 o One 1 Inter Connect Strip 7 o Five 5 24VDC Li Expander Pak 2400s o One 1 AC Input Power Cable 15 220 V 50 Hz Blue o One 1 AC Output Power Cable 15 220 V 50 Hz Green o One 1 Gen Comms Cable 15...

Страница 27: ...w Figure 9 System Setup Guide on the PRO Verter I Plate Figure 10 System connection diagram 24VDC Power Hub 2400 420W Solar Array 24VDC PRO Verter 5000 220 5 5 kW Yanmar YDG 5500 Inter Connect Strip 7...

Страница 28: ...Cable Transport Case 420W Expedition Solar Array C Kit Inventory o Four 4 105 W Photovoltaic PV Panels o One 1 Transport Case o One 1 Rollable Stand o Twelve 12 Sandbags o Ten 10 Stakes o One 1 30 So...

Страница 29: ...the System the Solar Arrays could be up to 50 from the PRO Verter trailer ALL Solar Stik equipment is designed for operation in adverse conditions however certain rules apply 1 If operating in wet env...

Страница 30: ...ble Figure 13 PRO Verter to generator connections PRO Verter front view GROUND GEN COMM 5 Connect System components Make connections between the System components that are to remain on the trailer acc...

Страница 31: ...uctions see the 420W Expedition Solar Array C Operator Manual The panels should be positioned for maximum daily sun exposure DO NOT secure the Solar Arrays to the ground until the entire System is set...

Страница 32: ...much as possible from exposure to particulate matter dust sand etc The air filter under the louvered vent cover must be kept clean to maximize the efficiency of the Power Hub Figure 18 Power Hub air i...

Страница 33: ...erter at the grounding lug is a safety measure The PRO Verter and the generator should be bonded to the trailer equipment grounding conductor which should be connected to the earth grounding rod When...

Страница 34: ...rify the Inverter function engages The LED next to INV will be illuminated when the inverter is operating 1 Connect loads to the PRO Verter If not already connected 2 Verify the generator has fuel and...

Страница 35: ...ink green indicating that the AGS function is initiating the generator start sequence ii Once the generator is operating verify the AC IN LED illuminates and the LCD displays CHARGE MODE within 90 sec...

Страница 36: ...e configured to provide a MINIMUM cumulative 200 A DC to the System for the PRO Verter to function at its rated power The state of charge reported by the PRO Verter 5000 will be accurate only if the t...

Страница 37: ...er Light green menu items represent resettable menu selections Press and hold the knob for 3 seconds to reset values Menu Map Color Coding Key F L0 PRO Verter Programming Menu Map The PRO Verter has b...

Страница 38: ...ol SOC Connect Set AC In Control AC In Disabled 04 PT Control Press Select See Setup Button 04 Menu Options Feature not utilized by PRO Verter 5000 METER Status 01 DC Meters Status 02 AC Meters Status...

Страница 39: ...ult 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 Start 100 SOC Available Statuses...

Страница 40: ...AM Set Screen Setup Pwr Save 15 min 02 Invert Setup 02A Search Watts OFF 02B LBCO Setting Volts 24 4 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...

Страница 41: ...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 Max Charge Time 12 0 Hrs Set Final Charge St...

Страница 42: ...efault 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 Set Start Gen AC Amps OFF Set Star...

Страница 43: ...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 1 00P Set Stop Quiet Minute 00 45...

Страница 44: ...l battery bank size is at least 200 Ah 04K Gen 100 SOC Start Days Off Set Gen 100 SOC Start Days Off Set 100 SOC Run Hour 1 00P Set 100 SOC Run Minute 0 45P Set 100 SOC Run AM PM 0 00P Set Gen 100 SOC...

Страница 45: ...ays 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 displays H1 the most recent fault H2...

Страница 46: ...in the Menus and Submenus section to assist in knowing when one menu ends and the next begins To change settings parameters in the SETUP and BATTERY CHARGE PARAMETERS menus move forward through the me...

Страница 47: ...he constant voltage phase With the Li Expander Pak 2400 the acceptance charge phase is not necessary Float Charge This final stage compensates for the battery s self discharge and temperature Temperat...

