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Solar Stik 24VDC HyPR 3000 Operator And Maintenance Manual

Security force assistance brigade (sfab) hybrid power system
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System Setup Operation and Maintenance Manual for the SFAB HPS
Operator and Maintenance Manual
for the Security Force Assistance
Brigade (SFAB) Hybrid Power System
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Version 1.0
Updated:20210413
April 2021
|
Solar Stik
, Inc.
|
1
®
PRELIMINARY DRAFT

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  • Page 1 System Setup Operation and Maintenance Manual for the SFAB HPS Operator and Maintenance Manual for the Security Force Assistance Brigade (SFAB) Hybrid Power System DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Version 1.0 Updated:20210413 April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 2: Table Of Contents

    Data Plate (D-Plate) ..........19 24VDC HyPR 3000-120 AC Power Input Port .
  • Page 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS) 24VDC HyPR 3000 PMCS HyPR 3000 Air Intake Filter Maintenance* ........48...
  • Page 4 Table 1. Charge Status Indicator—LED Status ....................... 41 Table 2. HyPR 3000 Preventive Maintenance Checks and Services ................48 Table 3. 24VDC Li Expander Pak 1300 In-storage Preventive Maintenance Checks and Services ....... 49 April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...
  • Page 5 System Setup Operation and Maintenance Manual for the SFAB HPS Revision History Section Page(s) Description Date First released as a PRELIMINARY DRAFT March 2020 April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 6: General Information, Equipment Description, And Theory Of Operation

    The introductory parts of this Manual describe Hybrid Power Systems (HPS) composed of Solar Stik components. However, the Solar Stik architecture is modular and open allowing Operators to integrate non-Solar Stik components as part of a HPS solution. Please contact Solar Stik Technical Support for assistance in optimizing the integration of other components.

  • Page 7: Theory Of Operation

    The following diagram illustrates where to connect power sources, 24VDC Li Expander Pak 1300s and loads to the HyPR. For normal operation, at least three (3) 24VDC Li Expander Pak 1300s must be connected. 24VDC HyPR 3000 24 VDC INPUT/OUTPUT 90-250 VAC...

  • Page 8: Modes Of Operation

    • ESMs do not cycle AC Power Processing Limits   3000 W AC Input from source(s) 2000 W AC Output for loads Grid Loads Energy Storage Figure 3. Using the HyPR 3000 in UPS Model April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 9: Figure 4. Using Hypr In Power Conditioning Model

    ESMs and/or to support small 120 VAC or 24 VDC loads. It is not necessary for a Solar Stik ESM to be connected to the HPS to take advantage of the Scavenging circuit. If ESM’s are not connected, however, the HyPR can only support loads up to the amount of power provided through the Scavenging circuit (Figure 1).

  • Page 10: Figure 6. Using Hypr In Inverter Mode

    • Connection to a vehicle NATO port is available. Vehicle / Other Solar AC Power Limits 2000 W with ESMs connected Loads ESMs Scavenge 9-36 VDC Figure 6. Using HyPR in Inverter Mode April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 11: Hypr 3000 Internal Circuits

    The arrows indicate the flow of current in the circuits. Several HyPR 3000 connectors shown below provide options to extend the DC bus by connecting another modular Solar Stik component to add functionality. This will become apparent when viewing System Connection Diagram. 24 VDC...

  • Page 12: The Inter-Connect System

    System Setup Operation and Maintenance Manual for the SFAB HPS The Inter-Connect System A Solar Stik System is comprised of three (3) distinct types of technologies: • Energy storage • Power management • Power generation All of the individual components that operate in these categories utilize a unique connection architecture known as the Inter-Connect Circuit.

