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Solar Stik 24VDC HyPR 3000 Operator And Maintenance Manual

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24VDC HyPR 3000 Operator and Maintenance Manual
Operator and Maintenance Manual
for the
24VDC HyPR 3000
P/N 20-0102020
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Updated:20240321
March 2024
|
Solar Stik
®
, Inc.
|
1

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  • Page 1 24VDC HyPR 3000 Operator and Maintenance Manual Operator and Maintenance Manual for the 24VDC HyPR 3000 P/N 20-0102020 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Updated:20240321 March 2024 Solar Stik ® , Inc.

  • Page 2: Important Safety Information And Instructions

    24VDC HyPR 3000 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 3000. Read all instructions and information contained in this manual.

  • Page 3: Fire Hazard

    24VDC HyPR 3000 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 4: Electric Shock Hazard

    24VDC HyPR 3000 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 5: Environmental And Handling Precautions

    24VDC HyPR 3000 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 6: Table Of Contents

    24VDC HyPR 3000 Operator and Maintenance Manual Contents Important Safety Information and Instructions ........2 Safety Information Labels .
  • Page 7 24VDC HyPR 3000 Operator and Maintenance Manual Battery Low-voltage Cut Off (LVCO) ........29 Solar Charging Status LED .
  • Page 8 24VDC HyPR 3000 Operator and Maintenance Manual List of Figures Figure 1. 24 VDC HyPR 3000 connections ........................12 Figure 2. The HyPR 3000 I-Plate ............................ 13 Figure 4. 24 VDC HyPR 3000 Faceplate ........................14 Figure 5. Schematized power ow from a top-down view of the interior of the HyPR 3000 ......... 15 Figure 6.

  • Page 9: General Information

    Solar Stik facility.The end-user will pay to ship the product to Solar Stik. If the product is covered under warranty, then Solar Stik will pay the return shipping of the repaired or replacement item. If the product is not covered by warranty, then the end-user will be quoted for the repair or replacement and return shipping.

  • Page 10: Equipment Description And Data

    DC and AC power outputs simultaneaously or independently. The HyPR is designed to be 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 11: Hypr 3000 Specifications, Environmental Control And Handling Requirements

    24VDC HyPR 3000 Operator and Maintenance Manual HyPR 3000 Specifications, Environmental Control and Handling Requirements General Safety Nominal Operating Voltage 24 VDC (1) 100 A (2) 20 A User programmable; factory default to 24.4 VDC Battery Low Voltage Cut-Off Breaker(s)

  • Page 12: Location And Description Of Major Components Introduction

    24VDC HyPR 3000 Operator and Maintenance Manual Location and Description of Major Components Introduction The HyPR 3000 utilizes a DC BUS to connect a variety of AC and DC power sources to power both AC and DC loads. The HyPR 3000 provides both AC and DC mechanisms, including solar inputs, VAC universal power inputs, 9-36 VDC inputs, 24 VDC input/output, NATO input/output and ESM input/output to charge ESMs or other connected DC loads while the system is operating or idle.

  • Page 13: Information Plate (I-Plate)

    24VDC HyPR 3000 Operator and Maintenance Manual Information Plate (I-Plate) The I-Plate is an application-speci c part of the HyPR. It provides condensed instructions for deploying and operating a System that includes a HyPR as manager of power within the System.

  • Page 14: Faceplate

    24VDC HyPR 3000 Operator and Maintenance Manual Faceplate Speci cations AC INPUT QR Code Power Control Switch USB Charging ports x4 Breakers / switches User Interface circuit LEDs Figure 4. 24 VDC HyPR 3000 Faceplate USER INTERFACE – When operated with a battery, the HyPR 3000 backlit LCD DC User Interface with...

  • Page 15: Theory Of Operation

    24VDC HyPR 3000 Operator and Maintenance Manual Theory of Operation The HyPR 3000 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 3000 internal DC circuitry (DC bus), or the “Inter-Connect”...

  • Page 16: Hypr 3000 Front

    24VDC HyPR 3000 Operator and Maintenance Manual HyPR 3000 Front Figure 6. HyPR 3000 front side Solar Power Input Port The HyPR accepts power from PV arrays to charge connected ESMs. Speci cations for the solar charge controller and compatible PV arrays are on the HyPR 3000 Faceplate. Functioning PV arrays must be connected for the DC INTERFACE to calculate and report ESM state of charge (SOC).

  • Page 17: Power Scavenging Port

    24VDC HyPR 3000 Operator and Maintenance Manual Power Scavenging Port Connect unregulated DC power ranging from 9 to 36 VDC to this 4-pin bayonet connector. Power between these voltages is converted to 28.3 VDC and applied to the DC bus to charge batteries or support small loads.

