1. Manuals
  2. Brands
  3. Solar Stik Manuals
  4. Power Supply
  5. USAF G-BOSS
  6. Setup and operation

Solar Stik USAF G-BOSS Setup And Operation

Medium and heavy hybrid power systems
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SYSTEM SETUP AND OPERATION
GUIDE FOR THE SOLAR STIK USAF
G-BOSS MEDIUM AND HEAVY
HYBRID POWER SYSTEMS
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Version 1.0
Updated:20201209
December 2020
|
Solar Stik
, Inc.
|
1
®
PRELIMINARY DRAFT

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the USAF G-BOSS and is the answer not in the manual?

Questions and answers

Related Manuals for Solar Stik USAF G-BOSS

Summary of Contents for Solar Stik USAF G-BOSS

  • Page 1 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEMS DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Version 1.0 Updated:20201209 December 2020 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 2: Table Of Contents

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Contents GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Introduction to Hybrid Power Systems The Hybrid Power System Flexible Open Architecture Important Safety Information and Instructions Safety Information Labels .
  • Page 3 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM OPERATOR INSTRUCTIONS 1 Connect System Components G-BOSS Heavy and Medium Kit Inventory ........31 a.
  • Page 4 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Float Charging..........53 Charger Standby .
  • Page 5 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Battery Monitoring Kit (BMK) Troubleshooting PRO-Verter BMK Circuit Operational Statuses ....... . . 67 BMK Ready .
  • Page 6 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM MAINTENANCE INSTRUCTIONS HPS Preventive Care and Maintenance 24VDC PRO-Verter 5000-120 PMCS Locking Component Cases to Prevent Tampering ABOUT SOLAR STIK, INC Contact List of Figures Figure 1.
  • Page 7 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Revision History Section Page(s) Description Date First released as a PRELIMINARY DRAFT February 2020 December 2020 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 8: General Information, Equipment Description, And Theory Of Operation

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION The introductory parts of this manual describe Hybrid Power Systems (HPSs) 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 an HPS solution.

  • Page 9: Important Safety Information And Instructions

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Important Safety Information and Instructions This manual contains important instructions that must be followed during the installation and operation of the System. Read all instructions and information contained in this manual.

  • Page 10: Fire Hazard

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 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 11: Electric Shock Hazard

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

  • Page 12: Environmental And Handling Precautions

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 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 13: Theory Of Operation

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM THEORY OF OPERATION Models of Operation Depending on the application, there are several operational models that can be configured using a PRO-Verter. Note: The PRO-Verter settings used in each model of operation are unique and not interchangeable.

  • Page 14: Ups (Automatic Functions)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM UPS (Automatic Functions) Operating conditions: A PRO-Verter connects critical AC loads directly to grid/utility or prime AC power when it is available and provides backup power for the load by supplying inverter AC (using energy from a connected battery bank) when the grid-utility or prime AC source is interrupted.

  • Page 15: Minimum Battery Capacity Required For Optimal System Operation

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM All batteries have a cycle life and therefore should be considered the “consumable” part of the HPS. The health of the battery can directly affect the function of the HPS over time, so proper cycling and cell-health management practices are strongly encouraged.

  • Page 16: Load Prioritization

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM The overall health of the HPS can be determined by the amount of cycling that occurs in a 24-hour period. If the HPS cycles more than twice daily or is experiencing irregular cycling, there are several factors that may be causing it: •...

  • Page 17: Overload" Conditions

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM “Overload” Conditions Overloading of the System can occur under the following conditions: • Load AC power demand is greater than the inverter’s rated output.

  • Page 18: Lag Time And Surge Rates

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Lag Time and Surge Rates The PRO-Verter’s Inverter function can provide up to 130% of its rated power output for brief surges that may be required to support a load. Most generators are also rated to support brief surge loads.

  • Page 19: Scaling And Modifying The Hps

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Scaling and Modifying the HPS When expanding or modifying the HPS architecture, scaling and stacking may be used to provide additional capabilities that may exceed the ability of any one component to handle.

