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Solar Stik Hybrid Power System 500 System Setup

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SYSTEM SETUP AND OPERATION
HYBRID POWER SYSTEM 500
This manual provides instructions for setting up, starting, running, and maintaining the Hybrid
Power System (HPS) 500. The current HPS 500 is configured to provide 500 watts constant power
to a load using power generated only from the included photovoltaic (PV) arrays. The number
of arrays assigned to the HPS will vary as they are subject to the geographic and environmental
conditions in which they will be operated.
The HPS 500 architecture is modular and scalable. It can be configured to include and manage a
fuel-driven generator or accept grid-utility power to supplement PV power if desired or required.
Information about connecting a fuel-powered generator or shore power is included in the Setup and
Operation Instructions.
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Version 1.0
Updated:20200113
January 2020
MANUAL FOR THE

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  • Page 1 SYSTEM SETUP AND OPERATION MANUAL FOR THE HYBRID POWER SYSTEM 500 This manual provides instructions for setting up, starting, running, and maintaining the Hybrid Power System (HPS) 500. The current HPS 500 is configured to provide 500 watts constant power to a load using power generated only from the included photovoltaic (PV) arrays.

  • Page 2: Table Of Contents

    System Setup and Operation Manual for HPS 500 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 ..........9 Fire Hazard .
  • Page 3 System Setup and Operation Manual for HPS 500 Connect PRO-Verter to Expander Paks........28 Deploy the PV Arrays .
  • Page 4 System Setup and Operation Manual for HPS 500 ........... . . 59 Unknown Mode ## .
  • Page 5 System Setup and Operation Manual for HPS 500 Resolving AGS Faults Using the LCD User Interface ......71 Fault Gen Run .
  • Page 6 System Setup and Operation Manual for HPS 500 RMK-related Troubleshooting RMK Status Indicator Light Not Illuminated When PRO-Verter Powers Up ....85 Cannot Communicate with RMK ........85 Status Light Stays Orange after Inserting USB Drive .
  • Page 7 System Setup and Operation Manual for HPS 500 Figure 19. Generator Status LEDs ..........................35 Figure 20. 24VDC PRO-Verter 5000 System battery bank SOC ................... 37 Figure 21. 24VDC Expander Pak 1000 SOC meter on Faceplate—100% SOC ............37 Figure 22. Reading the 24VDC Expander Pak 1000 SOC meter ..................38 Figure 23.

  • Page 8: General Information, Equipment Description, And Theory Of Operation Introduction To Hybrid Power Systems

    System Setup and Operation Manual for HPS 500 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Introduction to Hybrid Power Systems When a portable fuel-driven power generator is the primary source of power for an application, it must operate continuously to provide electricity to the load, even if the power requirements of connected loads are minimal or intermittent.

  • Page 9: Important Safety Information And Instructions

    System Setup and Operation Manual for HPS 500 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. Thoroughly read and understand the operator manual for each of the components in this System PRIOR to assembly and use of this System.

  • Page 10: Fire Hazard

    System Setup and Operation Manual for HPS 500 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. Class C fire - Fires involving energized electrical equipment such as motors, transformers, and appliances.

  • Page 11: Electric Shock Hazard

    System Setup and Operation Manual for HPS 500 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 12: Environmental And Handling Precautions

    System Setup and Operation Manual for HPS 500 Environmental and Handling Precautions All of the System components are ruggedized, yet there are a few things the operator can do to prevent failures and prolong the operational life of the System. Water If outdoor operation is necessary, the lids of all components should be closed and...

  • Page 13: Theory Of Operation

    System Setup and Operation Manual for HPS 500 THEORY OF OPERATION The HPS 500 Architecture, Function and Operation The HPS 500 System is designed as a fully independent power station, using renewable solar power as its primary means of power generation. The Power Hub, PRO-Verter and Expander Paks are designed to operate in concert, providing uninterrupted pure sine wave 230V AC and 24V DC power to the loads.

  • Page 14: Load Prioritization

    System Setup and Operation Manual for HPS 500 Load Prioritization When the HPS is fully functioning, providing power to the load is always prioritized over other functions. When the PV arrays are generating in sunlight, that power is immediately directed to the load once it flows into the HPS.

