Solar Stik 24VDC POWER HUB 2400 Installation instructions

OPERATOR AND
MAINTENANCE MANUAL
FOR
24VDC POWER HUB 2400
November 2020 |Solar Stik Inc.
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Version 1.11
Updated: 20201123
P/N 20-0302204
Interactive

Operator and Maintenance Manual 24VDC Power Hub 2400
November 2020 |Solar Stik®, Inc.2 |
Contents
GENERAL INFORMATION, THEORY OF OPERATION, AND EQUIPMENT DESCRIPTION
Power Hub Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Use of the Power Hub in a System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Limitations on Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
THEORY OF OPERATION
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Protection Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Metered Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maximum Power Point Tracking (MPPT) – Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Standard Inter-Connect Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connection Port Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Internal Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Information Plate (I-Plate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
The Power Hub 2400 Faceplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATOR INSTRUCTIONS
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connecting PV Arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connecting / Disconnecting the Power Hub From Service . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connecting Regulated 24 VDC Power Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connecting a 24VDC PRO-Verter or 24 VDC Expander Paks. . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connecting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connecting to Communications Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Powering up the Power Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power Hub 2400 User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to Use the BACK, NEXT, SELECT Buttons to Navigate the Menus . . . . . . . . . . . . . . . . . . . . 22
Monitoring the Charging Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The Menu Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Storing the Inter-Connect Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Locking Component Cases to Prevent Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Transporting the Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

|3November 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual 24VDC Power Hub 2400
Water Intrusion Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TROUBLESHOOTING PROCEDURES
Power Hub Will Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Other Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Recommended Operation Environment (Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Temperatures, Overheating, and Derating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
The Power Hub User Interface reports two (2) temperatures:. . . . . . . . . . . . . . . . . . . . . . . . . . 31
Causes of Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Hub Internal Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Foreign Object Debris (FOD) and Water Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MAINTENANCE INSTRUCTIONS
Preventive Maintenance, Checks and Service (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Clean Power Hub Air Intake Vent Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SUPPORTING INFORMATION
Power Hub Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Battery Monitor: Understanding Reported Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Assessing PV Array Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Troubleshooting Individual PV Arrays Using the Power Hub User Interface . . . . . . . . . . . . . . . . . . 36
Navigating the “Charge Unit Status” Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SUPPORTING INFORMATION
Product update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Warranty and Returns
Return Material Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ABOUT SOLAR STIK, INC.
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operator and Maintenance Manual 24VDC Power Hub 2400
November 2020 |Solar Stik®, Inc.4 |
List of Figures
Figure 1. A Power Hub in a Hybrid Power System........................................................................................................... 5
Figure 2. How a Power Hub works in a System............................................................................................................... 6
Figure 3. 24VDC Power Hub 2400 ................................................................................................................................... 7
Figure 4. Inter-Connect Plug .......................................................................................................................................... 15
Figure 5. Overview of Power Hub Connections ............................................................................................................. 16
Figure 6. Front—DC Output and Communications ........................................................................................................ 16
Figure 8. Right Side—Regulated 24 VDC Input and NATO Connector .......................................................................... 17
Figure 9. Left Side—Solar-only Ports ............................................................................................................................. 17
Figure 11. Back side—air intake vent............................................................................................................................. 18
Figure 10. Power Hub I-Plate ......................................................................................................................................... 18
Figure 12. Power Hub Faceplate.................................................................................................................................... 19
Figure 13. Power Hub Solar Input Only connectors....................................................................................................... 20
Figure 14. Do not disconnect an active Power Hub from an HPS ................................................................................. 20
Figure 15. Power Hub regulated 24 VDC inputs............................................................................................................. 21
Figure 16. Power Hub PRO-Verter or Expander Pak connection................................................................................... 21
Figure 17. Power Hub 24 VDC IN/OUT ports ................................................................................................................ 21
Figure 18. Power Hub Tech port..................................................................................................................................... 21
Figure 19. User Interface ................................................................................................................................................ 22
Figure 20. Back, Next, and Select buttons..................................................................................................................... 22
Figure 21. Power Hub User Interface ............................................................................................................................. 23
Figure 22. Inter-Connect Cable storage ......................................................................................................................... 28
Figure 23. Steel-reinforced padlock holes...................................................................................................................... 28
Figure 24. Lock securing Power Hub lid ........................................................................................................................ 28
Figure 25. Drain plug screw located under the TECH PORT.......................................................................................... 29
Figure 26. Removing the Power Hub air intake vent lter for cleaning .......................................................................... 33
Figure 27. Stacking Power Hubs.................................................................................................................................... 34
Figure 28. Power Hub as the primary power management device ................................................................................ 35
Figure 29. Power Hub as the secondary power management device............................................................................ 35
Figure 30. Power Hub 2400 SOLAR INPUT ONLY ports and their connection to charge controllers............................ 36
List of Tables
Table 1. Charge Status Indicator—LED Status............................................................................................................... 23
Table 2. Symptoms and Solutions for the Most Common Power Hub Issues ............................................................... 30
Table 3. 24VDC Power Hub 2400 PMCS........................................................................................................................ 33
Section Page(s) Description Date
Troubleshooting 30 Added Heat, Overheating, and Derating topic 01 Feb 2018
ALL ALL Major Update 20 April 2018
ALL ALL Major Update 24 Dec 2019
Added Product Update information (V1.11) 19 Nov 2020
Revision History

