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49

December 2020

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Solar Stik

®

, Inc.

SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM

PRELIMINARY DRAFT

TROUBLESHOOTING

The PRO-Verter is the central management device in most Systems and as such will be the primary
device to report and correct issues both within the PRO-Verter and the System.

Table 4. List of Faults and Source(s) of Problem

Most faults and System failures can be caused by two factors: (1) incorrect programming values
in the PRO-Verter (and possibly the Power Hub) or (2) incorrect setup. Ensure the PRO-Verter and
Power Hub programming values are set according to the Program Requirements.

Table 4 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 information will streamline the troubleshooting process by telling the operator what
to check first. 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. Refer to the component Manuals if faults are not System-related.

Fault

Excessive

Load

Generator Batteries

Power

Hub

AGS

Cable

AC Cable

Heat/

Derating

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Generator Faults

1. Press CTRL button. Scroll to “03 Gen Control”. Press SELECT. Rotate SELECT dial to “OFF”. Press SELECT.
2. Press CTRL button. Scroll to “03 Gen Control”. Press SELECT. Rotate SELECT dial to “ON” or “AUTO”. Press

SELECT.

Low Battery Fault

Apply AC power source to PRO-Verter to support loads and charge ESMs. Fault condition will reset automatically when
ESMs are charged above 24 VDC.

Overtemp Fault

Inverter will automatically reset after 60 seconds of cooling fan operation.

Overcurrent Fault

Check circuit breakers. If green LED is not illuminated, reset breaker.

Reverse Polarity Fault

LED indicator will illuminate if the AC input connections are not correct

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Содержание USAF G-BOSS

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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