Страница 48: ...ailable on the Power Hub 2400 Disabled Sealed lead acid and lithium batteries should never be equalized Total battery Amp hours from full are used to compute remaining battery capacity which is shown...

Страница 49: ...Hub NOT the batteries It provides a rough estimate of the temperature of any associated Expander Paks The battery temperature sensor is installed inside of the Power Hub It is not possible to reprogr...

Страница 50: ...ltage control if battery amp hours are unavailable Enables disables and sets ON time for Lighting Control mode Lighting Control mode is disabled if BOTH post dusk and pre dawn timers are set to DISABL...

Страница 51: ...Float Transition Current Range 0 1 to 10 0 A per 100 AH Set to 1 5 A 100 AH Sets Acceptance charge time Set to 0 5HRS Disabled Sets Float Charge Voltage set point 29 0 V SET ACCEPT CHG 29 0V SEL SET F...

Страница 52: ...erter 5000 J Hybrid System Bypass Mode Bypassing the Hybrid Power System may be helpful if the HPS is temporarily inoperable Figure 27 Hybrid Power System bypass connection Hybrid Mode Hybrid System B...

Страница 53: ...03 Gen Control AUTO Set Gen Control AUTO Set Gen Control ON Set Gen Control OFF P R R 1 Turn off the power switches on all components All circuits must be completely de energized before disconnecting...

Страница 54: ...provides the faults most commonly encountered when a System is running in Hybrid mode The source s of the problems that generates these faults is indicated by an X in the appropriate column This info...

Страница 55: ...computer or handheld device Each of the faults in the lists below is touch linked to an explanation of the fault and a solution to resolve the fault BMK Statuses BMK Ready Think n AGS Statuses AC In G...

Страница 56: ...ssover 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 electricity...

Страница 57: ...on 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 any communication data via the PRO Verter s In...

Страница 58: ...ate 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 Charge Time setting is reached Float Charging A...

Страница 59: ...ode the charger is not actively charging but does monitor the battery voltage When the battery voltage reaches the Set Rebulk Voltage setting from 03G Final Charge Stage menu the charger will restart...

Страница 60: ...rging 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 Charge LED is on steady and the unit says...

Страница 61: ...C 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 inverter s output capacity due to unaut...

Страница 62: ...t 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 0 5 VDC difference If not ensure all connectio...

Страница 63: ...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 connected to the PRO Verter Low Battery LBCO No power...

Страница 64: ...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 through relay that should be open while invertin...

Страница 65: ...s fault message displays when the internal AC transfer relay is not closed while charging Solution If one of these internal faults occurs the inverter will require an inverter or power reset to clear...

Страница 66: ...f 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 to section Resolving AGS Operationa...

Страница 67: ...appear only if the PRO Verter were programmed differently They are shown only as a reference Back to Quick Links page Start Amp Generator has autostarted based on the SETUP 04C Gen Run Amps setting St...

Страница 68: ...u 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 AGS has determined that...

Страница 69: ...loading and shutting down the generator successfully started and ran for more than two 2 minutes but the generator unexpectedly stopped before the active AGS autostop condition was finished This fault...

Страница 70: ...ve controls If the generator does not start check the generator for fault codes adequate fuel and refer to the generator Operator and Maintenance Manual If the generator starts reconnect it to the Sys...

Страница 71: ...g and keep the air intake filters clean to promote more efficient cooling Note After the fault clears and the reason for the fault is determined be sure to enable the AGS to autostart Go to the CTRL 0...

Страница 72: ...first connected 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 provi...

Страница 73: ...ear Faults menu See the diagram below Rotate the SELECT knob to display the second and third screens for the particular fault shown on the first screen After viewing all screens for the fault continue...

Страница 74: ...s until 04 AGS Meters or 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 sta...

Страница 75: ...ine 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 Days Since Gen Run Th...

Страница 76: ...lays 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 discharge current amps out of t...

Страница 77: ...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 or not communicating...

Страница 78: ...ment device e g PRO Verter or 24VDC Expander Pak 1000s Not registering charge current with panels operating in sun 1 Power Hub overheated 2 Batteries fully charged 29 0 VDC or near to that 1 Check int...