|5November 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual 24VDC Power Hub 2400
Power Hub Introduction
The primary function of the DC Power Hub is to serve as a singular collection, management and
distribution tool for DC power in a Hybrid Power System (HPS).
The Hub is designed specically for operation between energy-storage batteries and DC generation
sources, including photovoltaic (PV) arrays, wind generators, fuel cells, small hydro generation,
vehicular power, and more. It regulates the incoming power, making it compatible for a connected
battery, loads, or distribution devices such as inverters.
Power Hubs play a critical role in applications where any combination of the following is necessary:
• Renewable power generation is required to support a battery
• Reducing generator run-time in a hybrid system is critical
• Less reliance on grid-utility power is desirable
• DC power management and distribution is required for a battery platform
It is a modular component of the HPS architecture, and its exible design allows use with other
technologies that collectively meet specic mission requirements.
All Power Hubs are “Plug & Play”-compatible with the Inter-Connect circuit and are modular and
scalable. Their design allows multiple Power Hubs to be used in a single application where power
management requirements exceed the ability of a single Hub, or when multiple DC loads are
required to meet the demand.
The Power Hub includes one DC Inter-Connect Cable for connection to an HPS.
GENERAL INFORMATION, THEORY OF OPERATION,
AND EQUIPMENT DESCRIPTION
Figure 1. A Power Hub in a Hybrid Power System

Operator and Maintenance Manual 24VDC Power Hub 2400
November 2020 |Solar Stik®, Inc.6 |
Figure 2. How a Power Hub works in a System
Use of the Power Hub in a System
The Power Hub provides a portal to integrate multiple DC power sources into a hybrid power
network, from both unregulated (PV) and regulated power sources. (Figure 2). It funnels all incoming
power to the batteries, PRO-Verters, or loads automatically, using basic programming in the User
Interface to direct the ow.
Programming and connection of the Hub in a System will vary according to the specic functions the
system in which it is employed, but systems vary in accordance with the operator’s requirements.
Consequently, not every feature in the Power Hub may be used for an application.
The Power Hub can support operation with either lead-acid or lithium battery types. This manual
provides an overview of the core features and capabilities of the Power Hub along with a guide for
the User Interface menu windows. Other changes in programming may improve performance in
extreme environmental operating conditions. Contact Solar Stik or your eld service representative
(FSR) for assistance in altering operation congurations or programming.
(Energy Storage Module)
24VDC Power Hub 2400
DC
(AC and DC
Loads)
24VDC PRO-Verter
Power
Management
24 VDC Li Expander Pak
Energy Storage
Wind Hydro
Fuel Cell Vehicle
Regulated DC Power Options
Unregulated
DC Power
Solar
Fuel-powered
Generator
AC
(AC and DC
Loads)
24VDC PDM Plus
Power
Management
Power
Generation
(AC Power)