  • Page 13: Energy Storage-The Foundation Of A System

    • Capabilities including inverters, advanced power distribution and management modules can be added (or removed). Note: Scaling or modifying the System architecture should be done with all components in the System completely inactive and OFF. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 14: Important Safety Information And Instructions

    Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury All safety messages will describe what the potential hazard is, how to reduce the chance of injury, and what can happen if the instructions are not followed. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 15: Fire Hazard

    Sweep the nozzle or hose from side to side until the fire is out. Move forward or around the fire as the fire diminishes. Watch the area for reignition until the cause has been fixed. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 16: Electric Shock Hazard

    Wear safety glasses whenever working on any part of a system that requires exposure to mechanical or direct electrical contacts. DON’T LET THIS BE YOU! WARNING The System is NOT GFCI protected. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 17: Environmental And Handling Precautions

    System Setup Operation and Maintenance Manual for the SFAB HPS Environmental and Handling Precautions All Solar Stik components are ruggedized, yet there are a few things the operator can do to prevent failures and prolong the operational life of the Solar Stik System.

  • Page 18: Equipment Description 24Vdc Li Expander Pak 1300 External Features

    • Inter-Connect Port - Point of connection with the system 24 VDC bus, Inter-Connect network • Stacking Locks- Provide stability and alignment for stacked Expander Paks • Tech Port - Contact Solar Stik Technical Support for information. Stacking Locks (x4)

  • Page 19: Data Plate (D-Plate)

    System Setup Operation and Maintenance Manual for the SFAB HPS Data Plate (D-Plate) Figure 10. 24VDC Li Expander Pak 1300 D-Plate April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 20: 24Vdc Hypr 3000-120

    System Setup Operation and Maintenance Manual for the SFAB HPS 24VDC HyPR 3000-120 The HyPR 3000 is a power management component. The MAIN POWER switch is not a “kill all” switch. This switch turns on or off the flow of energy from any ESMs connected to the HyPR.

  • Page 21: Dc Power Input Ports - Solar And Scavenge

    Figure 13. HyPR 3000 power input ports NATO Port - 24 VDC Input/Output Port Description Connector Amps Voltage NATO Slave 24 VDC 24 VDC NATO Slave (unmetered) Figure 14. HyPR 3000 NATO port April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 22: Inter-Connect 24 Vdc Input/Output Port

    The HyPR Inter-Connect port is an ESM-dedicated port. This is a metered port. Description Connector Voltage Amps Battery Connection (metered port) Inter-Connect Port 24 VDC Figure 16. HyPR 3000 Expander Pak only port April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 23: 120 Vac Output Ports

    • GEN COMM #1 communicates with TQGs. TQG only 1 kW and 2 kW generators Description Connector Voltage Amps Amphenol HA100001-02-36 Gen Comm Ports Figure 18. HyPR 3000 generator communications ports April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 24: Cooling Vents

    The intake and exhaust vents have fans to move air through the case for cooling. Note: the exhaust vent may become hot to the touch during operation. Back side Left side Air intake vent Exhaust vent (has air filter) Figure 19. HyPR 3000 cooling vents April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 25: Faceplate

    The “Off” position defeats the HyPR AGS communication with any connected genset. Generator Status LEDs – Each displays the current status of a connected generator. A legend correlating the blinking pattern with a status is immediately above the LEDs. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...
  • Page 26 AGS TECH PORT – This port is used to program the Auto Generator Start/Stop module and to update firmware if/when necessary. Please contact Solar Stik Technical Support for further information. Specifications – A list of performance metrics and limitations for the HyPR; provides guidance when configuring a System.

  • Page 27: Hypr 3000 Breaker Panel

    Adjust this dial to match the maximum output of the AC power source connected to the HyPR. Properly setting this value will prevent overloading the AC power source. Figure 23. AC Input Control dial April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 28: Programmed System Operating Parameters

    System Setup Operation and Maintenance Manual for the SFAB HPS Programmed System Operating Parameters Several operating parameters are programmed at Solar Stik for a specific application. The values do not need to be changed when the HyPR is used as configured in this Manual. The values may be changed if a new configuration is required (e..g., using lead acid batteries instead of LiFePO...

  • Page 29: System Connection Diagram And Inventory

    System Setup Operation and Maintenance Manual for the SFAB HPS System Connection Diagram and Inventory Power Generation Power Management Load 24VDC HyPR 3000-120 AGS 120VAC Output (x4) Novatio 2kW Generator (x2)* 24 VDC (NATO) Universal AC Energy Inter-Connect Strip 7...