  • Page 15: Minimum Battery Capacity Required For Optimal Pro-Verter Operation

    System Setup and Operation Manual for HPS 500 Minimum Battery Capacity Required for Optimal PRO-Verter Operation A Hybrid Power System will function most efficiently when proper balance is achieved within the System’s architecture (Energy Storage, Power Management, and Power Generation). The central power management device is the PRO-Verter, so any components that are connected to it need to be rated for the amount of power that will be processed by it.

  • Page 16: Overload" Conditions

    System Setup and Operation Manual for HPS 500 “Overload” Conditions Over-loading of the PRO-Verter can occur under the following conditions: • Load AC power demand is greater than the inverter’s rated output • Load AC power demand is greater than the connected AC source (generator or grid-utility) •...

  • Page 17: Figure 2. Hybrid Power System In Operation

    System Setup and Operation Manual for HPS 500 If the generator can’t handle 130% surge, it will likely crash the system in the following ways: • The generator AC output voltage may drop below the VAC DROPOUT setting in the PRO-Verter •...

  • Page 18: System Operation Models

    System Setup and Operation Manual for HPS 500 System Operation Models DC-only/Inverter All power generated is from DC generators and AC loads are supported by the PRO-Verter’s Inverter function using energy stored in batteries. Hybrid The “Continuous Load” AC power requirement is LESS than the individual Inverter or Generator/ Grid AC power output ratings.

  • Page 19: Component Stacking

    System Setup and Operation Manual for HPS 500 Component Stacking When expanding or modifying the HPS architecture, stacking may be used to provide additional capabilities that may exceed the ability of any one component to handle. Power Hub Stacking Stacking Power Hubs provides a mechanism to expand the capacity of a system, in a modular way, to collect and store DC energy.

  • Page 20: Pro-Verter Stacking

    System Setup and Operation Manual for HPS 500 PRO-Verter Stacking Stacking PRO-Verters, of the same or different types, provides a mechanism to power a wide variety of AC loads from the same system. The dashed-line box surrounds the stacked PRO-Verters. Communication Cable 120 VAC Loads...

  • Page 21: Equipment Description The Inter-Connect System

    System Setup and Operation Manual for HPS 500 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: Figure 5. Inter-Connect Plug

    System Setup and Operation Manual for HPS 500 The Inter-Connect Plug Polarized • 200 A maximum current • 24 VDC connection only • Mechanically “locks” into place • Rotate knob clockwise to lock, • counterclockwise to release Can be repaired or modified in the field •...

  • Page 23: Color-Coded Connections

    System Setup and Operation Manual for HPS 500 Color-coded Connections Cables and ports are color-coded based on their function. Cable Color Example Ports Orange: PV Circuit Connection Red: DC Circuit Connection Blue: AC Input Connection Gray: AGS Communication Connection Green: AC Output Connection Figure 6.

  • Page 24: System Connection Diagram

    System Setup and Operation Manual for HPS 500 System Connection Diagram Power Generation Energy Storage 24VDC Expander Pak 1000 (x6) Cable Legend A 24VDC 30’ Solar Cable B 24VDC 5’ Inter-Connect Cable 3-5 kW Generator with Inter-Connect Strip 7 Remote Auto Start/ 24VDC Expander Pak 1000 (x6) C Generator AC Input Power Cable Stop...

  • Page 25: System Accessories

    System Setup and Operation Manual for HPS 500 System Accessories The generator provides an additional source of stable and predictable power when diesel fuel is available. 19-0401001 Yanmar YDG5500 Generator with RsEK The Power Distribution Module (PDM) provides additional load connections including USB, 12V, and 120V AC 60Hz devices.

  • Page 26: Operator Instructions System Setup

    System Setup and Operation Manual for HPS 500 OPERATOR INSTRUCTIONS System Setup 1 Identify Locations for System Components Survey the site where the System will be deployed. The PV arrays should be located in a non-shaded area. All components except the PV arrays should be located in a shaded area with appropriate distance allowed for all cable connections.

  • Page 27: Inventory System Components

    System Setup and Operation Manual for HPS 500 2 Inventory System Components Inventory the System components using the list in the Kit Inventory section. Make connections between the System components according to the diagrams on the PRO- Verter I-Plate and in this manual. The lines connecting the components indicate the colors of the connections to be made.

