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Solar Stik 24VDC HyPR 2500 Operator And Maintenance Manual

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24VDC HyPR 2500 Operator and Maintenance Manual
Operator and Maintenance Manual
for the
24VDC HyPR 2500
P/N 20-0104050
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Updated:20231116
November 2023
|
Solar Stik
®
, Inc.
|
1

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  • Page 1 24VDC HyPR 2500 Operator and Maintenance Manual Operator and Maintenance Manual for the 24VDC HyPR 2500 P/N 20-0104050 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Updated:20231116 November 2023 Solar Stik ® , Inc.

  • Page 2: Table Of Contents

    24VDC HyPR 2500 Operator and Maintenance Manual Contents GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Introduction ........... . . 5 Requirements for HyPR Operation .
  • Page 3 24VDC HyPR 2500 Operator and Maintenance Manual Current ........... 25 Connecting Generators to HyPR .
  • Page 4 24VDC HyPR 2500 Operator and Maintenance Manual List of Figures Figure 1. Schematized power ow from a top-down view of the interior of the HyPR 2500 ........... 7 Figure 2. Using the HyPR 2500 in Hybrid Model ......................12 Figure 3. Using the HyPR 2500 in UPS Model ....................... 12 Figure 4.

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

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

  • Page 6: Hypr 2500 Capabilities And Controls

    24VDC HyPR 2500 Operator and Maintenance Manual HyPR 2500 Capabilities and Controls The HyPR features speci c capabilities for the system in which it is employed and, while many of the circuits in the HyPR are fully automatic, outside user-established limits, not every HyPR feature may be used in every application.

  • Page 7: Theory Of Operation

    24VDC HyPR 2500 Operator and Maintenance Manual Theory of Operation The HyPR 2500 coordinates the support of AC and DC loads using power supplied from AC and/ or DC sources. Both AC and DC power sources energize the HyPR 2500 internal DC circuitry (DC bus), or the “Inter-Connect”...

  • Page 8: General Information

    24VDC HyPR 2500 Operator and Maintenance Manual General Information Circuit breakers on Faceplate are only for IN/OUT circuit limit protections. They are NOT “function controls” or “function protections”. The internal DC Bus is limited to 100 A total current ow. This may restrict some HyPR functionality in certain operating modes.

  • Page 9: Dc Functions

    24VDC HyPR 2500 Operator and Maintenance Manual DC Functions The DC bus is effectively the nervous system of the HyPR. All HyPR functions are regulated directly by the DC bus voltage. The DC bus voltage is functionally equivalent to the System battery voltage.

  • Page 10: Modes Of Operation

    24VDC HyPR 2500 Operator and Maintenance Manual Modes of Operation There are several operational modes in which the HyPR may be con gured, depending on the application, Hybrid Mode–The hybrid mode allows the use of a smaller generator based on average, continuous total loads over a 24-hour period, versus a larger generator that will support “peak”...

  • Page 11: Selecting An Ac Power Source

    24VDC HyPR 2500 Operator and Maintenance Manual Selecting an AC Power Source HyPRs can be used with grid-utility or generator AC power sources, and can easily be con gured to work with the current limits of both the DC/AC power source circuits and the DC/AC load circuits.

  • Page 12: Temperature-Dependent Power Processing

    • Do not overload the HyPR. Manage power processing demand by paying close attention to what is “plugged in. Prioritize critical loads. • Shade the HyPR 2500 to reduce solar loading. Solar Stik data indicates that solar loading of a Pelican case can increase internal heat by ~40 ºF (~ 22 ºC) above ambient.

  • Page 13: Important Safety Information And Instructions

    24VDC HyPR 2500 Operator and Maintenance Manual Important Safety Information and Instructions This manual contains important instructions that must be followed during the setup and operation of a the HyPR 2500. Read all instructions and information contained in this manual.

  • Page 14: Fire Hazard

    24VDC HyPR 2500 Operator and Maintenance Manual Fire Hazard Fire Types Class A fire - Fires in ordinary combustibles such as wood, paper, cloth, trash, and plastics. Class B fire - Fires in ammable liquids such as gasoline, petroleum, oil, and paint.

  • Page 15: Electric Shock Hazard

    24VDC HyPR 2500 Operator and Maintenance Manual Electric Shock Hazard WARNING Standing water around the electrical equipment and/or intrusion of water into the System components can increase the risk of electrical shock. HIGH VOLTAGE: System components, PV arrays, and generators may produce lethal line voltages.

  • Page 16: Environmental And Handling Precautions

    24VDC HyPR 2500 Operator and Maintenance Manual Environmental and Handling Precautions All Solar Stik components are ruggedized, yet there are a few things the operator can do to prevent failures and prolong the operational life of the Solar Stik System.

  • Page 17: The Inter-Connect System

    24VDC HyPR 2500 Operator and Maintenance Manual The Inter-Connect System A Solar Stik System is comprised of three (3) distinct types of technologies: • Energy storage • Power management • Power generation All of the individual components that operate in these categories utilize a unique connection architecture known as the Inter-Connect Circuit.

  • Page 18: 24Vdc Linear Inter-Connect Cable

    24VDC HyPR 2500 Operator and Maintenance Manual 24VDC Linear Inter-Connect Cable Inter-Connect Cables for use with ESMs have two types of plugs: straight and angled. The straight plug connects to the ESM to facilitate stacking (Figure 7). Polarized • 200 A maximum current •...