|7November 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual 24VDC Power Hub 2400
Figure 3. 24VDC Power Hub 2400
Modes of Operation
Depending on the application, there are several operational modes that can be congured using a
Power Hub:
Hybrid
DC loads, DC generation and batteries are all connected to a Power Hub. It is the central power
management device in the system. The Power Hub provides constant DC power to a load by
alternating between power from batteries and power from a DC generator (such as a PV array). In the
hybrid conguration, the batteries cycle regularly, which maximizes electrical efciency throughout
the circuit, minimizing dependency on any one DC source.
Direct DC Support
The Power Hub can be congured to provide DC into a system conguration where DC is used for
any of the following:
• Peak Shaving
• Inverter operation
• Battery charging
Product Safety Information and Instructions
This manual contains important safety instructions that must be followed during the installation
and operation of this product. Read all instructions and safety information contained in this manual
before installing or using this product.
All electrical connections must be made using the proper polarized connectors.
While this product is designed for indoor/outdoor operation, the interior of the Power Hub 2400 must
not be exposed to rain, snow, moisture, or liquids. Close and latch and/or lock the cases when the
System is unattended.
The Power Hub is not eld serviceable beyond simple preventive maintenance. Do not attempt to
open or service the unit. If repair is needed, contact your FSR.
Exercise caution when handling or operating the Power Hub. Live power may be present at more
than one point.

Operator and Maintenance Manual 24VDC Power Hub 2400
November 2020 |Solar Stik®, Inc.8 |
Since the use of this manual and the conditions or methods of operation, use, and maintenance of
this product are beyond the control of Solar Stik, this company does not assume responsibility and
expressly disclaims liability for loss, damage, or expense—whether direct, indirect, consequential, or
incidental—arising out of or anyway connected with such operation, use, or maintenance.
Due to continuous improvements and product updates, the images shown in this manual may not
exactly match the unit purchased.
This equipment CAN BE USED FOR CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER
MEDICAL EQUIPMENT or devices; however, without limiting the generality of the foregoing, Solar
Stik makes no representations or warranties regarding the use of the System in connection with life
support systems or other medical equipment devices.
Limitations on Liability
Safety Information Labels
Your safety and the safety of others is very important.
Always read and obey all safety messages.
This is the safety alert symbol. This symbol alerts you to potential hazards that can kill you or
hurt you and others. All safety messages will follow the safety alert symbol and the word
“DANGER”, “WARNING”, or “CAUTION”. These words are dened as:
DANGER Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
All safety messages will tell you what the potential hazard is, how to reduce the chance of injury, and
what can happen if the instructions are not followed.

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Operator and Maintenance Manual 24VDC Power Hub 2400
Use Sweeping Motion
These additional cautionary steps will ensure
your safety:
• System components should not be operated in
standing water.
• Close and latch the component lids if it is
precipitating.
• System cables should not be routed through
standing water.
• Cable connections should remain dry.
• Unused ports on System components should
be covered when not in use to reduce the
possibility of water intrusion.
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.
Class C fire - Fires involving energized electrical equipment such as motors, transformers, and
appliances. Remove the power source and the class C re becomes a class A or B re.
Recommended Fire Extinguisher
NSN 4210-00-288-7219 Fire Extinguisher, Carbon Dioxide, 10 lb
Carbon dioxide is a liqueed gas, which is highly effective ghting class B and C res. These
extinguishers are ideal for areas where contamination and/or cleanup are a concern, such as data
processing centers, labs, and telecommunication rooms.
Using the Fire Extinguisher
When using the extinguisher on a re, remember PASS:
Pull the pin.
Aim the nozzle or hose at the base of the re from a safe distance.
Squeeze the operating lever to discharge the re extinguishing agent.
Sweep the nozzle or hose from side to side until the re is out. Move forward or around the re as the
re diminishes.
Watch the area for reignition until the cause has been xed.
WARNING
Only CO2(carbon dioxide) re extinguishers should
be used with equipment.

Operator and Maintenance Manual 24VDC Power Hub 2400
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Electric Shock Hazard
DON’T LET THIS BE YOU!
HIGH VOLTAGE: System components, PV arrays, and generators may have lethal line voltages.
Extreme care should be taken to protect against electrocution. Always work with another
person in case an emergency occurs. Disconnect power before performing maintenance. Wear
safety glasses whenever working on any part of a System that requires exposure to mechanical
or direct electrical contacts.
WARNING
Standing water around the electrical equipment and/or intrusion of water into the System
components can increase the risk of electrical shock.