  • Page 28: Connect System Components

    System Setup and Operation Manual for HPS 500 3 Connect System Components One 5’ Inter-Connect Cable is stored on the Faceplate of each Expander Pak. The Inter-Connect sockets on the Faceplate are not electrically active and serve only to secure the cable for storage and transport.

  • Page 29: Deploy The Pv Arrays

    System Setup and Operation Manual for HPS 500 Deploy the PV Arrays For detailed setup instructions, see the Solar Venture 350W Operator Manual. The panels should be positioned for maximum daily sun exposure. DO NOT secure the PV arrays to the ground until the entire System is setup Figure 10.

  • Page 30: Connect The Pro-Verter To The Power Hub

    System Setup and Operation Manual for HPS 500 Connect the PRO-Verter to the Power Hub Connect the PRO-Verter (“24VDC In/Out” port) to the Power Hub (“Expander Pak/PRO-Verter Only” port) using an Inter-Connect Cable. This is a red-to-red connection. This cable is stored on the Faceplate of the Power Hub.

  • Page 31: Connect Pro-Verter To Ac Loads

    System Setup and Operation Manual for HPS 500 Connect PRO-Verter to AC Loads Connect the PRO-Verter (“220 AC Out” port) to the loads using a green-to-green connection. Load Radio Net 1 Radio Net 5 Radio Net 2 Radio Net 6 Radio Interop Console PRO-Verter Radio Net 3...

  • Page 32: Secure The Pv Arrays To The Ground

    System Setup and Operation Manual for HPS 500 4 Secure the PV Arrays to the Ground Do not secure the arrays to the ground before establishing proper location and orientation WARNING Failure to properly secure the PV array(s) to the ground with sandbags could result in PV panel damage, injury, or death in high winds.

  • Page 33: Connect Pro-Verter To An Ac Power Source

    System Setup and Operation Manual for HPS 500 5 Connect PRO-Verter to an AC Power Source* Grid Power: Use an AC power cable to connect AC power from the grid to the “AC INPUT” port on the left-hand side of the PRO-Verter 5000. Generator: Make power and communications connections between the generator and PRO-Verter: •...

  • Page 34: System Activation

    System Setup and Operation Manual for HPS 500 System Activation 1. Verify the generator (if connected) has fuel and oil and that the generator starter battery cables are connected. If no generator is connected, skip to Step 4. 2. Turn on the generator MAIN SWITCH and AC BREAKER switch by toggling it up. 3.

  • Page 35: System Initialization And Calibration

    System Setup and Operation Manual for HPS 500 System Initialization and Calibration 1 Set the PRO-Verter clock Rotate the SELECT knob. Press SELECT until local time is programmed. 2 Test the PRO-Verter and generator operation (if RsEK-modified generator is connected) Go to Step 3.

  • Page 36: Tips To Keep The System Running Safely And Smoothly

    System Setup and Operation Manual for HPS 500 3 Calibrate the System a With generator (skip this step if no generator is connected) Allow the generator to run until it turns off automatically. The energy storage modules (ESMs) will then be charged fully and the System will be calibrated. During normal operation, the generator runs only to charge the ESMs and support the load while doing so;...

  • Page 37: Monitoring System Batteries

    System Setup and Operation Manual for HPS 500 Monitoring System Batteries The batteries are the heart of this power System. The state of charge (SOC) is a critical metric in understanding the health of the HPS. This System provides two (2) SOC readouts: 1.

  • Page 38: Maintaining Expander Pak Health

    System Setup and Operation Manual for HPS 500 Reading the Display 1. The rightmost LED is lit only when the Expander Pak is charged fully (Figure 22, right). 2. As the Expander Pak SOC decreases, successive LEDs light up moving to the left, one on at a time (Figure 22, left).

  • Page 39: Pro-Verter Programming Menu Map

    System Setup and Operation Manual for HPS 500 PRO-Verter Programming Menu Map The PRO-Verter has been programmed at the factory to operate with the HPS. The programming map on the following pages is a representation of how to navigate the information in the PRO-Verter user interface.

  • Page 40: Meter Button Menus: Read-Only Displays

    System Setup and Operation Manual for HPS 500 METER Button Menus: Read-only Displays METER Status 01 DC Meters 01A DC Volts 01B DC Amps 26.2 VDC 0 Amps Status 02 AC Meters 02A Output Volts 02B Load Amps 02C Input Amps 02D Inv/Chg Amps 02E Input AC1 02F Input AC2...

