Table of Contents
Troubleshooting
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Summary of Contents for Solar Stik 24VDC POWER HUB 2400
- Page 1 OPERATOR AND MAINTENANCE MANUAL 24VDC POWER HUB 2400 P/N 20-0302204 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Version 1.11 Interactive Updated: 20201123 November 2020 Solar Stik Inc.
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Page 2: Table Of Contents
Operator and Maintenance Manual 24VDC Power Hub 2400 Contents GENERAL INFORMATION, THEORY OF OPERATION, AND EQUIPMENT DESCRIPTION Power Hub Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Use of the Power Hub in a System . - Page 3 Operator and Maintenance Manual 24VDC Power Hub 2400 Water Intrusion Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TROUBLESHOOTING PROCEDURES Power Hub Will Not Power Up .
- Page 4 Figure 30. Power Hub 2400 SOLAR INPUT ONLY ports and their connection to charge controllers ......36 List of Tables Table 1. Charge Status Indicator—LED Status ....................... 23 Table 2. Symptoms and Solutions for the Most Common Power Hub Issues ............... 30 Table 3. 24VDC Power Hub 2400 PMCS ........................33 Revision History Section Page(s)
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Page 5: General Information, Theory Of Operation, And Equipment Description
Operator and Maintenance Manual 24VDC Power Hub 2400 GENERAL INFORMATION, THEORY OF OPERATION, AND EQUIPMENT DESCRIPTION Power Hub Introduction The primary function of the DC Power Hub is to serve as a singular collection, management and distribution tool for DC power in a Hybrid Power System (HPS). -
Page 6: Use Of The Power Hub In A System
Power Hub along with a guide for the User Interface menu windows. Other changes in programming may improve performance in extreme environmental operating conditions. Contact Solar Stik or your field service representative (FSR) for assistance in altering operation configurations or programming. -
Page 7: Modes Of Operation
Operator and Maintenance Manual 24VDC Power Hub 2400 Modes of Operation Depending on the application, there are several operational modes that can be configured using a Power Hub: Hybrid DC loads, DC generation and batteries are all connected to a Power Hub. It is the central power management device in the system. -
Page 8: Safety Information Labels
Since the use of this manual and the conditions or methods of operation, use, and maintenance of this product are beyond the control of Solar Stik, this company does not assume responsibility and expressly disclaims liability for loss, damage, or expense—whether direct, indirect, consequential, or incidental—arising out of or anyway connected with such operation, use, or maintenance. -
Page 9: Fire Hazard
Operator and Maintenance Manual 24VDC Power Hub 2400 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 10: Electric Shock Hazard
Operator and Maintenance Manual 24VDC Power Hub 2400 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. DON’T LET THIS BE YOU! HIGH VOLTAGE: System components, PV arrays, and generators may have lethal line voltages. -
Page 11: Environmental And Handling Precautions
Operator and Maintenance Manual 24VDC Power Hub 2400 Environmental and Handling Precautions All components are ruggedized, yet there are a few things the operator can do to prevent failures and prolong the operational life of the product. Water If outdoor operation is necessary, the lids of all components should be closed and latched. -
Page 12: Theory Of Operation
Operator and Maintenance Manual 24VDC Power Hub 2400 THEORY OF OPERATION Operation Overview The Power Hub has multiple DC connections on its exterior, allowing for multiple configuration possibilities. Original models require connection to an active 24 V battery circuit in order for it to operate whereas newer models also operate with power from solar arrays. -
Page 13: Protection Circuits
Operator and Maintenance Manual 24VDC Power Hub 2400 Protection Circuits The Power Hub serves as a DC junction within the Inter-Connect Circuit . When connected to an active 24 V DC Inter-Connect network, it allows DC to flow through its internal bus, with ONLY the PV circuit offering limit protections: •... -
Page 14: Equipment Description
Operator and Maintenance Manual 24VDC Power Hub 2400 The first indication of heat-related derating may be the appearance that the PV arrays are “not producing any power” when they should be. If this is the case, check the temperatures. (Note: The Power Hub User Interface will also report 0 VDC charging current when the System batteries are fully charged.) -
