Solar Stik 24VDC HyPR 3000 Instructions d'installation

|1November 2023 |Solar Stik®, Inc.

24VDC HyPR 2500 Operator and Maintenance Manual

Operator and Maintenance Manual

for the

24VDC HyPR 2500

Updated:20231116

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

P/N 20-0104050

November 2023 |Solar Stik®, Inc.2 |

24VDC HyPR 2500 Operator and Maintenance Manual

Contents

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Requirements for HyPR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

HyPR 2500 Capabilities and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

User Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Data Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Theory of Operation

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

AC Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Inverting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DC Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Load Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Selecting an AC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Battery Current Requirements for HyPR AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Temperature-dependent Power Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Derating Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

How to Minimize Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Important Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

24VDC Linear Inter-Connect Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

The Standard Inter-Connect Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

EQUIPMENT DESCRIPTION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

AC Power Input Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connecting Generators to HyPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

24 VDC IN/OUT Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

120 VAC OUTPUT Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

24 VDC HyPR Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

AC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AC Input Current Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Breakers / Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

|3November 2023 |Solar Stik®, Inc.

24VDC HyPR 2500 Operator and Maintenance Manual

Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Connecting Generators to HyPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Operator Instructions

HyPR Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Navigating DC User Interface Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Monitoring the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

BATTERY MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Consumed Amp-hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

State-of-charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Synchronizing the Battery Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Synchronizing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SOC Display Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Historical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Maintenance

Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

HyPR 2500 Air Intake Filter Maintenance* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Water Intrusion Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Transporting the HyPR 2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

TECHNICAL SPECIFICATIONS

ABOUT SOLAR STIK, INC.

Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

November 2023 |Solar Stik®, Inc.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. Using HyPR in Power Conditioning Model...................................................................................................... 13

Figure 5. Using HyPR in Scavenge Model...................................................................................................................... 13

Figure 6. Using HyPR in Inverter Mode .......................................................................................................................... 14

Figure 7. Linear Inter-Connect Plug................................................................................................................................ 23

Figure 8. Inter-Connect Plug .......................................................................................................................................... 23

Figure 9. 24 VDC HyPR 2500 connections..................................................................................................................... 24

Figure 10. The HyPR 2500 I-Plate .................................................................................................................................. 25

Figure 11. HyPR 2500 AC power input port................................................................................................................... 26

Figure 12. HyPR 2500 solar input port ........................................................................................................................... 26

Figure 13. HyPR 2500 DC power scavenging port......................................................................................................... 27

Figure 14. HyPR Expander Expander Pak / ESM connection port ................................................................................ 28

Figure 15. HyPR 24 VDC input / output ports ................................................................................................................ 29

Figure 16. HyPR 120 VAC output ports.......................................................................................................................... 29

Figure 18. Expander Pak generator communications ports........................................................................................... 30

Figure 17. HyPR 2500 cooling vents .............................................................................................................................. 30

Figure 19. 24 VDC HyPR 2500 Faceplate ...................................................................................................................... 31

Figure 20. HyPR 2500 DC Interface ............................................................................................................................... 33

Figure 23. AC Input Control dial ..................................................................................................................................... 34

Figure 21. Generator mode control switches and LEDs................................................................................................. 34

Figure 22. Generator Status LED blinking pattern.......................................................................................................... 34

Figure 24. HyPR 2500 breakers...................................................................................................................................... 35

Figure 25. HyPR Inverter / AC OUTPUT status LED ...................................................................................................... 35

Figure 27. Connecting generators to HyPR.................................................................................................................... 36

Figure 26. Compatible generator options....................................................................................................................... 36

Figure 28. MEP-831A and MEP-802A Gen Comm Cable connections ......................................................................... 37

Figure 29. Defender 1 kW and Ranger 2 kW Gen Comm Cable connections ............................................................... 38

Figure 30. Connecting two 1 kW generators in parallel with the “Y” AC power cable................................................... 39