  • Page 41: Setup Button Menus

    System Setup and Operation Manual for HPS 500 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.) 11:18AM Set Clock Set Clock Set Clock...
  • Page 42 System Setup and Operation Manual for HPS 500 SETUP Button Menus continued Setup: 03 Charger SETUP Status 03 Charger Setup AC Input must be set to match the 03A AC Input Range: 5 A to 60 A Amps = 25A output current of the AC power source.
  • Page 43 System Setup and Operation Manual for HPS 500 SETUP Button Menus continued Setup: 04 AGS Setup continued SETUP Status AGS Function Notes 04 AGS Setup • After 30 seconds at or below 23.0 V, the PRO-Verter sends the 04A Gen Run VDC start signal to the Generator.
  • Page 44 System Setup and Operation Manual for HPS 500 SETUP Button Menus continued Setup: 04 AGS Setup continued SETUP Status 04 AGS Setup 04E Gen Run Temp Ext Input Set Gen Run Temp Set Gen Run Temp Set Gen Run Temp Start = OFF Start = Ext Input Start = 65F-95F...
  • Page 45 System Setup and Operation Manual for HPS 500 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 Set Gen 100% SOC Set Gen 100% SOC Start Days = Off Days = 1-255 Days Set 100% SOC Run...

  • Page 46: Tech Button Menus

    System Setup and Operation Manual for HPS 500 TECH Button Menus Inv BTS ###F TECH Inv Tfmer ###F Inv FETs ###F Read-only Displays 01 Temperatures AGS Sensor ###F Press Select ACLD Temp ###F PT BTS ###F PT FETs ###F 01 Temperatures PT Inductor ###F Inv BTS...

  • Page 47: The Power Hub 2500 User Interface

    System Setup and Operation Manual for HPS 500 The Power Hub 2500 User Interface The user interface consists of an LCD screen and buttons for navigating Pages, Menu, and submenu items (Figure 23). Using the buttons and navigating the contents is simple and highly intuitive.

  • Page 48: Menu Button

    System Setup and Operation Manual for HPS 500 Battery Icon: Reports battery SOC, voltage, and net current to/from the System battery. A positive value is net charging; a negative value is net discharging. For example, +30 amps of charge current and -5 amps of load current will display a net current of +25.0 amps.

  • Page 49: Power Hub 3500: Solar Power Monitor

    System Setup and Operation Manual for HPS 500 Power Hub 3500: Solar Power Monitor Press the Menu button one time to display the device list. The window that will appear is illustrated below. Solar Charger #1& #2 will appear in lines 2 and 3. Use the Up/Down navigation buttons to highlight the any of the solar chargers.

  • Page 50: Power Hub Battery Monitor Understanding Reported Values

    System Setup and Operation Manual for HPS 500 Power Hub Battery Monitor Understanding Reported Values The voltage and current flowing out of the Power Hub (reported in the Battery Monitor submenu) are accurate only in certain configurations. The SOC reported by the battery monitor is accurate when both batteries and loads are connected directly to the Power Hub as shown in Figure 26.

  • Page 51: Navigating The Power Hub Battery Monitor Data

    System Setup and Operation Manual for HPS 500 Navigating the Power Hub Battery Monitor Data Press the Menu button one time to display the device list. The window that will appear is illustrated below. The Battery Monitor will be the first device listed. Values for the current battery SOC, DC bus voltage, and current (amps) will appear in the fields on that line.

  • Page 52: User Interface Settings Menus

    System Setup and Operation Manual for HPS 500 User Interface Settings Menus Settings are accessed from the device list. The settings menus contain several parameters that may need to be changed during the course of normal operation. Many of the options are not relevant to the Power Hub.
  • Page 53 System Setup and Operation Manual for HPS 500 User Interface Settings Menus (continued) Time VRM online portal Time Settings (Part 2) Logging enabled Enabled > General XXXXXXXXX VRM Portal ID > Firmware 15 min Log interval > Date & Time Last contact >...

  • Page 54: Locking Component Cases To Prevent Tampering

    System Setup and Operation Manual for HPS 500 Locking Component Cases to Prevent Tampering Each component of the System is either sealed or can be secured with a padlock to deter tampering. Two or more latches allow the cases to be sealed to prevent damage to the internal components from environmental factors.

