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Solar Stik ATSC MS3 L0 Setup And Operation Manual

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SYSTEM SETUP AND OPERATION
MANUAL
FOR
ATSC MS3 L0
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Version 1.0
Updated:20200214
February 2020
|
Solar Stik
, Inc.
|
1
®

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  • Page 1 SYSTEM SETUP AND OPERATION MANUAL ATSC MS3 L0 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Version 1.0 Updated:20200214 February 2020 Solar Stik , Inc. ®...

  • Page 2: Table Of Contents

    System Setup and Operation Manual for ATSC MS3 L0 Contents GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Introduction to Hybrid Power Systems The Hybrid Power System Flexible Open Architecture The L0 Hybrid Power System Peak-Power Loads Defined ......... . . 10 ECU Soft-starts .
  • Page 3 System Setup and Operation Manual for ATSC MS3 L0 OPERATOR INSTRUCTIONS A System Setup 1. Inventory System components......... 28 2.
  • Page 4 System Setup and Operation Manual for ATSC MS3 L0 No Inverter Comm..........57 .
  • Page 5 System Setup and Operation Manual for ATSC MS3 L0 Resolving AGS Operational Statuses ........69 No Comm .
  • Page 6 System Setup and Operation Manual for ATSC MS3 L0 Generator Fails to Stop ..........82 RMK-related Troubleshooting RMK Status Indicator Light Not Illuminated When PRO-Verter Powers Up .
  • Page 7 System Setup and Operation Manual for ATSC MS3 L0 List of Figures Figure 1. MS3 L0 HPS ..............................9 Figure 2. PRO-Verter grounding lug ..........................13 Figure 3. Hybrid Power System in Operation ......................... 20 Figure 4. Example-Stacking PRO-Verters ........................21 Figure 5.
  • Page 8 System Setup and Operation Manual for ATSC MS3 L0 List of Tables Table 1. Charge Status Indicator—LED Status ....................... 47 Table 2. List of Faults and Source(s) of Problem ......................54 Table 3. Troubleshooting the User Interface LCD Screen....................56 Table 4.

  • Page 9: General Information, Equipment Description, And Theory Of Operation Introduction To Hybrid Power Systems

    System Setup and Operation Manual for ATSC MS3 L0 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 10: The L0 Hybrid Power System

    System Setup and Operation Manual for ATSC MS3 L0 The L0 Hybrid Power System The Solar Stik Hybrid System (HPS) integrated into the L0 platform is configured for operation with compact Yanmar YDG5500 diesel-fuel generator. The generator is rated for lower output than the peak AC power requirement.

  • Page 11: Important Safety Information And Instructions

    System Setup and Operation Manual for ATSC MS3 L0 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 12: Fire Hazard

    System Setup and Operation Manual for ATSC MS3 L0 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 13: Electric Shock Hazard

    System Setup and Operation Manual for ATSC MS3 L0 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 14: Environmental And Handling Precautions

    System Setup and Operation Manual for ATSC MS3 L0 Environmental and Handling Precautions All of the System components are ruggedized, yet there are a few precautions the operator can do to prevent failures and prolong the operational life of the System.

  • Page 15: Theory Of Operation

    System Setup and Operation Manual for ATSC MS3 L0 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 16: Ups (Automatic Functions)

    System architecture changes are necessary. To learn more, contact Solar Stik Technical Support. The HPS Architecture, Function, and Operation The Solar Stik HPS incorporates three technologies that comprise a network: • Energy storage • Power management •...

  • Page 17: Minimum Battery Capacity Required For Optimal System Operation

    System Setup and Operation Manual for ATSC MS3 L0 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 18: Load Prioritization

    System Setup and Operation Manual for ATSC MS3 L0 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 19: Overload" Conditions

    System Setup and Operation Manual for ATSC MS3 L0 “Overload” Conditions Over loading of the System can occur under the following conditions: • Load AC power demand is greater than the inverter’s rated output. • Load AC and DC power demand is greater than the connected AC source (generator or grid utility).

  • Page 20: Lag Time And Surge Rates

    System Setup and Operation Manual for ATSC MS3 L0 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 21: Scaling And Modifying The Hps

    System Setup and Operation Manual for ATSC MS3 L0 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.