Figure 31. Navigating the DC Interface .......................................................................................................................... 41

Figure 32. Abbreviated HyPR DC Interface Menu Map.................................................................................................. 42

Figure 33. Cleaning/replacing HyPR 2500 air intake vent lter ...................................................................................... 43

Figure 35. HyPR human transportation. ......................................................................................................................... 44

Figure 34. Drain plug screw located under the TECH PORT.......................................................................................... 44

List of Tables

Table 1. Charge Status Indicator—LED Status............................................................................................................... 33

Revision History

Section Page(s) Description Date

First released as a PRELIMINARY DRAFT 16 Nov 2023

|5November 2023 |Solar Stik®, Inc.

24VDC HyPR 2500 Operator and Maintenance Manual

GENERAL INFORMATION, EQUIPMENT DESCRIPTION,

AND THEORY OF OPERATION

Introduction

A Hybrid Power Router (HyPR) is a power management device which processes and routes a variety

of power inputs to both 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.

Some features of the HyPR include:

• The ability to act as the primary power management device in a Hybrid Power System (HPS) or as

a supplemental power manager in AC, DC, or AC/DC systems.

• The ability to work in concert with additional power management devices when high-power or

individual control over multiple loads/voltages is required (eg. PRO-Verters).

• Support of simultaneous AC and DC outputs.

• Plug and play compatibility with the Solar Stik Inter-Connect circuit.

• Efcient management of available power to loads.

This manual provides operation and safety information for the HyPR 2500. The HyPR 2500 has been

designed specically to support Hybrid, UPS, and Power Conditioning.

When operating the HyPR within a system, consult the Faceplate and the System Manual for specic

operation guidelines.

Requirements for HyPR Operation

• Total power INPUT must exceed total power OUTPUT in any particular operation mode.

• The HyPR requires the presence of battery (DC bus) voltage to operate at its full rated power.

• Based on the application, the user must congure the system so there is “balanced” operation

between the HyPR’s internal functions.

HyPR 2500 accepts universal (120 VAC) single-phase AC input voltage, allowing connection to any

generator or grid AC power source. It is ideally suited for use where available AC power quality is

poor or AC line voltages vary. AC and DC cables for the HyPR are sold separately, as they must

match voltage type and associated current-conducting ability.

November 2023 |Solar Stik®, Inc.6 |

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.

Most functions and modes are controlled by programmable settings at the User Interface(s).

• “Functions” are related to specic circuits or hardware in the HyPR.

• “Modes” refer to the operational employment of the HyPR circuits.

The faceplate contains breakers that control the input and output of both AC and DC power.

When the main power breaker switch is turned on:

• The HyPR DC INTERFACE will power up and report DC bus voltage and amperage data on the

home screen located on the front of the HyPR.

• The inverter (DC>AC) will be active, but only operational once the HyPR AC OUTPUT breaker is

engaged.

• The charger (AC>DC) will be active, but only operational once the HyPR AC INPUT breaker is

engaged.

Data Management

• The HyPR DC Interface provides basic DC circuit data, including ESM/bus voltage and net

current only when active ESMs are connected.

• If no ESMs are connected to the HyPR, then only the DC bus voltage is available from the HyPR

DC INTERFACE.

• DC bus voltage is the only accurately-reported metric from the HyPR DC INTERFACE when

ESMs are not connected.

User Control Functions

|7November 2023 |Solar Stik®, Inc.

24VDC HyPR 2500 Operator and Maintenance Manual

Figure 1. Schematized power ow from a top-down view of the interior of the HyPR 2500

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” circuit. The presence of DC bus voltage (battery voltage) enables the full

function of the HyPR 2500 internal circuits. System voltage and net current can be monitored on the

DC User Interface.

A schematized illustration of the DC bus and its relationship to internal components, inputs and

outputs is shown below. The arrows indicate the ow of current in the circuits.