Страница 79: ...d or cannot be corrected by listed corrective actions contact the Field Service Representative Equipment Condition Assumption Statement The Power Hub is fully functional and operating normally Lower T...

Страница 80: ...LED Color Frequency Condition Green Flashing Normal operation Red Flashing Protection circuits engaged 1 Cell overvoltage 2 Cell undervoltage 3 Overcurrent charge or discharge 4 Overtemperature 160 F...

Страница 81: ...tely 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 genera...

Страница 82: ...for the System 3 Verify all Expander Pak switches are in the ON position 4 If the internal transformer is in danger of overheating the AGS will automatically start the generator to ensure continuity...

Страница 83: ...PRO Verter Cannot Communicate with RMK Conditions Observed or Possible Causes or Inability to Communicate with RMK Possible Causes A RMK does not have green light B RMK has not been at green light st...

Страница 84: ...IP address of the gateway gateway host name 2 If using DHCP consult the documentation for the DHCP server Status Light Stays Orange after Inserting USB Drive Cause RMK automatically copying large num...

Страница 85: ...er Hub and PRO Verter turn on to maintain the internal temperature within the optimal operating range The fans are audible when operating Clogged air intake filters can significantly exacerbate heat r...

Страница 86: ...s located inside the Power Hub Note THIS IS NOT REPORTING THE TEMPERATURE OF THE BATTERIES but rather the temperature inside the Power Hub case This value is reported independently for each of the thr...

Страница 87: ...rOvertemp during peak demand ensure that the AGS is set to Auto FAVS 5 Menu and that Set Gen Run Temp is set to 1 0 Hrs If this option is available by following the Menu Map below Set Gen Run Temp Off...

Страница 88: ...month or more frequently as warranted to minimize the accumulation of internal heat See the component manual for air filter cleaning instructions Follow the generator maintenance procedures listed in...

Страница 89: ...The Inter Connect Strip 7 is a DC bus for the entire System and should be placed in a protected and dry location to minimize the possibility of water intrusion If water enters the Strip power down th...

Страница 90: ...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 damage to the internal components f...

Страница 91: ...g 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 Restoring SOC Parity The only meth...

Страница 92: ...et Exercise Run Minute 8 00 Set Exercise Run AM PM 8 00A Set Exercise Run Time 1 25 5 Hrs Set Exercise Run Time 12 0 Hrs 1 Press the SETUP Button on the PRO Verter user interface password may be requi...

Страница 93: ...nto each of the fields Start with the frequency e g every 3 days as shown and at an appropriate time of day 4 Confirm that the SOC of the System battery bank reported in METER 05B is 100 Note Ensure t...

Страница 94: ...egular 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 application is that it will cycle 1 2 times...

Страница 95: ...nual 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 the power stored in the battery c...

Страница 96: ...oceed 2 Battery Status LED color M Q 1 Push and hold the Battery Status LED button 2 Record the color of the Battery Status LED in the maintenance service log 3 If the Battery Status LED is flashing r...

Страница 97: ...d 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 replacement is not immediately available th...

Страница 98: ...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 column of Figure 33 3 Reinstall the...

Страница 99: ...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 1...

Страница 100: ...to personnel and damage to any connected equipment 3 PV array output Q2 1 Ensure each PV array is oriented for optimal sun exposure 2 Independently check on the Power Hub User Interface the power outp...

Страница 101: ...the panel is considered under load such as a charge controller Power Hub or Power Pak Voltage open circuit Voc is unregulated panel voltage and measured directly from the leads of a panel or an array...

Страница 102: ...ace will report very low to no charging current even in full sun if the connected batteries are fully charged 3 Disconnect two 2 of the three 3 PV arrays from the Power Hub Leave one 1 connected as a...

Страница 103: ...he master but for the pair of solar panels connected to SLAVE1 input ports Press NEXT The number 2 displays in the upper left corner This is SLAVE2 Charge Unit 2 This window reports same as the master...

Страница 104: ...scribed in the next section and Figure 3 Procedure to Measure Voc of a Single PAM Quarter Panel To measure the Voc of a PAM quarter panel carefully place the leads of the voltmeter in on the quarter p...

Страница 105: ...e 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...

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