  • Page 19: Equipment Description Introduction

    24VDC HyPR 2500 Operator and Maintenance Manual EQUIPMENT DESCRIPTION Introduction The HyPR 2500 manages power between power sources and loads. The HyPR 2500 provides both AC and DC mechanisms to charge ESMs while the system is operating or idle. The HyPR 2500 provides important battery status information and therefore increased security for continuity of operations.

  • Page 20: Ac Power Input Port

    24VDC HyPR 2500 Operator and Maintenance Manual AC Power Input Port Connect AC power sources to the 120 INPUT port. The HyPR 2500 accepts 120 V power. Power via this connection charges batteries and supports DC loads connected the 24VDC IN/OUT ports.

  • Page 21: 24 Vdc In/Out Ports

    24VDC HyPR 2500 Operator and Maintenance Manual 24 VDC IN/OUT Ports Connect Energy Storage Modules(ESMs) to this metered Inter-Connect port. Use Inter-Connect cables to connect multiple ESMs to an Inter-Connect Strip and to the HyPR 2500 24 VDC IN/OUT port.

  • Page 22: 120 Vac Output Ports

    24VDC HyPR 2500 Operator and Maintenance Manual 120 VAC OUTPUT Ports Connect AC loads to the 120 VAC output ports. This port can provide 1100 W (9 A) continuous power output. Brief surges of up to 2000 W are tolerated. This port is limited to 9 A.

  • Page 23: 24 Vdc Hypr Faceplate

    24VDC HyPR 2500 Operator and Maintenance Manual 24 VDC HyPR Faceplate Figure 12. 24 VDC HyPR 2500 Faceplate AC INPUT CONTROL breakers – Allows selection of AC input current limit. This must be adjusted to match the maximum recommended current output limit of the AC power source.

  • Page 24: Ac Interface

    24VDC HyPR 2500 Operator and Maintenance Manual AC Interface AC Input Current Limit Switch This switch may be thought of as the battery charging rate limiter. Toggle this switch to match the maximum output of the AC power source connected to the HyPR. Properly setting this value will prevent overloading the AC power source.

  • Page 25: Dc Interface

    24VDC HyPR 2500 Operator and Maintenance Manual DC Interface The DC Interface consists of an LCD screen and three (3) menu navigation buttons. System voltage and net current are reported on the DC INTERFACE home screen. There are some programmable settings that will be important to change or con rm, depending on System con guration.

  • Page 26: Connecting Generators To Hypr

    24VDC HyPR 2500 Operator and Maintenance Manual Connecting Generators to HyPR Connect generator power cables to the “AC INPUT” port on the left side of the HyPR. fuel-powered generator 1-2 kW 120 VAC, 50 / 60 Hz Figure 15. Connecting generators to HyPR...

  • Page 27: Operator Instructions

    3. Check/Con rm/Program total Ah capacity in HyPR DC User Interface (typically programmed at Solar Stik for the application illustrated on the HyPR 2500 Faceplate.) 4. Set HyPR AC INPUT CONTROL to match output limit of generator(s) or shore power.

  • Page 28: Navigating Dc User Interface Menus

    24VDC HyPR 2500 Operator and Maintenance Manual Navigating DC User Interface Menus Monitoring the Battery The HyPR has a BATTERY MONITOR that reports any connected ESM battery status as well as all power that ows into and out of the battery. The BATTERY MONITOR constantly measures the battery voltage (V) and battery current (I).

  • Page 29: Battery Monitor

    (–) buttons for scrolling access to the read-only battery metrics (see below). The BATTERY MONITOR has been programmed by Solar Stik for your application so under normal operating conditions, there is no reason to use the SETUP or SELECT buttons.

  • Page 30: Synchronizing The Battery Monitor

    24VDC HyPR 2500 Operator and Maintenance Manual Synchronizing the Battery Monitor For a reliable readout, the SOC as displayed by the BATTERY MONITOR has to be synchronized regularly with the true SOC of the battery. This is accomplished by fully charging the battery. The BATTERY MONITOR resets to “fully charged”...

  • Page 31: Historical Data

    24VDC HyPR 2500 Operator and Maintenance Manual Historical Data The BATTERY MONITOR tracks several parameters regarding the state of the battery. These can be used to evaluate usage patterns and battery health. Enter historical data by pressing the SELECT button when in normal mode.

  • Page 32: Maintenance

    24VDC HyPR 2500 Operator and Maintenance Manual Maintenance Preventive Maintenance Checks and Services (PMCS) Item to be Item # Inspected Interval Procedures Non-mission Capable 1. Inspect case for visible damage ~If the case is broken or split or and missing items.

  • Page 33: Water Intrusion Remediation

    24VDC HyPR 2500 Operator and Maintenance Manual Water Intrusion Remediation If water intrusion is suspected, and the System is still functional, disconnect power sources entering the HyPR 2500 from the most distant location possible, power down the System (turn off the power switches on all of the System components) and then disconnect the HyPR 2500 from the System.

  • Page 34: Technical Specifications

    24VDC HyPR 2500 Operator and Maintenance Manual TECHNICAL SPECIFICATIONS Safety General Breaker(s) (1) 30 A, (1) 100 A, (1) 9 A 24 VDC Nominal Operating Voltage Built and designed to MIL-STD-810G Battery Chemistry LiPO /Pb Compatible Certifications and IP65 Operational Voltage Range...

  • Page 35: About Solar Stik, Inc

    • Solar Stik New Equipment Training (on site) teaches Hybrid System con guration options with hands-on deployment of actual systems to enhance student understanding. Solar Stik Training Courses are tailored to the speci c needs of the students. To schedule Solar Stik Training or to learn more about the curriculum, please contact us.

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