Page 15: The Standard Inter-Connect Plug
Operator and Maintenance Manual 24VDC Power Hub 2400 Optimize with Data Data collection for a System occurs through the Inter-Connect network. Power management devices such as Power Hubs and PRO-Verters meter voltage, current and time through the circuit, providing critical real-time data the operator can use to troubleshoot and verify System performance. -
Page 16: Connection Port Details
Operator and Maintenance Manual 24VDC Power Hub 2400 Connection Port Details Port placards assist in making the correct connections between components. Please review the information on all of these plates and labels, as they contain the basic information required to set up and operate the Hub. -
Page 17: Figure 8. Right Side-Regulated 24 Vdc Input And Nato Connector
Operator and Maintenance Manual 24VDC Power Hub 2400 Description Connector Amps Voltage A 24 VDC NATO Slave (unmetered) NATO Slave 100 A 24 VDC B Regulated 24 VDC Input Only (unmetered) Inter-Connect Port 50 A each 24 VDC A. For connection to a Tactical Vehicle or generator. -
Page 18: Internal Cooling
Operator and Maintenance Manual 24VDC Power Hub 2400 Internal Cooling Air Intake Figure 11. Back side—air intake vent Thermostatically controlled, internal cooling fans turn on at 104 ºF (40 ºC) and turn off when the internal temperature drops to 90 ºF (32 ºC). -
Page 19: The Power Hub 2400 Faceplate
Operator and Maintenance Manual 24VDC Power Hub 2400 The Power Hub 2400 Faceplate The Faceplate provides Operator Access to the User Interface, PV charging Specifications and recommended charger settings. A Universal Communications Module or Remote Monitoring Kit (RMK) may be installed on the Faceplate at the location indicated below. The two (2) Inter-Connect ports are not electrically active;... -
Page 20: Operator Instructions
Faceplate (Figure 12). The bayonet connector for the Solar Cable is keyed and unique within the System. It cannot be connected improperly, and no other Solar Stik cable in the kit will fit. PV Arrays (x6) -
Page 21: Connecting Regulated 24 Vdc Power Sources
Operator and Maintenance Manual 24VDC Power Hub 2400 Connecting Regulated 24 VDC Power Sources Connect regulated 24 VDC power sources such as wind generators and fuel cells to the three (3) Inter- Connect ports. Connect 24 VDC power from Military Vehicles (e.g., HMMWV) and TQGs to the NATO port. -
Page 22: Power Hub 2400 User Interface
Operator and Maintenance Manual 24VDC Power Hub 2400 Power Hub 2400 User Interface The User 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. Using the menu navigation buttons is described in the next section. -
Page 23: Monitoring The Charging Status Led
Operator and Maintenance Manual 24VDC Power Hub 2400 Monitoring the Charging Status LED Blinking LED indicates charge control operation status Table 1. Charge Status Indicator—LED Status Charge status LED Charge Mode Charge Off Continuously On Bulk Blinking – 1 second On / 1 second Off Acceptance Blinking –... -
Page 24: The Menu Windows
Operator and Maintenance Manual 24VDC Power Hub 2400 The Menu Windows General Information Menu Provides basic information including battery voltage, current in and out, net current, and remaining capacity. Home Screen: Shows battery voltage and “net” battery current. Net battery current is the sum of all chargers and loads connected to the battery. - Page 25 Operator and Maintenance Manual 24VDC Power Hub 2400 Advanced Information Menu Provide detailed battery information including discharge cycles, temperature, battery-event tracking information, and more LAST FULL CHARGE Days since last full charge. Day counter accuracy is 10 DAYS AGO +1/-0 days, as day counter transitions occur following the 24-hour period when battery power was applied.
- Page 26 Operator and Maintenance Manual 24VDC Power Hub 2400 Operation and Setup Menu Provides operational setup and auxiliary functions Set for total amp hours of all connected battery(s). (The SET BAT AMP-HRS value must be greater than or equal to the total capacity...
- Page 27 Operator and Maintenance Manual 24VDC Power Hub 2400 Battery Charge Parameter Setup Menu Provides access to battery charge parameters SET ACCEPT CHG Sets Acceptance Charge Voltage set-point = 29.0 V 29.0V SET FLOAT CHG Sets Float Charge Voltage set-point = 29.0 V 29.0V...