  • Page 20: Power Hub Stacking Example

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Power Hub Stacking Example Stacking Power Hubs of the same or different types provides a mechanism to add DC power sources to a system. The dashed-line box surrounds the stacked Power Hubs.

  • Page 21: Equipment Description

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Equipment Description The Inter-Connect System The 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 22: The Standard Inter-Connect Plug

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM The Standard Inter-Connect Plug Polarized • 200 A maximum current • 24 VDC connection only • Mechanically “locks” into place • Rotate dial clockwise to lock, counterclockwise to release •...

  • Page 23: 24Vdc Power Distribution (Pdm) 3000 Description

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 24VDC Power Distribution (PDM) 3000 Description The PDM 3000 draws power from the HPS 24 VDC bus and converts it to stable, regulated 28 VDC output.

  • Page 24: Figure 9. Pdm 3000 Right Side

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM The 2-pin connector 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 disengaging power circuits to the tower and the PDU.

  • Page 25: Pdm 3000 I-Plate

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PDM 3000 I-Plate Figure 11. PDM 3000 top, Faceplate, specs, and cautions December 2020 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 26: 24Vdc Pro-Verter 5000-120 Ags Description Pro-Verter 5000 Exterior Features

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 24VDC PRO-Verter 5000-120 AGS Description PRO-Verter 5000 Exterior Features Note: Ports vary among PRO-Verters according to model selected. Description Connector Voltage Amps A Battery Connection (metered port) Inter-Connect Port...

  • Page 27: Figure 14. Pro-Verter 5000-120 Ags Right Exterior

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter 5000 Exterior Features Description Connector Voltage Amps A 120 VAC Output HBL61CM65 120 VAC B DC load /Power Hub Connection Inter-Connect Port...

  • Page 28: Pro-Verter 5000 Information Plate

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter 5000 Information Plate The Information Plate (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.

  • Page 29: Pro-Verter 5000-120 Faceplate

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter 5000-120 Faceplate Remote Monitoring Kit Connection Ports and Cables Specifications Mounting Location Auto Generator Start Alarm ON/OFF Switch TQG Start/Stop (AGS)Controller Generator Status LEDs and...
  • Page 30 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM AC IN and AC OUT Breakers—Circuit breakers protect against overcurrent conditions in dedicated circuits. If too much amperage flows due to short-circuit, inadequate or improper loading, or component failure, these will protect the System and Operator.

  • Page 31: Operator Instructions

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM OPERATOR INSTRUCTIONS 1 Connect System Components The connection diagram below illustrates the HEAVY and MEDIUM configurations of G-BOSS USAF. Energy Storage Li ESM 2000 (x6)

  • Page 32: Connect Pro-Verter To Energy Storage Modules

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM a Connect PRO-Verter to Energy Storage Modules Use 5’ Inter-Connect cables (E) to connect the System batteries to PRO-Verter as shown in Figure 18.

  • Page 33: Connect Pro-Verter -Generator Comms Cables

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM c Connect PRO-Verter -Generator Comms Cables i MEP-831 TQG and (optional) MEP-802A Connect TQG port on the front of the PRO-Verter and the AUTO GENERATOR CONTROL port on the TQG using the TQG GEN COMM Cable (Heavy, 50’;...

  • Page 34: Figure 21. Mep-1030 Ammps 5 Kw Generator Communication Cable Connections

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM ii MEP-1030 AMMPS 5 kW Generator (optional) Connect to “AMMPS” Gen Comm Port 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).

  • Page 35: Connect Pro-Verter 5000 To Pdm 3000

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

  • Page 36: Connect Pro-Verter 5000 To Data Distribution Unit (Optional)

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

  • Page 37: Connect Pro-Verter 5000 To 120 Vac Loads (Optional)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM f Connect PRO-Verter 5000 to 120 VAC Loads (Optional) Connect 120 VAC loads to the PRO-Verter AC outputs on the right side of the PRO-Verter. Connect loads of no more than 20 amps for one (1) outlet and no more than 25 amps total between the two (2) outlets.