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Operator and Maintenance Manual 24VDC Power Hub 2400
Environmental and Handling Precautions
All components are ruggedized, yet there are a few things the operator can do to prevent failures
and prolong the operational life of the product.
Water
If outdoor operation is necessary, the lids
of all components should be closed and
latched. During operation, cases should be
placed upright, especially during inclement
weather. Lids should be open only to access
operator controls and closed at all other
times.
Impact
Equipment should not be dropped onto hard
surfaces at a height greater than one foot
when transporting or during operation.
Dust/Foreign Object Intrusion
Air intake lters should be cleaned once per
month, or more frequently when conditions
warrant. Minimize exposure to high levels
of particulates and foreign object debris by
exercising common-sense placement and
protection during both operation and storage.
Heat
Heat and solar loading reduces efciency,
causes Power Hub derating, and shortens
life expectancy. Shade the Power Hub to
prevent the negative effects of heat.

Operator and Maintenance Manual 24VDC Power Hub 2400
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THEORY OF OPERATION
Operation Overview
The Power Hub has multiple DC connections on its exterior, allowing for multiple conguration
possibilities.
Original models require connection to an active 24 V battery circuit in order for it to operate whereas
newer models also operate with power from solar arrays. A minimum of three (3) energy storage
modules (i.e., Expander Paks; ESMs) must be present and functioning for the Power Hub to operate
at its rated power, however, for lower power congurations, a single ESM or small bank of ESMs
may be used.
The Hub has an internal DC bus that can support multiple regulated DC generation sources to
include the following:
• Wind
• Fuel Cell
• Vehicular
• Hydro
It also has a dedicated circuit for managing unregulated power from PV arrays. The Hub has a
sophisticated ultra-fast Maximum Power Point Tracking (MPPT) PV charge controller system that
regulates PV power, and optimizes PV power production based on two factors:
1. Available PV power
2. Battery state of charge (SOC)
The MPPT process allows a PV array to operate at its rated/available voltage, converting the higher
PV voltage into charging current (amps), which is then provided to the battery at the appropriate
voltage, improving performance and life of the batteries.
Battery Charging
When the Power Hub is connected to an active battery bank, it will automatically calibrate its charge
algorithm in accordance with the voltage of the connected battery.
The solar charger controllers can be programmed to charge using several algorithms, including
multi-stage charging for lead-acid batteries as well as Constant Current / Constant Voltage (CC/CV)
for lithium battery types. Selection of charge proles should be based on battery chemistry, capacity
and operating conditions.

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Operator and Maintenance Manual 24VDC Power Hub 2400
Protection Circuits
The Power Hub serves as a DC junction within the Inter-Connect Circuit. When connected to an
active 24 V DC Inter-Connect network, it allows DC to ow through its internal bus, with ONLY the
PV circuit offering limit protections:
• The bayonet connector for the Solar Leash is keyed and unique to the PV circuit. It cannot be
connected improperly, and no other System cable will t.
• The PV charge controller is fully protected against voltage transients, over-temperature, over-
current, reverse battery connections, and reverse PV connections. An automatic current limit
feature allows use of its full rated capability without worrying about overload from excessive PV
input current.
Other DC power sources and batteries that connect to the Hub have their own individual circuit
protections, so the Hub does not need circuit breakers for individual loads or other connected
equipment. If a short-circuit conditions occurs within the DC network, only affected batteries, loads,
and power sources will engage their protections circuits, leaving non-problematic circuits active.
(See Circuit Breaker Protections in the Inter-Connect section for more details.)
Metered Circuits
Information regarding the status of the batteries and the overall ow of power into and out of the
system can be obtained from the Power Hub User Interface. Precise data is available in both real-
time and historical models.
DC power values are tracked as it ows in through the PV Controller circuits, as well as power that
ows out to a connected battery, PRO-Verter or additional Power Hub(s).
Only certain ports are metered on the Hub. Follow recommended connection diagrams on the
I-Plate and the System manual for proper metering of DC values.
Maximum Power Point Tracking (MPPT) – Charge Controls
The Power Hub 2400 contains three (3) photovoltaic (PV) charge controllers. Each charge controller
has two (2) input ports; both ports are parallel.
The Master Charge Unit is connected directly to the Power Hub User Interface, which reports
System activity as well as activity unique to each of the three (3) charge controllers. Monitoring
each charge controller and its solar input(s) independently facilitates system optimization and
troubleshooting of the PV arrays.
Derating
Derating is a condition where the PV power management functions are diminished due to high
temperatures.
Excessive heat in the Power Hub reduces its ability to supply to DC into the Inter-Connect circuit (i.e.
to the batteries and other connected devices). It is usually caused by poor airow over the internal
charge controls or by solar loading in high-heat environments.

