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Solar Stik 24VDC HyPR 3000 Operator And Maintenance Manual

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24VDC HyPR 3000 Operator and Maintenance Manual
Operator and Maintenance Manual
for the
24VDC HyPR 3000
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 24VDC HyPR 3000 Operator and Maintenance Manual Operator and Maintenance Manual for the 24VDC HyPR 3000 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

    24VDC HyPR 3000 Operator and Maintenance Manual Contents GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Introduction Requirements for HyPR Operation HyPR 3000 Capabilities and Controls User Control Functions Data Management Theory of Operation General Information AC Functions Charging ........... . . 8 Inverting .
  • Page 3 24VDC HyPR 3000 Operator and Maintenance Manual 120 VAC OUTPUT Ports GEN COMM Ports Cooling Vents Faceplate DC Interface Solar Charging Status LED ......... . . 33 AC Interface AC Input Control Dial .
  • Page 4 24VDC HyPR 3000 Operator and Maintenance Manual List of Figures Figure 1. Schematized power flow from a top-down view of the interior of the HyPR 3000 ........... 7 Figure 2. Using the HyPR 3000 in Hybrid Model ......................12 Figure 3. Using the HyPR 3000 in UPS Model ....................... 12 Figure 4.

  • Page 5: General Information, Equipment Description, And Theory Of Operation Introduction

    DC and AC power outputs. The HyPR is a modular, portable component of the Solar Stik Architecture and its design and flexible function affords the operator a “multi-tool” for applications demanding a singular power solution to meet specific, and evolving, mission requirements.

  • Page 6: Hypr 3000 Capabilities And Controls

    24VDC HyPR 3000 Operator and Maintenance Manual HyPR 3000 Capabilities and Controls The HyPR features specific capabilities for the system in which it is employed and, while many of the circuits in the HyPR are fully automatic, outside user-established limits, not every HyPR feature may be used in every application.

  • Page 7: Theory Of Operation

    24VDC HyPR 3000 Operator and Maintenance Manual Theory of Operation The HyPR 3000 coordinates the support of AC and DC loads using power supplied from AC and/ or DC sources. Both AC and DC power sources energize the HyPR 3000 internal DC circuitry (DC bus), or the “Inter-Connect”...

  • Page 8: General Information

    24VDC HyPR 3000 Operator and Maintenance Manual General Information Circuit breakers on faceplate are only for IN/OUT circuit limit protections. They are NOT “function controls” or “function protections”. The internal DC Bus is limited to 100 A total current flow. This may restrict some HyPR functionality in certain operating modes.

  • Page 9: Dc Functions

    24VDC HyPR 3000 Operator and Maintenance Manual DC Functions The DC bus is effectively the nervous system of the HyPR. All HyPR functions are regulated directly or indirectly by the DC bus voltage. The DC bus voltage is functionally equivalent to the System battery voltage.

  • Page 10: Auto Generator Start / Stop

    • Generator stop set point = 29.0 VDC The generator start and stop voltage set points are programmable via a TECH PORT on the Faceplate. Contact Solar Stik Technical Support for assistance if reprogramming is required. April 2021 Solar Stik , Inc.

  • Page 11: Load Prioritization

    24VDC HyPR 3000 Operator and Maintenance Manual Load Prioritization In every operation mode, the HyPR will prioritize power to the load. It executes functions based on real-time operating conditions, which include: • total power available at the INPUTS • total power needed at the OUTPUTS •...

  • Page 12: Modes Of Operation

    24VDC HyPR 3000 Operator and Maintenance Manual Modes of Operation There are several operational modes in which the HyPR may be configured, depending on the application, Hybrid Mode–The hybrid mode allows the use of a smaller generator based on average, continuous total loads over a 24-hour period, versus a larger generator that will support “peak”...

  • Page 13: 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 14: Figure 6. Using Hypr In Inverter Mode

    24VDC HyPR 3000 Operator and Maintenance Manual Inverter Mode – The HyPR 3000 may be used in inverter mode when no AC power generation sources are available. This allows the combined total input of DC sources (including ESMs) to be dedicated to AC loads.

  • Page 15: Selecting An Ac Power Source

    AC load should not exceed the maximum continuous output of the AC power generator (i.e., maximum load AC power requirement ≤ generator AC power output). Moreover, to use the HyPR in hybrid mode, a fuel-powered generator must be compatible with Solar Stik auto generator start/stop capabilities.