  • Page 22: Power Hub Stacking Example

    System Setup and Operation Manual for ATSC MS3 L0 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 23: Equipment Description

    System Setup and Operation Manual for ATSC MS3 L0 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 24: The Standard Inter-Connect Plug

    System Setup and Operation Manual for ATSC MS3 L0 The Standard 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 25: Color-Coded Connections

    System Setup and Operation Manual for ATSC MS3 L0 Color-coded Connections Cables and ports are color coded based on their function. Cable Color Example Ports Orange: Solar Circuit Connection Red: DC Circuit Connection Blue: AC Input Connection Gray: AGS Communication...

  • Page 26: Trailer Inventory

    System Setup and Operation Manual for ATSC MS3 L0 Trailer Inventory o Three (3) o One (1) o One (1) 420W Expedition Solar Array-Cs 24VDC PRO-Verter 5000-220 24VDC Power Hub 2400 in transport cases (includes one 5’ Inter- Connect Cable)

  • Page 27: The Information Plate (I-Plate)

    System Setup and Operation Manual for ATSC MS3 L0 The Information Plate (I-Plate) The I-Plate in the PRO-Verter provides critical setup and safety information for the Operator including a System connection diagram, shown in detail below. Figure 9. System Setup Guide on the PRO-Verter I-Plate...

  • Page 28: Operator Instructions

    System Setup and Operation Manual for ATSC MS3 L0 OPERATOR INSTRUCTIONS A System Setup 1 Inventory System components Inventory the System components using the list in the Trailer Inventory section. 2 Remove Solar Arrays, Power Hub, and 20’ Inter-Connect Cable...

  • Page 29: Identify Locations For System Components

    Figure 12. Working-space distance for the Solar Arrays, Power Hub, and the trailer b Minimize Potential for Water and Dust Intrusion ALL Solar Stik equipment is designed for operation in adverse 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 30: Connect System Components

    System Setup and Operation Manual for ATSC MS3 L0 5 Connect System components Make connections between the System components that are to remain on the trailer according to the diagram 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 31: Connect Pro-Verter To Shelter Service Panel

    System Setup and Operation Manual for ATSC MS3 L0 c Connect PRO-Verter to shelter service panel Connect the PRO-Verter (“220 AC OUT” port) to the shelter service panel using a green-to-green connection. AC Output Power Cable PRO-Verter left side view...

  • Page 32: Connect Pv Arrays To Power Hub

    System Setup and Operation Manual for ATSC MS3 L0 e Connect PV Arrays to Power Hub Connect one (1) Solar Leash to one (1) SOLAR ONLY port from each pair of ports (CHARGE UNIT#0, CHARGE UNIT#1, CHARGE UNIT#2). These are orange-to-orange connections.

  • Page 33: Connect Remote Monitoring Kit To Pc Or Lan (Rmk; Optional)

    System Setup and Operation Manual for ATSC MS3 L0 g Connect Remote Monitoring Kit to PC or LAN (RMK; optional) The RMK provides remote access to vital operating data of the PRO-Verter via the User Interface on the Faceplate. RMK data can be...

  • Page 34: B System Activation

    System Setup and Operation Manual for ATSC MS3 L0 B System Activation 1. Connect loads to the PRO-Verter (If not already connected). 2. Verify the generator has fuel and oil and that the generator starter battery cables are connected. 3. Turn on the generator MAIN SWITCH and AC BREAKER switch by toggling it up (Figure 22, arrows).

  • Page 35: C System Initialization And Calibration

    System Setup and Operation Manual for ATSC MS3 L0 C 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 The Generator Status LED (Figure 16, left side) will be illuminated green.

  • Page 36: D Order Of Operations: Activation And Deactivation Of The System

    System Setup and Operation Manual for ATSC MS3 L0 D Order of Operations: Activation and Deactivation of the System L0 Isolation of Operations: When deploying the L0, it is recommended that the ECUs not be engaged. The sensors can be powered up before raising the tower, but the ECUs must remain off. Failure to follow this recommendation may result in overloading of the HPS.

  • Page 37: F L0 Pro-Verter Programming Menu Map

    Light green menu items represent resettable menu selections. Press and hold the knob for 3 seconds to reset values. Orange menu items indicate values that are set by Solar Stik for a specific application. These values (with the exception of setting the clock to local time) should not be changed by the user without consulting tech@solarstik.com.