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The rst indication of heat-related derating may be the appearance that the PV arrays are “not
producing any power” when they should be. If this is the case, check the temperatures. (Note: The
Power Hub User Interface will also report 0 VDC charging current when the System batteries are
fully charged.)
If the internal temperature of the Power Hub is greater than 104 ºF (40 ºC), the Power Hub
performance will be degraded (See: Power Hub Internal Temperature Reading).
If the system is not operating at rated power, be sure to check the air filters on the case of
the Power Hub and/or shade the case from direct sunlight if operating outdoors.
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.
The Inter-Connect Circuit is the connection framework of the System’s DC power network. It uses
a simple, polarized, locking connection that is common throughout the architecture. All power
management, energy storage, and power generation components are compatible with the Inter-
Connect Circuit.
Using a common, polarized connector allows rapid “Plug & Play” scaling of components, adaptation
of capabilities within the architecture, technology refreshment, and swapping of components when
conditions warrant. It also ensures that there is no unsafe way to make connections.
Circuit Breaker Protections
The Inter-Connect network is protected from overloads and short circuits through a network of circuit
breakers strategically placed throughout the circuit. It ensures the potential for a reverse polarity
connection within the circuit is minimized. If a problem occurs in a leg of the Inter-Connect Circuit,
the affected leg will disconnect from the primary network, leaving the other circuits functioning. If a
major failure occurs in the circuit, then the entire network will shut down for System and Operator
protection.
Operate with Voltage
The Inter-Connect Circuit communicates simple battery voltage to all components on the network,
allowing them to independently coordinate their respective functions. Battery voltage is used to
trigger actions such as Automatic Generator Start/Stop (AGS) function, power distribution timing,
and more. Therefore, the proper setup of the Inter-Connect Circuit is critical to properly communicate
voltage to all points in the System and to ensure all of the components operate together to provide
seamless power to the load.
Equipment Description

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Operator and Maintenance Manual 24VDC Power Hub 2400
Figure 4. Inter-Connect Plug
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 modied in the eld
Optimize with Data
Data collection for a System occurs through the Inter-Connect network. Power management
devices such as Power Hubs and PRO-Verters meter voltage, current and time through the
circuit, providing critical real-time data the operator can use to troubleshoot and verify System
performance. Data collection enables programming/architectural changes to optimize performance
based on evolving conditions.

Operator and Maintenance Manual 24VDC Power Hub 2400
November 2020 |Solar Stik®, Inc.16 |
Description Connector Voltage
A24VDC Load Port (unmetered) Inter-Connect Port 24 VDC
BExhaust Vent - -
CModem Port Ethernet - RJF21B -
D24VDC Battery/PRO-Verter Port (metered) Inter-Connect Port 24 VDC
BC
DA
Figure 5. Overview of Power Hub Connections
Connection Port Details
Port placards assist in making the correct connections between components. Please review the
information on all of these plates and labels, as they contain the basic information required to set up
and operate the Hub.
A. May be connected to Power Distribution Modules (PDMs) or 24 VDC loads.
C. For external modem connection to the remote monitoring kit (RMK) if present (optional).
D. For connection to a 24VDC PRO-Verter or 24VDC Expander Paks.
Expander Pak/
PRO-Verter*
Modem
24 VDC Input/
Output
Unregulated DC
Solar Inputs
Regulated DC
Power Inputs
Overview
Figure 6. Front—DC Output and Communications