  • Page 18: Esm Only Port

    24VDC HyPR 3000 Operator and Maintenance Manual ESM Only Port Connect Energy Storage Module (ESMs) to this metered Inter-Connect port. Use Inter-Connect cables to connect multiple ESMs to an Inter-Connect Strip 7 and to the HyPR 3000 ESM ONLY port.

  • Page 19: Bb-2590 Charging Ports

    24VDC HyPR 3000 Operator and Maintenance Manual BB-2590 Charging Ports These connectors provide a DC charging port for BB-2590 Batteries. Description Connector Voltage Amps BB-2590 Charging Port P/N 07-1002119 SZ10, Bayonet, 6POS, Socket 16.4 VAC Figure 12. BB-2590 Charging Only ports 24 VDC NATO Input/Output Port The NATO port is a direct connection to the HyPR DC bus.

  • Page 20: Ac Power Input Port

    24VDC HyPR 3000 Operator and Maintenance Manual AC Power Input Port Connect AC power sources to the 120-230 VAC INPUT port. Power via this connection is capable of charging batteries and can support DC loads connected the 24VDC IN/OUT and NATO ports.

  • Page 21: Vents

    24VDC HyPR 3000 Operator and Maintenance Manual Vents Exhaust vents have fans to remove air from the case. Ambient air enters the case through the intake vents and also have fans to force air into the case. The air filters must be cleaned or replaced on a regular basis, especially when operating in dusty environments.

  • Page 22: General Information

    24VDC HyPR 3000 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 23: Hypr 3000 Controls

    24VDC HyPR 3000 Operator and Maintenance Manual HyPR 3000 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 24: Dc Functions

    24VDC HyPR 3000 Operator and Maintenance Manual DC Functions The DC bus is effectively the nervous system of the HyPR. All HyPR functions are regulated directly or indirectly by the DC bus voltage. The DC bus voltage is functionally equivalent to the System battery voltage.

  • Page 25: Load Prioritization

    24VDC HyPR 3000 Operator and Maintenance Manual Drawing power from a vehicle battery in scavenge mode has the potential to overdischarge the vehicle starter battery rapidly. Run the vehicle motor when scavenging power from a vehicle to avoid overdischarging the starter battery.

  • Page 26: Modes Of Operation

    24VDC HyPR 3000 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 27: Battery Current Requirements For Hypr Ac Output

    VDC which is appropriate for charging ESMs and/or to support small 120 VAC or 24 VDC loads. It is not necessary for a Solar Stik ESM to be connected to the HPS to take advantage of the Scavenging circuit. If ESM’s are not connected, however, the HyPR can only support loads up to the amount of power provided through the Scavenging circuit (Figure 1).

  • Page 28: Dc User Interface

    24VDC HyPR 3000 Operator and Maintenance Manual DC User Interface The DC 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. System voltage and net current are reported on the DC INTERFACE home screen.

  • Page 29: Battery Low-Voltage Cut Off (Lvco)

    24VDC HyPR 3000 Operator and Maintenance Manual Solar Charging Status LED The user interface charging status LED reports charging only via solar power input. The LED will not illuminate when the HyPR 3000 is charging connected batteries using AC power. The information in this section is relevant only when solar panels are part of the system.

  • Page 30: Ac Interface

    24VDC HyPR 3000 Operator and Maintenance Manual AC Interface AC Input Power Control Switch This control 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 31: Operator Instructions

    4. Check/Con rm/Program total Ah capacity in HyPR DC User Interface (typically programmed at Solar Stik for the application illustrated on the HyPR 3000 I Plate.) 5. Set HyPR AC INPUT CONTROL to match output limit of generator(s) or shore power.

  • Page 32: Navigating Dc User Interface Menus

    24VDC HyPR 3000 Operator and Maintenance Manual Navigating DC User Interface Menus The user interface has four main menus: 1. General Information 2. Advanced Information 3. Operation Setup 4. Battery Charger Parameter Setup. The Home screen is in the General Information menu.

  • Page 33: Programmable Parameters

    SET ACCEPT CHG and SET FLOAT CHG - These values will vary depending on the System battery type. These settings are programmed by Solar Stik in accordance with the intended application. If changes to the intended application are required, please contact Solar Stik Technical Support for assistance with these settings.

  • Page 34: Maintenance

    24VDC HyPR 3000 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 35: 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 3000 to reduce solar loading. Solar Stik data indicate that solar loading of a Pelican case can increase internal heat by ~40 ºF (~ 22 ºC) above ambient.

  • Page 36: Water Intrusion Remediation

    24VDC HyPR 3000 Operator and Maintenance Manual Water Intrusion Remediation If water intrusion is suspected, and the System is still functional, disconnect power sources entering the HyPR 3000 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 3000 from the System.

  • Page 37: 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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20-0102020

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