  • Page 38: System Activation And Initialization

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 2 System Activation and Initialization a. Activate the Hybrid Power System 1. Turn on the System battery main power switches. 2. Turn on PRO-Verter User Interface.

  • Page 39: Pdm 3000: Pdu And/Or Tower Operation

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 3 PDM 3000: PDU and/or Tower Operation After the Hybrid Power System has been calibrated, turn on the PDM 3000 breaker(s)/switch(s) for the circuit(s) in use (Tower and/or PDU). Turn off PDM 3000 breaker(s)/switches for circuit(s) not in use.

  • Page 40: Overview To The Pro-Verter User Interface Menu Windows

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Overview to the PRO-Verter User Interface Menu Windows The columns below provide a condensed version of the menu windows that constitute the menu tree of each button.

  • Page 41: Programming Menu Map

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Programming Menu Map FAVS Button Menus FAVS F1 Battery Type F2 AmpHour Size F3 AC Input F4 LBCO F5 Gen Run VDC CC/CV...

  • Page 42: Meter Button Menus Continued

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM METER Button Menus continued METER 04 AGS Meters Auto 04E Since Gen Run 04F Since 100% 04B DC Volts-AGS 04A AGS Status 04C Gen Run Time...

  • Page 43: Setup Button Menus

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM SETUP Button Menus Setup: 01 System & 02 Inverter Setup SETUP 01 System Setup 01A Set Clock Range: 12:00AM - 12:00PM (NOTE: Ensure that the clock is set to local time.)
  • Page 44 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM SETUP Button Menus continued Setup: 03 Charger SETUP Status 03 Charger Setup 03A AC Input Range: 5 A to 60 A Amps = 25A 03B VAC Dropout Range: 60-100 VAC;...
  • Page 45 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM SETUP Button Menus continued Setup: 04 AGS Setup continued SETUP Status AGS Function Notes 04 AGS Setup • After 15 seconds at or below 25.0 V, the PRO-Verter sends the 04A Gen Run VDC start signal to the Generator.
  • Page 46 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM SETUP Button Menus continued Setup: 04 AGS Setup continued SETUP Status 04 AGS Setup 04E Gen Run Temp Ext Input Set Gen Run Temp...
  • Page 47 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM SETUP Button Menus continued Setup: 04 AGS Setup, 05 BMK Setup continued SETUP Default Off 04K Gen 100% SOC Range: Off, 1-255 Start Days = Off...

  • Page 48: Tech Button Menus

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM TECH Button Menus Inv BTS ###F Inv Tfmer ###F TECH Inv FETs ###F Read-only Displays 01 Temperatures AGS Sensor ###F Press Select ACLD Temp...

  • Page 49: Troubleshooting

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

  • Page 50: Pro-Verter Troubleshooting

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Troubleshooting Quick Links 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 solution to resolve the fault.

  • Page 51: Pro-Verter Lcd Screen Troubleshooting Table

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter LCD Screen Troubleshooting Table If the display is not functioning correctly, use Table 5 to help find a solution. Table 5. Troubleshooting the LCD Screen...

  • Page 52: Pro-Verter Inverter Mode Status Messages

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Inverter Mode Status Messages View the top line of the LCD screen and the corresponding message in this section to identify and understand the particular Inverter mode.

  • Page 53: Pro-Verter Charger Mode Status Messages

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Charger Mode Status Messages When AC power (utility or generator) is connected to the PRO-Verter, it automatically begins to monitor the AC input for acceptable voltage. Once the AC input is accepted, the AC transfer relay (inside the PRO-Verter) closes and Charger mode begins.

  • Page 54: Full Charge

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Full Charge This status indicates that the PRO-Verter is in Battery Saver mode. This mode maintains the batteries without overcharging. After four (4) hours of float charging, the charger turns off and “Full Charge”...