  • Page 30: Components Listing

    System Setup Operation and Maintenance Manual for the SFAB HPS Components listing 24VDC HyPR 3000-120 AGS 24VDC Li Expander Pak 1300 24VDC Inter-Connect Strip 7 Item # 20-0102008 Item # 21-0202316 Item # 13-1000160 Cable, Power Y, Banana-M/L5- Cable, Gen Comm, 10-PIN/12- Cable, Power, Whip, CB6TA18- 30P, 120VAC, 10’, 10AWG...

  • Page 31: Information Plate

    Configure System as shown in System Setup Diagram. Loads are supported by ESMs. The HyPR automatically starts/stops the generator(s) 24VDC HyPR 3000-120 AGS based on ESM voltage and continuously cycles the ESMs. Ensure location of the equipment is in accordance with safety and operation protocols of Security Force Assistance Brigade (SFAB) Operations.

  • Page 32: Operator Instructions

    Figure 25. Minimize solar loading Minimize Potential for Water and Dust Intrusion ALL Solar Stik equipment is designed for operation in adverse conditions; however, certain rules apply: • If operating in wet environments, use common-sense placement to avoid water intrusion from flooding or precipitation.

  • Page 33: Connect System Components

    Note: At least three (3) Expander Pak 1300s must be connected for the HyPR 3000 to operate at rated capacity. Li Expander Pak 1300 Inter-Connect HyPR 3000 Strip 7 Figure 26. Connecting ESMs to HyPR 3000 April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 34: Connect Hypr To Ac Power Source

    The HyPR may be connected to AC grid power at voltages ranging from 120-230 VAC and 40- 70 Hz. The cable necessary to connect to grid power is a custom cable and not described in the System inventory. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 35: Connecting Generators

    The power output from the generators is merged into a single “Y” cable connected to the 120 - 230 VAC INPUT port on the left side of the HyPR. AC Power “Y” Cable HyPR 3000 Figure 29. HyPR/generator power connections April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 36: Figure 30. Hypr/Generator Comms Connections

    Connect GEN COMM ports #1 and #2 on the front of the HyPR to the E-START ports on the generators using the 10’ Gen Comm Cable. HyPR 3000 Gen Comm Ports Ranger 2 kW generator Ranger 2 kW generator Figure 30. HyPR/generator comms connections April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 37: Optional: Connecting Hypr 3000 To A 3 Kw Tqg

    System Setup Operation and Maintenance Manual for the SFAB HPS Optional: Connecting HyPR 3000 to a 3 kW TQG The HyPR 3000 can remotely start/stop TQGs that have been modified with a Solar Stik Remote- start Enabling Kit (RsEK). Note: Connect the TQG to GEN COMM #1 port. GEN COMM #2 port does not support auto start/stop of a TQG.

  • Page 38: Connect Ac Loads To Hypr 3000

    Ensure generator has adequate JP-8 fuel. b. Rotate generator power switch counterclockwise to ON position. c. Rotate fuel tank vent valve to OPEN position. Figure 33. Prepping the 2 kW generator for operation April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 39: Optional: Connect Solar Power To Hypr 3000

    Connect solar array(s) to the HyPR 3000 to charge Expander Paks and/or support loads. Specifications for the solar charge controller and compatible PV arrays are on the HyPR 3000 Faceplate. Solar arrays provided by Solar Stik will be paired with the appropriate solar cable.