  • Page 38: Ctrl Button Menus

    System Setup and Operation Manual for ATSC MS3 L0 CTRL Button Menus CTRL 01 AC In Control Auto Connect Set AC In Control Set AC In Control Set AC In Control Set AC In Control Set AC In Control Auto Connect...

  • Page 39: Meter Button Menus Continued

    System Setup and Operation Manual for ATSC MS3 L0 METER Button Menus continued METER 04 AGS Meters Auto 04F Since 100% 04E Since Gen Run 04B DC Volts-AGS 04C Gen Run Time 04D AGS Temp 04A AGS Status ## Days...

  • Page 40: Setup Button Menus

    System Setup and Operation Manual for ATSC MS3 L0 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 41 System Setup and Operation Manual for ATSC MS3 L0 SETUP Button Menus continued Setup: 03 Charger SETUP Status 03 Charger Setup 03A AC Input Range: 5 A to 60 A Amps = 20A 03B VAC Dropout Default = 150 UPS Mode...
  • Page 42 System Setup and Operation Manual for ATSC MS3 L0 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 43 System Setup and Operation Manual for ATSC MS3 L0 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...
  • Page 44 System Setup and Operation Manual for ATSC MS3 L0 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...

  • Page 45: Tech Button Menus

    System Setup and Operation Manual for ATSC MS3 L0 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...

  • Page 46: G Power Hub User Interface Menu Operation

    System Setup and Operation Manual for ATSC MS3 L0 G Power Hub User Interface Menu Operation How to Use the BACK, NEXT, SELECT Buttons to Navigate the Menus To move forward through screens in a menu, press NEXT. • Note: It is only possible to move forward through the menu items.

  • Page 47: H Monitoring The Charging Status On Power Hub

    System Setup and Operation Manual for ATSC MS3 L0 H Monitoring the Charging Status on Power Hub 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 –...

  • Page 48: I Power Hub User Interface Menu Windows

    System Setup and Operation Manual for ATSC MS3 L0 I Power Hub User Interface 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.
  • Page 49 System Setup and Operation Manual for ATSC MS3 L0 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 50 System Setup and Operation Manual for ATSC MS3 L0 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 51 System Setup and Operation Manual for ATSC MS3 L0 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...

  • Page 52: J Hybrid System Bypass Mode

    System Setup and Operation Manual for ATSC MS3 L0 J Hybrid System Bypass Mode Bypassing the Hybrid Power System may be helpful if the HPS is temporarily inoperable. Hybrid Mode PRO-Verter 5000 Generator Load Hybrid System Bypass Mode PRO-Verter 5000...

  • Page 53: K System Breakdown And Storage

    System Setup and Operation Manual for ATSC MS3 L0 K System Breakdown and Storage Prior to System breakdown, charge the Expander Paks fully • Start the generator manually. CTRL>03 Gen Control>ON. Allow the generator to run until the charging amps drop to 3–4 A, as reported by the LCD User Interface home screen.

  • Page 54: Troubleshooting

    System Setup and Operation Manual for ATSC MS3 L0 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 55: Pro-Verter: Quick Links To Statuses, Faults, And Resolutions

    System Setup and Operation Manual for ATSC MS3 L0 Troubleshooting PRO-Verter: 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 56: Pro-Verter Troubleshooting

    System Setup and Operation Manual for ATSC MS3 L0 PRO-Verter Troubleshooting The User Interface LCD Screen Table 3. Troubleshooting the User Interface 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 57: Pro-Verter Inverter-Mode Status Messages

    Network. Solution The inverter may need to be serviced. Contact Solar Stik Technical Support. This message tells indicates that there is no AC available on the inverter’s AC output. The inverter function is OFF, and there is no utility or generator AC power sensed on its input.