AC Input

24 VDC bus/Inter-Connect System

120 VAC,

60 Hz

24 VDC

Inter-Connect

Port

120 VAC

60 Hz

AC-

DC charger

Inverter

Breaker “location”

Direction of current ow

AC Output

Breaker “location”

November 2023 |Solar Stik®, Inc.8 |

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.

Current ow on the DC bus is controlled by voltage. Power will always be prioritized to the loads and

will only cease when the voltage drops to low-voltage disconnects located within the inverter (AC

loads), the ESMs and DC Interface (DC loads).

24VDC IN/OUT ports operate directly from the internal DC bus. Power in/out of these ports will only

be reected in the “net” current on the display.

System recovery from overdischarged batteries is possible using AC power or alternative 24 VDC

power sources. System recovery using PV power is not an option.

Inverter “continuous AC power output” uctuates based on conditions such as temperature (heat

derating = efciency loss).

AC Functions

The HyPR employs two (2) separate AC functions that operate on the DC bus:

Charging

AC>DC converter provides up to 100 A to the DC bus (~2000 W).

Inverting

DC>AC inverter removes up to 9 A at 120 VAC from the internal DC bus (~1100 W).

When conguring the HyPR for use, it is important to understand how to establish balance between

the power available from sources and the power required by the loads.

When using AC power sources in Hybrid or UPS models, the AC INPUT setting must be set for the

following conditions:

• Continuity of AC load operation

• Battery charging

• Not to exceed the power output of the AC source

When small expeditionary generators are used, the HyPR can be used for dynamic loads that would

normally cause overloading of the generator.

|9November 2023 |Solar Stik®, Inc.

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.

Direct connections to the DC bus can be made via the two (2) Inter-Connect ports. AC Input and AC

output ports are direct connections to the DC bus (See “Figure 1. Schematized power ow from a

top-down view of the interior of the HyPR 2500” on page 7).

DC power will ow into or out of the HyPR via the direct connections (Inter-Connect Port).

The indirect connections allow power to ow to the bus after being altered from its original form, for

example:

• AC power converted to 28.2 VDC

• Inverter converts energy stored in batteries to 120 VAC power output.

Load Prioritization

In every operation mode, the HyPR will prioritize power to the load. It executes functions based on

real-time operating conditions, which include:

• total power available at the INPUTS

• total power needed at the OUTPUTS

• battery SOC

• temperature

• user programming for special conditions

HyPRs can be used with grid-utility or generator AC power.

With load prioritization, the load will always be the rst to receive power. Any incoming power not

consumed by the load is stored in the batteries. Stored energy is for use to support loads when

these inputs are not available (e.g., grid failure, generator maintenance periods, etc.) and to reduce

reliance on fuel-powered generators.

November 2023 |Solar Stik®, Inc.10 |

24VDC HyPR 2500 Operator and Maintenance Manual

Energy Storage

Loads

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” loads, which are

usually momentary or short in duration:

• AC power generation source with ESMs

• DC power generation source with ESMs

• AC and DC power generation sources (combinations of the above) with ESMs

AC Power Limits

2000 W AC Input from source(s)

1100 W AC Output for loads

Modes of Operation

UPS Mode–The HyPR 2500 is capable of operating as an Uninterruptible Power Supply/Source,

providing instantaneous emergency power to a load in the event that primary power source fails. In

this mode, the HyPR 2500 will to provide power to the load until it can be turned off safely or until

primary power is restored. In this mode, power duration is limited to that contained in the ESM’s

connected to the HyPR 2500.

• AC utility / grid power sources with ESMs

• ESMs do not cycle

Figure 2. Using the HyPR 2500 in Hybrid Model

Grid or AC

Energy Storage

Loads

AC Power Limits 

2000 W AC Input from source(s)

1100 W AC Output for loads

Figure 3. Using the HyPR 2500 in UPS Model

There are several operational modes in which the HyPR may be congured, depending on the

application,

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