  • Page 40: System Operation

    5. Confirm charging operation begins within 5 minutes. AC Input Control Settings The table provides recommended settings for four (4) potential generator configurations. Settings maximize ESM charging while protecting the generator from faulting due to overloading. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 41: System Monitoring

    Solar Charging Status LED Charge Mode Charge Off Continuously On Bulk Blinking – 1 second On / 1 second Off Acceptance Blinking – 0.2 second On / 1 second Off Float April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 42: State Of Charge (Soc) Calculation

    The battery voltage and the System net current are reported on the HyPR DC Interface home screen. Note: The HyPR must be connected to ESMs in order for the DC Interface to report net System current. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 43: Dc Interface Menu Windows

    OFF status, –or– load control status depending on OUTPUT function selected in the charge controller Disabled: Sealed lead-acid and lithium batteries should EQUALIZE NOW AT AT 29.2V never be equalized. ENTER ADVANCED DSPLY/SETUP SEL To Advanced Information Menu April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...
  • Page 44 (as is the case in the HyPR 3000) there is no need to enter these submenus. All relevant data are available elsewhere in the read only menus. ENTER SETUP MENUS To Operation and Setup Menus April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...
  • Page 45 RESET DEFAULT SETTINGS amp hour readings will result. Restores all factory default settings in the charge control SET BAT CHARGE system. PARAMETERS SEL To Battery Charge Parameter Setup Menus April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...
  • Page 46 SET FLOAT CURRENT Range 0.1 to 10.0 A per 100 AH 1.5A Set to 1.5 A/100 AH SET ACCEPT TIME Sets Acceptance charge time Set to = 0.5HRS 0.5HRS End of Menus April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 47: Troubleshooting

    Solution: Decrease AC INPUT CONTROL setting. Symptom: AC output turns off Cause: Generator failed to start; load exceeds inverter output; low-voltage disconnect; inverter overheated, Solution: Inspect generator, loads, and settings; allow inverter to cool down. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 48: Preventive Maintenance Checks And Service (Pmcs) 24Vdc Hypr 3000 Pmcs

    System Setup Operation and Maintenance Manual for the SFAB HPS PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS) 24VDC HyPR 3000 PMCS Table 2. HyPR 3000 Preventive Maintenance Checks and Services Item to be Item # Inspected Interval Procedures Non-mission Capable 1. Inspect case for visible damage ~If the case is broken or split or and missing items.

  • Page 49: 24Vdc Li Expander Pak 1300 Pmcs

    Failure to follow these instructions may result in permanent equipment failure and/or personal injury Required Tools Solar Stik HyPR 3000, PRO-Verter or LiFePO battery maintenance charger. Table 3. 24VDC Li Expander Pak 1300 In-storage Preventive Maintenance Checks and Services Item to be...

  • Page 50: Expander Pak Storage

    Do NOT leave Li Expander Paks on a constant charge during long periods of storage. Cell damage may occur. Once the battery reaches 100% SOC during maintenance charging, the charging source should be removed until the next charging interval is determined. April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 51: How To Charge Expander Pak 1300S

    INPUT, SOLAR ONLY, 6-36 VDC INPUT and 24VDC IN/OUT. Battery charging rates among the these connections will vary. All four (4) ports many be used simultaneously. Adaptors for each connector type are available from Solar Stik. The solar charge controller and the AC > DC converter/charger are programmed to charge batteries at 29.0 VDC while the 9-36 VDC INPUT converts DC power in this voltage rage to 29.0 VDC.

  • Page 52: Water Intrusion Remediation

    The HyPR 3000 transports like a briefcase or rolls on wheels when transport handle is extended. It is safe for all modes of transportation, including land, sea, and air. There are no transport restrictions. Figure 40. HyPR transport wheels and pull-handle April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 53: Technical Specifications

    • Reset 23 ºF (-5 ºC) • Trip 131 ºF (55 ºC) High-temperature Charging • Reset 122 ºF (50 ºC) • Trip 194 ºF (90 ºC) High-temperature Discharging • Reset 131 ºF (55 ºC) April 2021 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 54: 24Vdc Hypr 3000-120

    System Setup Operation and Maintenance Manual for the SFAB HPS 24VDC HyPR 3000-120 General Safety Nominal Operating Voltage 24 VDC (1) 100A, (3) 20A, (1) 30 A Breaker(s) Battery Chemistry LiPO /Pb Compatible Fuse(s) Operational Voltage Range 25-29 VDC Certifications...

  • Page 55: About Solar Stik, Inc

    • 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 the students. To schedule Solar Stik Training or to learn more about the curriculum, please contact us.

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