  • Page 55: System Breakdown And Storage

    System Setup and Operation Manual for HPS 500 System Breakdown and Storage Prior to System breakdown, charge the Expander Paks fully Do not place a discharged Expander Pak into storage With a generator or grid power • Start the generator manually. CTRL>03 Gen Control>ON. Allow the generator to run until the charging amps drop to single digits, as reported by the user interface home screen.

  • Page 56: Troubleshooting Procedures System Troubleshooting With Pro-Verter

    System Setup and Operation Manual for HPS 500 TROUBLESHOOTING PROCEDURES System Troubleshooting with PRO-Verter 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. Most faults and System failures can be caused by two factors: 1.

  • Page 57: Quick Links To Statuses, Faults, And Resolutions Reported By The Pro-Verter

    System Setup and Operation Manual for HPS 500 Quick Links to Statuses, Faults, and Resolutions Reported by the PRO-Verter 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. AGS Faults AGS Statuses BMK Faults...

  • Page 58: Pro-Verter Lcd Screen Troubleshooting Table

    System Setup and Operation Manual for HPS 500 PRO-Verter LCD Screen Troubleshooting Table If the display is not functioning correctly, use Table 2 to help find a solution. Table 2. Troubleshooting the LCD Screen Symptom Possible Cause(s) Solution Remove the LCD user interface and LCD Screen on but not Dust/dirt buildup inside of the clean with compressed air.

  • Page 59: Pro-Verter Inverter Mode Status Messages

    System Setup and Operation Manual for HPS 500 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. Inverting The inverter is transforming battery DC into AC for the PRO-Verter Output. Inverter Standby The PRO-Verter is receiving AC power from an external source (grid or generator) and is passing it through to the load.

  • Page 60: Pro-Verter Charger Mode Status Messages

    System Setup and Operation Manual for HPS 500 PRO-Verter Charger Mode Status Messages When AC power (grid 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 61: Full Charge

    System Setup and Operation Manual for HPS 500 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 62: Pro-Verter Charger Problems: Solutions And Explanations

    System Setup and Operation Manual for HPS 500 PRO-Verter Charger Problems: Solutions and Explanations 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 63: Pro-Verter Inverter Problems: Solutions And Explanations

    System Setup and Operation Manual for HPS 500 PRO-Verter Inverter Problems: Solutions and Explanations 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 64: Dead Batt Charge

    System Setup and Operation Manual for HPS 500 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 65: High Batt Temp

    System Setup and Operation Manual for HPS 500 High Batt Temp This fault message indicates the PRO-Verter has shut down because the battery temperature sensor (BTS) inside of the PRO-Verter has reached a temperature greater than 129 °F (54 °C). Solution Once the BTS has cooled down to less than 120 °F (49 °C), it automatically restarts and continues operation.

  • Page 66: Overcurrent

    System Setup and Operation Manual for HPS 500 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 67: Unknown Fault

    System Setup and Operation Manual for HPS 500 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 68: Pro-Verter Ags Functional Tests

    System Setup and Operation Manual for HPS 500 PRO-Verter AGS Functional Tests 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). When the autostart/autostop settings have been established and programmed, perform the following tests to verify that the AGS system is functioning correctly and there is communication between the remote/inverter and the AGS.

  • Page 69: Ags Start Statuses Table (Meter 04)

    System Setup and Operation Manual for HPS 500 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 the intended autostart condition, refer to step 2 of System Initialization and Calibration to change (or...

  • Page 70: Ags Operational Statuses (Meter 04)

    System Setup and Operation Manual for HPS 500 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. When AC In displays, the AGS is prevented or locked out from all autostarting conditions, except for when the generator needs to exercise—if enabled.

  • Page 71: Resolving Ags Operational Statuses

    System Setup and Operation Manual for HPS 500 Resolving AGS Operational Statuses No Comm The “No Comm” status suggests that some wiring connections may be incorrect. Solution 1. Ensure the GREEN READY indicator on the AGS status display is on (blinking or solid) to indicate that the AGS controller is getting power.

  • Page 72: Fault Test

    System Setup and Operation Manual for HPS 500 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. Note: The LCD user interface can be set to manually turn the generator on and off, which can be used to test the generator wiring to the AGS.