  • Page 16: Battery Current Requirements For Hypr Ac Output

    24VDC HyPR 3000 Operator and Maintenance Manual Battery Current Requirements for HyPR AC Output A bank of batteries with the capacity to provide > 84 amps of current is required for the HyPR (inverter) to operate at its full rated capacity (2000 W). Battery banks with smaller current capacity are sufficient to power up the HyPR and support loads (AC and DC) that do not exceed the current capacity of the connected batteries.

  • Page 17: How To Minimize Derating

    • Do not overload the HyPR. Manage power processing demand by paying close attention to what is “plugged in. Prioritize critical loads. • Shade the HyPR 3000 to reduce solar loading. Solar Stik data indicate that solar loading of a Pelican case can increase internal heat by ~40 ºF (~ 22 ºC) above ambient.

  • Page 18: Important Safety Information And Instructions

    24VDC HyPR 3000 Operator and Maintenance Manual Important Safety Information and Instructions This manual contains important instructions that must be followed during the setup and operation of a the HyPR 3000. Read all instructions and information contained in this manual.

  • Page 19: Fire Hazard

    24VDC HyPR 3000 Operator and Maintenance Manual Fire Hazard Fire Types Class A fire - Fires in ordinary combustibles such as wood, paper, cloth, trash, and plastics. Class B fire - Fires in flammable liquids such as gasoline, petroleum, oil, and paint.

  • Page 20: Electric Shock Hazard

    24VDC HyPR 3000 Operator and Maintenance Manual Electric Shock Hazard WARNING Standing water around the electrical equipment and/or intrusion of water into the System components can increase the risk of electrical shock. HIGH VOLTAGE: System components, PV arrays, and generators may produce lethal line voltages.

  • Page 21: Environmental And Handling Precautions

    24VDC HyPR 3000 Operator and Maintenance Manual 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 22: The Inter-Connect System

    24VDC HyPR 3000 Operator and Maintenance Manual 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 23: 24Vdc Linear Inter-Connect Cable

    24VDC HyPR 3000 Operator and Maintenance Manual 24VDC Linear Inter-Connect Cable 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 7).

  • Page 24: Equipment Description Introduction

    24VDC HyPR 3000 Operator and Maintenance Manual EQUIPMENT DESCRIPTION Introduction The HyPR 3000 manages power between power sources and loads. The HyPR 3000 provides both AC and DC mechanisms to charge ESMs while the system is operating or idle. The HyPR 3000 provides important battery status information and therefore increased security for continuity of operations.

  • Page 25: Information Plate (I-Plate)

    24VDC HyPR 3000 Operator and Maintenance Manual Information Plate (I-Plate) The I-Plate is an application-specific part of the HyPR. It provides condensed instructions for deploying and operating a System that includes a HyPR as manager of power within the System.

  • Page 26: Ac Power Input Port

    24VDC HyPR 3000 Operator and Maintenance Manual AC Power Input Port Connect AC power sources to the 120-230VAC INPUT port. The HyPR 3000 accepts “universal” (85 - 264 V) power. Power via this connection charges batteries and supports DC loads connected the 24VDC IN/OUT and NATO ports.

  • Page 27: Power Scavenging Port

    24VDC HyPR 3000 Operator and Maintenance Manual Power Scavenging Port Connect unregulated DC power ranging from 9 to 36 VDC to this 4-pin bayonet connector. Power between these voltages is converted to 28.3 VDC and applied to the DC bus to charge batteries or support small loads.

  • Page 28: Expander Pak Only Port

    24VDC HyPR 3000 Operator and Maintenance Manual Expander Pak Only Port Connect Expander Paks (ESMs) to this metered Inter-Connect port. Use Inter-Connect cables to connect multiple ESMs to an Inter-Connect Strip 7 and to the HyPR 3000 EXPANDER PAK ONLY port.

  • Page 29: 24 Vdc In/Out Ports

    24VDC HyPR 3000 Operator and Maintenance Manual 24 VDC IN/OUT Ports The Inter-Connect Port is a direct connection to the HyPR DC bus. This port is not metered; may be used to parallel HyPRs or to connect additional power management components.

  • Page 30: Gen Comm Ports

    24VDC HyPR 3000 Operator and Maintenance Manual GEN COMM Ports These connectors provide a communication link between the HyPR and auto start/stop-capable generators. • GEN COMM #1 and GEN COMM #2 communicate with 1 kW and 2 kW generators. • GEN COMM #1 communicates with TQGs.