  • Page 58: Pro-Verter Charger -Mode Status Messages

    System Setup and Operation Manual for ATSC MS3 L0 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 59: Full Charge

    System Setup and Operation Manual for ATSC MS3 L0 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 60: Pro-Verter Charger Problems: Solutions And Explanations

    System Setup and Operation Manual for ATSC MS3 L0 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 61: Pro-Verter Inverter Problems: Solutions And Explanations

    System Setup and Operation Manual for ATSC MS3 L0 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 62: Dead Batt Charge

    System Setup and Operation Manual for ATSC MS3 L0 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 63: High Battery

    System Setup and Operation Manual for ATSC MS3 L0 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 64: Overcurrent

    System Setup and Operation Manual for ATSC MS3 L0 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 65: Unknown Fault

    After resetting the inverter, press the INVERTER ON/OFF button on the User Interface to turn the inverter on and then verify that the fault has cleared (i.e., manual restart). If the internal fault remains or returns, the inverter may require repair at a Solar Stik. Call Solar Stik Technical Support: 800-793-4364, Ext 102.

  • Page 66: Pro-Verter Ags Functional Tests

    System Setup and Operation Manual for ATSC MS3 L0 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 67: Ags Start Statuses Table (Meter 04)

    System Setup and Operation Manual for ATSC MS3 L0 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 68: Ags Operational Statuses (Meter 04)

    System Setup and Operation Manual for ATSC MS3 L0 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 69: Resolving Ags Operational Statuses

    If an AGS fault occurs, use the LCD User Interface and the information in this section to resolve the issue. Note: PRO-Verters in a Solar Stik Hybrid Power System are programmed to start and stop generators based on DC voltage. The faults highlighted in...

  • Page 70: Fault Test

    System Setup and Operation Manual for ATSC MS3 L0 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 71: Fault Maxrn

    System Setup and Operation Manual for ATSC MS3 L0 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 72: Pro-Verter Battery Monitoring (Bmk) Circuit Operational Statuses

    System Setup and Operation Manual for ATSC MS3 L0 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 73: Fault History (Tech 04)

    System Setup and Operation Manual for ATSC MS3 L0 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...

  • Page 74: Pro-Verter: Historical Data Collection

    System Setup and Operation Manual for ATSC MS3 L0 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 75: Auto Generator Start/Stop (Ags) Data

    System Setup and Operation Manual for ATSC MS3 L0 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.

  • Page 76: Battery Monitor (Bmk) Data (Meter 05)

    System Setup and Operation Manual for ATSC MS3 L0 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 77: Total Ah Out

    System Setup and Operation Manual for ATSC MS3 L0 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 78: Power Hub-Related Troubleshooting Power Hub Will Not Power Up

    System Setup and Operation Manual for ATSC MS3 L0 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 79: Pv Array-Related Troubleshooting

    System Setup and Operation Manual for ATSC MS3 L0 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 80: Li Expander Pak-Related Troubleshooting

    System Setup and Operation Manual for ATSC MS3 L0 Li Expander Pak–related Troubleshooting It is most important to maintain Li Expander Paks in such a way that they will never reach a red-flash state Battery Status LED Problem Red-flash or no-light Battery Status LED...

  • Page 81: Generator-Related Troubleshooting Testing The Ags Function

    System Setup and Operation Manual for ATSC MS3 L0 Generator-related 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. When...

  • Page 82: Generator Starts, Then Shuts Down When Load Is Transferred

    System Setup and Operation Manual for ATSC MS3 L0 Generator Starts, Then Shuts Down When Load Is Transferred Cause The motor in the generator cannot sustain a significant load until the engine is fully warmed up. Solution Gen warm-up and cool down phases are critical for repetitive start/stop function. Make sure the Gen Warm-up setting is at least 75 seconds in duration.

  • Page 83: Rmk-Related Troubleshooting

    System Setup and Operation Manual for ATSC MS3 L0 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 84: Status Light Stays Orange After Inserting Usb Drive

    System Setup and Operation Manual for ATSC MS3 L0 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.

  • Page 85: Heat And System Derating

    System Setup and Operation Manual for ATSC MS3 L0 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 86: Power Hub Temperature Reports

    System Setup and Operation Manual for ATSC MS3 L0 Power Hub Temperature Reports The first indication of overheating may be the appearance that the solar arrays are “not producing any power” when they should be. If this is the case, check the temperature.

  • Page 87: Pro-Verter High-Temp Generator Auto-Start

    System Setup and Operation Manual for ATSC MS3 L0 PRO-Verter High-temp Generator Auto-Start When a heavy load (≥100% rated output) is placed on the PRO-Verter while inverting, the internal transformer temperature will rise in accordance with the amount of power it is processing. If the internal “Transformer Temperature”...