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Page 28: Storing The Inter-Connect Cable
Operator and Maintenance Manual 24VDC Power Hub 2400 Storing the Inter-Connect Cable The 5’ Inter-Connect cable can be coiled and stored using the connectors on the Faceplate. Note: These connectors are not electrically active. Figure 22. Inter-Connect Cable storage Locking Component Cases to Prevent Tampering The Power Hub 2400 can be secured with a padlock to deter tampering. -
Page 29: Transporting The Power Hub
Operator and Maintenance Manual 24VDC Power Hub 2400 Transporting the Power Hub The Power Hub transports like a briefcase and is safe for all modes of transportation, including land, sea, and air. There are no transport restrictions. Water Intrusion Remediation... -
Page 30: Troubleshooting Procedures
Operator and Maintenance Manual 24VDC Power Hub 2400 TROUBLESHOOTING PROCEDURES Power Hub Will Not Power Up 24VDC Power Hub 2400s beginning with Serial Number 430288, will operate when power from solar arrays is present (connection to an active battery not required). This feature (added beginning November 2020) allows recovery of System operation when the System batteries are overdischarged. -
Page 31: Recommended Operation Environment (Location)
Operator and Maintenance Manual 24VDC Power Hub 2400 Recommended Operation Environment (Location) Direct ground placement of any power management or energy storage component is generally not recommended, but possible if no other option is available. If it is necessary, preventative measures for water and dust should be taken. -
Page 32: Power Hub Internal Cooling
Foreign Object Debris (FOD) and Water Intrusion All Solar Stik equipment is designed for operation in adverse environmental conditions, however, certain rules apply: 1. If operating in wet environments, use common-sense placement to avoid water intrusion by either flooding or precipitation. -
Page 33: Maintenance Instructions
Operator and Maintenance Manual 24VDC Power Hub 2400 MAINTENANCE INSTRUCTIONS Preventive Maintenance, Checks and Service (PMCS) Table 3. 24VDC Power Hub 2400 PMCS Item to be Item # Inspected Interval Procedures Non-mission Capable 1. Inspect case for visible damage and missing items. -
Page 34: Supporting Information
SUPPORTING INFORMATION Power Hub Stacking All Solar Stik Systems are scalable, and the method used for scaling Power Management components is “Stacking”. Multiple Power Hubs can be stacked when conditions warrant. Stacking can be used when a greater contribution from PV is desired, and the PV rating exceeds the ability of a single Power Hub to regulate. -
Page 35: Battery Monitor: Understanding Reported Values
Operator and Maintenance Manual 24VDC Power Hub 2400 Battery Monitor: Understanding Reported Values The voltage and current flowing out of the Power Hub are accurate in any System configuration. The Batt Capacity % reported by the General Information Menus is accurate when both batteries and loads are connected directly to the Power Hub as shown in Figure 28. -
Page 36: Assessing Pv Array Performance
Operator and Maintenance Manual 24VDC Power Hub 2400 Assessing PV Array Performance The amount of power that is produced by a PV panel depends primarily on two (2) operating conditions: • Direct sunlight onto the PV cell • Temperature MPPT charge controllers optimize the power production based on two factors: •... -
Page 37: Navigating The "Charge Unit Status" Submenus
Operator and Maintenance Manual 24VDC Power Hub 2400 Navigating the “Charge Unit Status” Submenus The VIEW CHARGE UNIT STATUS menu option provides a way to monitor the output of PV arrays independently. Independent monitoring allows you to optimize the PV array performance and simplifies the identification and correction of problems with individual panels in a PV array should they arise. -
Page 38: Supporting Information
Operator and Maintenance Manual 24VDC Power Hub 2400 SUPPORTING INFORMATION Product update 24VDC Power Hub 2400s beginning with Serial Number 430288, will operate when power from solar arrays is present. This feature (added beginning November 2020) allows recovery of System operation when the System batteries are overdischarged. -
Page 39: Warranty And Returns
1. Solar Stik warrants, unless otherwise agreed to between buyer and seller (Solar Stik Inc), for a period of one (1) year from Solar Stik’s delivery of such Products, the Products shall be free from defects in materials and workmanship and shall conform to the contractual specifications or to specification sheet of the Product. - Page 40 Operator and Maintenance Manual 24VDC Power Hub 2400 November 2020 Solar Stik , Inc. ®...
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Page 41: 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. Contact...
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