  • Page 31: Faceplate

    24VDC HyPR 3000 Operator and Maintenance Manual Faceplate Specifications AGS Alarm AGS Alarm Control Switch Generator Type Selection Switch Generator Control Switches and Status AC OUTPUT LEDs Status LED AC Input Control dial Tech port (AGS programming & firmware refresh)
  • Page 32 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 33: Dc Interface

    24VDC HyPR 3000 Operator and Maintenance Manual DC Interface The DC Interface consists of an LED that reports the battery charging status (see Table 1 for a functional description), an LCD screen and three (3) menu navigation buttons. System voltage and net current are reported on the DC INTERFACE home screen.

  • Page 34: Ac Interface Ac Input Control Dial

    24VDC HyPR 3000 Operator and Maintenance Manual AC Interface AC Input Control Dial This control may be thought of as the battery charging rate limit. 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.

  • Page 35: Breakers / Switches Panel

    24VDC HyPR 3000 Operator and Maintenance Manual Breakers / Switches Panel The HyPR can be configured into a System in many ways. Understanding the function of each breaker and its associated circuit is critical to proper operation. Circuit breaker panel is only for IN / OUT circuit limit protections.

  • Page 36: Connecting Generators To Hypr

    2 kW MPG 1 kW MPG May be paralleled May be paralleled Figure 25. Compatible generator options Note: The TQGs above must have a Solar Stik RsEK installed to be compatible with the HyPR. April 2021 Solar Stik , Inc. ®...

  • Page 37: Hypr Gen Comm Port Specificity

    Connect ONLY to Gen Comm #1 port on the front of the HyPR and the Auto Generator Control port on the TQG using a TQG Gen Comm Cable. A Solar Stik Remote-start Enabling Kit (RsEK) must be installed on a TQG to communicate with the HyPR.

  • Page 38: Figure 28. Defender 1 Kw And Ranger 2 Kw Gen Comm Cable Connections

    24VDC HyPR 3000 Operator and Maintenance Manual Defender 1 kW and Ranger 2 kW MPGs Connect to Gen Comm ports #1 and/or #2 on the front of the HyPR to the DC OUT / AUTOSTART port on the generator using a Ranger/Defender Gen Comm Cable.

  • Page 39: Mpg Parallel Connections

    24VDC HyPR 3000 Operator and Maintenance Manual MPG Parallel Connections The HyPR has the ability to receive power from two (2) MPGs simultaneously. The power output from each of two generators is merged into a single “Y” cable connected to a single power input port on the left side of the HyPR (Figure 12).

  • Page 40: Operator Instructions

    4. Check/Confirm/Program total Ah capacity in HyPR DC User Interface (typically programmed at Solar Stik for the application illustrated on the HyPR 3000 I Plate.) 5. Set HyPR AC INPUT CONTROL to match output limit of generator(s) or shore power.

  • Page 41: Navigating Dc User Interface Menus

    24VDC HyPR 3000 Operator and Maintenance Manual Navigating DC User Interface Menus The user interface has four main menus: 1. General Information, 2. Advanced Information, 3. Operation Setup, and 4. Battery Charger Parameter Setup. The Home screen is in the General Information menu.

  • Page 42: Programmable Parameters

    SET ACCEPT CHG and SET FLOAT CHG - These values will vary depending on the System battery type. These settings are programmed by Solar Stik in accordance with the intended application. If changes to the intended application are required, please contact Solar Stik Technical Support for assistance with these settings.

  • Page 43: Maintenance

    24VDC HyPR 3000 Operator and Maintenance Manual Maintenance Preventive Maintenance Checks and Services (PMCS) 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 44: Figure 33. Replacing Hypr Air Intake Filter (Left); Cleaning A Hypr Air Intake Filter (Right)

    24VDC HyPR 3000 Operator and Maintenance Manual 2 Remove and inspect the filter. Replace the filter if it is damaged (arrows in Figure 33). If the filter is in good shape, clean it by rinsing it with water to remove the particulate matter then dry it.

  • Page 45: Water Intrusion Remediation

    24VDC HyPR 3000 Operator and Maintenance Manual Water Intrusion Remediation If water intrusion is suspected, and the System is still functional, disconnect power sources entering the HyPR 3000 from the most distant location possible, power down the System (turn off the power switches on all of the System components) and then disconnect the HyPR 3000 from the System.

  • Page 46: Technical Specifications

    24VDC HyPR 3000 Operator and Maintenance Manual TECHNICAL SPECIFICATIONS General Safety Nominal Operating Voltage 24 VDC Breaker(s) (1) 100A, (3) 20A, (1) 30 A Battery Chemistry LiPO /Pb Compatible Fuse(s) Operational Voltage Range 25-29 VDC Certifications Built and designed to MIL-STD-810G and IP65...

  • Page 47: 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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