  • Page 88: Maintenance Instructions Hps Preventive Care And Maintenance

    System Setup and Operation Manual for ATSC MS3 L0 MAINTENANCE INSTRUCTIONS HPS Preventive Care and Maintenance Follow these procedures to maintain the System. • Shade the components (except the PV arrays) from direct sun exposure and shelter them from the elements •...

  • Page 89: Water Intrusion-Prevention And Remediation

    System Setup and Operation Manual for ATSC MS3 L0 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: Locking Component Cases To Prevent Tampering

    System Setup and Operation Manual for ATSC MS3 L0 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. Two or more latches allow the cases to be sealed to prevent damage to the internal components from environmental factors.

  • Page 91: Soc Disparity Among Expander Paks

    System Setup and Operation Manual for ATSC MS3 L0 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: •...

  • Page 92: Maintaining Soc Parity

    System Setup and Operation Manual for ATSC MS3 L0 Maintaining SOC Parity The PRO-Verter has two programmable “maintenance” functions in the AGS menus that can be used to maintain 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 93: Method To Maintain Expander Pak Soc Parity Using Gen 100% Soc

    System Setup and Operation Manual for ATSC MS3 L0 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 94: Energy Storage Modules - Supplemental Information

    System Setup and Operation Manual for ATSC MS3 L0 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 95: Terminal (End-Of-Life) Battery Performance

    System Setup and Operation Manual for ATSC MS3 L0 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 96: Preventive Maintenance Checks And Services (Pmcs)

    System Setup and Operation Manual for ATSC MS3 L0 Preventive Maintenance Checks and Services (PMCS) The tables that follow describe PMCS at the field operator level. 24VDC Expander Pak 2400 PMCS Required Tools Solar Stik PRO-Verter or LiFePO battery maintenance charger.

  • Page 97: 24Vdc Pro-Verter 5000-220 Pmcs

    System Setup and Operation Manual for ATSC MS3 L0 24VDC PRO-Verter 5000-220 PMCS Table 7. 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 98: Figure 33. Replacing Pro-Verter Filter (Left); Cleaning A Pro-Verter Filter (Right)

    System Setup and Operation Manual for ATSC MS3 L0 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.

  • Page 99: 24Vdc Power Hub 2400 Pmcs

    System Setup and Operation Manual for ATSC MS3 L0 24VDC Power Hub 2400 PMCS Table 8. 24VDC Power Hub 2400 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 100: Pam 420W Pv Array Pmcs And Troubleshooting

    The following tests/inspections and corrective actions should be prioritized in the order listed. This document cannot list all issues that may occur, nor all tests or inspections and corrective actions. If an issue cannot be corrected by following these procedures, contact Solar Stik Tech Support. February 2020 Solar Stik , Inc.

  • Page 101: Maximum Power (Vmp) And Open Circuit Voltages (Voc)

    System Setup and Operation Manual for ATSC MS3 L0 CAUTION Photovoltaic panels produce electricity when exposed to light • Live power may be present at multiple points • Never route the cables through standing water • All cables and connections should remain dry •...

  • Page 102: Procedure To Measure Pv Array V

    System Setup and Operation Manual for ATSC MS3 L0 Procedure to Measure PV Array V with a Power Hub 2400 1. Disconnect one (1) PV array from each of the three (3) charge controllers. 2. Read and record the performance metrics for each PV array as reported by the User Interface in charge units 0, 1 and 2.

  • Page 103: Navigating The User Interface Menus "View Charge Unit Status" Submenus

    System Setup and Operation Manual for ATSC MS3 L0 Navigating the User Interface Menus “View Charge Unit Status” Submenus Enter “Advanced Information Menu”. Advance to “VIEW CHARGE UNIT STATUS”. User Interface Menus General Advanced Press and hold SELECT for 4 seconds.

  • Page 104: Procedure To Measure Pam V

    System Setup and Operation Manual for ATSC MS3 L0 Procedure to Measure PAM V from a single PAM, carefully place the leads of the voltmeter on pins A and C in the To measure V bayonet connector at the end of the Solar Leash (DO NOT SHORT THESE PINS). Pin B is unused.

  • Page 105: 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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