  • Page 55: Pro-Verter Charger Troubleshooting

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Charger Troubleshooting Unit won’t transfer to Charge mode when connected to generator or grid AC Solution: Is the charge (CHG) LED on the User Interface blinking? If not, the charger does not recognize the incoming AC as being within acceptable limits.

  • Page 56: Pro-Verter Inverter Troubleshooting

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Inverter Troubleshooting Most faults (inverter, AGS, and BMK) also alternate with the inverter/charger status. The FAULT LED comes on and a fault status is displayed by the LCD User Interface when an abnormal condition is detected.

  • Page 57: Dead Batt Charge

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Dead Batt Charge This fault indicates that the PRO-Verter is connected to a 220 VAC source and is attempting to close its internal relay and begin charging, but it has detected less than 18 volts on the battery bank or determined that no battery is present.

  • Page 58: High Battery

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM High Battery The inverter has turned off because the DC bus voltage has exceeded 34 volts. This fault message displays and the FAULT (red) LED turns on when the battery voltage is above the High Battery Cut- Out (HBCO) value.

  • Page 59: Overcurrent

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Overcurrent This fault may be the result of an excessive AC load and causes the inverter to shut down to protect internal power components. If the overload condition lasts for less than 10 seconds, the unit automatically restarts and resumes operation.

  • Page 60: Unknown Fault

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Solution Allow the inverter to cool down, then press the INVERTER ON/OFF button (manual restart) to resume operation. To resume normal operation, reduce the load to within normal operating parameters. Shade the PRO-Verter to reduce solar loading.

  • Page 61: Pro-Verter Ags Troubleshooting

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter AGS Troubleshooting These tests are applicable when the PRO-Verter is connected to a fuel driven generator that has been modified with a Remote-start Enabling Kit (RsEK).

  • Page 62: Ags Start Statuses Table (Meter 04)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM AGS Start Statuses Table (Meter 04) The following “Start” statuses identify the condition that autostarted the generator. The list below includes all possible statuses. If the autostart condition occurred sooner than expected, or it was not...

  • Page 63: Ags Operational Statuses (Meter 04)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM AGS Operational Statuses (Meter 04) AC In The inverter/charger is connected to another source, such as a grid or an alternate generator, and is not controlled by the AGS.

  • Page 64: Resolving Ags Operational Statuses

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Resolving AGS Operational Statuses No Comm The “No Comm” status suggests that some wiring connections may be incorrect or compromised. Solution 1. Ensure the...

  • Page 65: Fault Test

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM For these AGS faults, refer to the Solution immediately following Fault Test The generator failed to autostart and run after the red TEST button is pressed on the AGS controller.

  • Page 66: Fault Maxrn

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Fault MaxRn Generator turned off because the SETUP: 04F Max Gen Run Time setting had been met. This fault can occur when the autostop condition (FAVS F5: Gen Run VDC) exceeded the Max Gen Run Time setting.

  • Page 67: Pro-Verter Battery Monitoring Kit (Bmk) Troubleshooting

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Battery Monitoring Kit (BMK) Troubleshooting PRO-Verter BMK Circuit Operational Statuses A Battery Monitor status message may be an operational or fault message. Access the METER: 05A BMK Status menu to view its current operating status.

  • Page 68: Pro-Verter Fault History (Tech 04)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter Fault History (Tech 04) Tech 04 in the LCD user interface provide provides the fault history for the inverter (04A) and the AGS (04B).

  • Page 69: Pro-Verter: Historical Data Collection

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM PRO-Verter: Historical Data Collection The PRO-Verters can provide some historical data for generator and battery operation. Press the METER button on the PRO-Verter Controller to access both the BMK and AGS functions.

  • Page 70: Auto Generator Start/Stop (Ags) Data

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Auto Generator Start/Stop (AGS) Data Gen Run Time This menu displays the time the generator has been running since the AGS circuit auto started the generator.