  • Page 73: Fault Maxrn

    System Setup and Operation Manual for HPS 500 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 74: Pro-Verter Battery Monitoring (Bmk) Circuit Operational Statuses

    System Setup and Operation Manual for HPS 500 PRO-Verter Battery Monitoring (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. The status is important when determining if the circuit is working correctly or for troubleshooting a Battery Monitor installation.

  • Page 75: Fault History (Tech 04)

    System Setup and Operation Manual for HPS 500 Fault History (Tech 04) Tech 04 in the LCD user interface provide provides the fault history for the inverter (04A) and the AGS (04B). The following is an example of how to read and understand the fault history in 04B AGS Faults Press the SELECT knob, rotate the knob until the 04B AGS Faults menu displays, and then press the SELECT knob.

  • Page 76: Pro-Verter: Historical Data Collection

    System Setup and Operation Manual for HPS 500 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. Scroll through 01 DC Meters, 02 AC Meters, 03 Timers until 04 AGS Meters or 05 BMK Meters is displayed.

  • Page 77: Auto Generator Start/Stop (Ags) Data

    System Setup and Operation Manual for HPS 500 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. This menu does not display run time when the generator has been manually started. This hour meter resets each time the generator is stopped.

  • Page 78: Battery Monitor (Bmk) Data (Meter 05)

    System Setup and Operation Manual for HPS 500 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. BMK Status This menu selection offers read only displays that give the current operating status of the battery monitor.

  • Page 79: Auto Generator Start/Stop (Ags) Data

    System Setup and Operation Manual for HPS 500 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. This menu does not display run time when the generator has been manually started. This hour meter resets each time the generator is stopped.

  • Page 80: Power Hub-Related Troubleshooting Power Hub Will Not Power Up

    System Setup and Operation Manual for HPS 500 Power Hub–related Troubleshooting Power Hub Will Not Power Up If the Power Hub 2500 is not powered up, it probably is not connected to an active 24 VDC battery and/or there is no PV input. The LCD user interface will power up and be navigable when connected to either of these power sources.

  • Page 81: Pv Array-Related Troubleshooting

    System Setup and Operation Manual for HPS 500 PV Array–related Troubleshooting This section contains troubleshooting information for locating and correcting operating troubles that may develop in the PV array. Each malfunction is followed by a list of tests or inspections to help you to determine probable causes and corrective actions to take.

  • Page 82: Derating, Solar Loading, And Airflow

    System Setup and Operation Manual for HPS 500 Derating, Solar Loading, and Airflow PV arrays may accumulate excessive amounts of heat due to solar loading and lack of airflow, resulting in derating. Locate PV arrays where airflow is unobstructed to reduce the impact of solar loading–induced derating.

  • Page 83: Generator Will Not Start

    System Setup and Operation Manual for HPS 500 Generator Will Not Start Causes • Out of gas (diesel fuel) (“OG”) • Auto Gen Start (AGS) control module on generator in “fault” mode • Gen Control (CTRL 03) function set to OFF •...

  • Page 84: Generator Fails To Stop

    System Setup and Operation Manual for HPS 500 Generator Fails to Stop See also: Max Gen Run fault Causes • Charge function in standby mode • AC circuits running at the generator’s full-rated output (batteries not being charged) • Gen Run VDC value altered from factory setting •...

  • Page 85: Rmk-Related Troubleshooting

    System Setup and Operation Manual for HPS 500 RMK-related Troubleshooting RMK Status Indicator Light Not Illuminated When PRO-Verter Powers Up Cause Power failure or RMK malfunction Solution 1. With the PRO-Verter on, measure voltage at the RMK power source (see PRO-Verter 5000 Operator Manual) and at an Inter-Connect port on the PRO-Verter.

  • Page 86: Status Light Stays Orange After Inserting Usb Drive

    System Setup and Operation Manual for HPS 500 Solution E 1. If not using DHCP, add this line under the netmask (where [host name] is the DNS name or IP address of the gateway): gateway [host name] 2. If using DHCP, consult the documentation for the DHCP server. Status Light Stays Orange after Inserting USB Drive Cause RMK automatically copying large number of log files to USB drive...