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Operator and Maintenance Manual 24VDC Power Hub 2400
Description Connector Watts Amps
ASolar Input Cannon Bayonet Receptacle
CB2-22-2SC 420 W Max 7.5 A @ 57 VDC*
15 A @ 28.5 V*
A
(A)
Neg-
(C)
Pos+
(B)
N/A
A. Connections for Solar Panel Input
A
B
Description Connector Amps Voltage
A24 VDC NATO Slave (unmetered) NATO Slave 100 A 24 VDC
BRegulated 24 VDC Input Only (unmetered) Inter-Connect Port 50 A each 24 VDC
Figure 8. Right Side—Regulated 24 VDC Input and NATO Connector
A. For connection to a Tactical Vehicle or generator.
B. For connection to 24 VDC regulated power sources such as wind, vehicle, fuel
cell, hydroelectric charging, or stacked 24 VDC components.
Figure 9. Left Side—Solar-only Ports

Operator and Maintenance Manual 24VDC Power Hub 2400
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Figure 10. Power Hub I-Plate
Air Intake
Figure 11. Back side—air intake vent
Thermostatically controlled, internal cooling fans turn on at 104 ºF (40 ºC) and turn off when the
internal temperature drops to 90 ºF (32 ºC).
Internal Cooling
The Power Hub I-Plate provides concise, abbreviated information for setting up and running a Power
Hub as part of a System (Quick-start Guide and Operating Information). All System components
should be connected as described on the I-Plate. Warnings and Notices are provided. Be familiar
with their content before operating the Power Hub. An I-Plate is (usually) tailored to a customer’s
specic application.
Information Plate (I-Plate)

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Operator and Maintenance Manual 24VDC Power Hub 2400
Inter-Connect Ports for
Cable Storage. These
ports have no electrical
connection
Universal Communications
Module/Remote
Monitoring Kit (optional)
Connections for Universal
Communications Module/
Remote Monitoring Kit
User Interface
The Power Hub 2400 Faceplate
The Faceplate provides Operator Access to the User Interface, PV charging Specications and
recommended charger settings. A Universal Communications Module or Remote Monitoring Kit
(RMK) may be installed on the Faceplate at the location indicated below. The two (2) Inter-Connect
ports are not electrically active; they are for Inter-Connect Cable storage.
Figure 12. Power Hub Faceplate
Specications

Operator and Maintenance Manual 24VDC Power Hub 2400
November 2020 |Solar Stik®, Inc.20 |
OPERATOR INSTRUCTIONS
Connecting PV Arrays
Up to six (6) PV arrays can be connected to the Power Hub Solar Input Only ports using solar
cables. The Power Hub 2400 contains three (3) solar charge controllers. Each charge controller has
two (2) input ports. When connecting three (3) arrays, choose one port from each of the three (3)
charge controllers. After the rst three (3) ports are connected to PV arrays, the remaining ports may
be connected to additional PV arrays at random.
Each of the three (3) solar chargers safely accepts up to 800 watts of power from PV arrays or 400
watts max per input connector. Different types of PV arrays can be connected to the Power Hub
simultaneously as long as their specications meet the requirements shown on the Faceplate (Figure
12). The bayonet connector for the Solar Cable is keyed and unique within the System. It cannot be
connected improperly, and no other Solar Stik cable in the kit will t.
Connections
Figure 13. Power Hub Solar Input Only connectors
PV Arrays (x6)
Charge
Unit
#2
Charge
Unit
#0
Charge
Unit
#1
NOTICE
Power Hubs with serial numbers lower than 430288 must be connected to a 24 VDC battery
directly or indirectly via the PRO-Verter to operate (see product update).
Connecting / Disconnecting the Power Hub From Service
Power Hub 2400
PV Array(s)
PRO-Verter
Figure 14. Do not disconnect an active Power Hub from an HPS
Connect PV arrays last when assembling a Solar Stik System. DO NOT
disconnect the Power Hub from the PRO-Verter (Inter-Connect
connection) in a Hybrid Power System with active PV arrays connected to
the Power Hub.