  • Page 71: Battery Monitor (Bmk) Data (Meter 05)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Battery Monitor (BMK) Data (Meter 05) This section describes what battery bank information is available from the battery monitor when using the LCD user interface.

  • Page 72: Total Ah Out

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Total AH Out This meter displays the total amp hours removed from the battery since the PRO-Verter was first connected. This display can be used as a battery service life indicator. The value is displayed in 0.1 k [or 100 amp hours (“k”...

  • Page 73: Generator Troubleshooting Testing The Ags Function

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Generator Troubleshooting Testing the AGS Function Push the red AGS Test button at the AGS interface to confirm all wiring from the generator to the AGS module is correct and the AGS circuit is configured correctly for a particular generator.

  • Page 74: Generator Short-Cycles

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Generator Short-cycles Causes • Incorrect setup of the Inter-Connect Circuit • Incorrect voltage setting in the Gen Run VDC menu • Expander Pak(s) not turned on •...

  • Page 75: Soc Disparity Among System Batteries

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM SOC Disparity Among System Batteries When cycling multiple batteries in a bank, it is possible to see the states of charge (SOC) lose parity between them due to the following reasons: •...

  • Page 76: Maintaining Soc Parity

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Maintaining SOC Parity The PRO-Verter has two programmable “maintenance” functions in the AGS menus that can be used to maintain battery SOC parity: Gen Exercise and Gen 100% SOC...

  • Page 77: System Recovery To Restore Overdischarged Batteries

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Default Off 1. Press the SETUP Button on the PRO-Verter user 04K Gen 100% SOC Range: Off, 1-255 interface (password may be required).

  • Page 78: Energy Storage Modules-Supplemental Information

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Energy Storage Modules—Supplemental Information Batteries in high-efficiency hybrid power systems will cycle as they work. The total amount of battery cycles that can be expected is called the cycle-life of the battery, and this is usually associated with the chemistry and the type of cycling that occurs (light or heavy duty).

  • Page 79: Terminal (End-Of-Life) Battery Performance

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Terminal (End-of-Life) Battery Performance When a LiFePO battery has reached the end of its service life (“health” is less than 50%), it loses its ability to retain electrical energy in its cells, and the cycle performance will be severely degraded.

  • Page 80: Maintenance Instructions Hps Preventive Care And Maintenance

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM MAINTENANCE INSTRUCTIONS HPS Preventive Care and Maintenance Follow these procedures to maintain the System. See PMCS tables for details. • Shade the components (except the PV arrays) from direct sun exposure and shelter them from the elements •...

  • Page 81: 24Vdc Pro-Verter 5000-120 Pmcs

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 24VDC PRO-Verter 5000-120 PMCS Table 6. 24VDC PRO-Verter 5000-120 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 82: Figure 28. Replacing Pro-Verter Filter (Left); Cleaning A Pro-Verter Filter (Right)

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM 2. Remove and inspect the filter. Replace the filter if it is damaged (arrows in Figure 28). If the filter is in good shape, clean it by rinsing it with water to remove the particulate matter and dry it.

  • Page 83: Locking Component Cases To Prevent Tampering

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM Locking Component Cases to Prevent Tampering Each component of the System is either sealed (e.g., the Li Expander Paks) or can be secured with a padlock to deter tampering.
  • Page 84 SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM December 2020 Solar Stik , Inc. ® PRELIMINARY DRAFT...

  • Page 85: About Solar Stik, Inc

    SYSTEM SETUP AND OPERATION GUIDE FOR THE SOLAR STIK USAF G-BOSS MEDIUM AND HEAVY HYBRID POWER SYSTEM ABOUT SOLAR STIK, INC Mission Statement Using American-made components and constant innovation, Solar Stik creates portable power solutions that enable self-sufficiency for the soldier, the sailor, and beyond. In doing so, we save lives, change lives, and help revive American manufacturing.

Table of Contents