  • Page 87: Heat And System Derating

    System Setup and Operation Manual for HPS 500 Heat and System Derating The function and efficiency of all electronic equipment is related to and dependent upon the temperature at which it is operating. It performs optimally within a narrow temperature range and less so as the temperature exceeds the upper end of that range.

  • Page 88: Pro-Verter Temperature Reports

    System Setup and Operation Manual for HPS 500 PRO-Verter Temperature Reports The PRO-Verter user interface reports a range of temperatures in the first submenu after pushing the TECH button. Like the Power Hub, the battery temperature sensor (BTS) is inside the PRO-Verter case and not in the batteries.

  • Page 89: Water Intrusion-Prevention And Remediation

    System Setup and Operation Manual for HPS 500 Water Intrusion—Prevention and Remediation WARNING Standing water around the electrical equipment or intrusion of water into the System components can increase the risk of electrical shock. Lids on the Power Hub 2500 and the PRO-Verter should be closed whenever possible while the •...

  • Page 90: Energy Storage Modules - Supplemental Information

    System Setup and Operation Manual for HPS 500 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 91: Terminal (End-Of-Life) Battery Performance

    System Setup and Operation Manual for HPS 500 Terminal (End-of-Life) Battery Performance When a lead-acid 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. Symptoms will include: •...

  • Page 92: Soc Disparity Among Expander Paks

    System Setup and Operation Manual for HPS 500 SOC Disparity Among Expander Paks 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: • High Cycling – fast charge and discharge rates with an inadequate battery bank (more than 2 cycles per day) will cause some batteries to work harder than others, creating disparity in their individual SOCs.

  • Page 93: Maintaining Soc Parity

    System Setup and Operation Manual for HPS 500 Maintaining SOC Parity The PRO-Verter has two programmable “maintenance” functions in the AGS menus that can be used to keep battery SOC parity correct: Gen Exercise and Gen 100% SOC Method to Maintain Expander Pak SOC Parity using Gen Exercise The Gen Exercise function will periodically start and run the generator to maintain the generator starter battery and lubricate internal parts of the generator on a regular basis.

  • Page 94: Method To Maintain Expander Pak Soc Parity Using Gen 100% Soc

    System Setup and Operation Manual for HPS 500 Method to Maintain Expander Pak SOC Parity using Gen 100% SOC The feature “Gen 100% SOC” is designed specifically for the purpose of equalizing the SOC of all Expander Paks in an HPS to 100%. After the SOC of the bank has been below 100% for a programmable number of days (three in the example below), the PRO-Verter will start and run the generator until the bank is at 100% SOC.

  • Page 95: Preventive Maintenance Checks And Services (Pmcs)

    System Setup and Operation Manual for HPS 500 Preventive Maintenance Checks and Services (PMCS) The tables that follow describe PMCS at the field operator level. 24VDC Expander Pak 1000 PMCS Table 4. 24VDC Expander Pak 1000 PCMS Interval at Interval at 91-140 ºF 77-90 ºF (33-60 ºC)

  • Page 96: 24Vdc Pro-Verter 5000-220 Pmcs

    System Setup and Operation Manual for HPS 500 24VDC PRO-Verter 5000-220 PMCS Table 5. 24VDC PRO-Verter 5000-220 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 97: Figure 33. Replacing Pro-Verter Filter (Left); Cleaning A Pro-Verter Filter (Right)

    System Setup and Operation Manual for HPS 500 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 and dry it. Replace the filter if it is crushed, rotted, or cracked as illustrated in the left column of Figure 33.

  • Page 98: 24Vdc Power Hub 2500 Pmcs

    System Setup and Operation Manual for HPS 500 24VDC Power Hub 2500 PMCS Table 6. 24VDC Power Hub 2500 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 99: Solar Venture 350W Pv Array Pmcs

    System Setup and Operation Manual for HPS 500 Solar Venture 350W PV Array PMCS Table 7. Solar Venture 350W PV Array PMCS Item to be Item # Inspected Interval Procedures Non-mission Capable 1. Inspect PV panels and support ~If the PV panels and/or the frame for visible damage frame are damaged to the point of being non-functional, the PV...

  • Page 100: Procedure To Measure Pv Array V

    System Setup and Operation Manual for HPS 500 Procedure to Measure PV Array V with a Power Hub 2500 1. Disconnect all but two (2) PV arrays; leave one (1) PV array connected to each of the two (2) solar charge controllers.

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