Solar Stik ATSC MS3 L0 Manual instruction

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

February 2020 |Solar Stik®, Inc.2 |
System Setup and Operation Manual for ATSC MS3 L0
Contents
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
Introduction to Hybrid Power Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The Hybrid Power System Flexible Open Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
The L0 Hybrid Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Peak-Power Loads Dened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ECU Soft-starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sequential Deployment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L0 Hybrid Power Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Important Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THEORY OF OPERATION
Models of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DC-only/Inverter (Automatic Functions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hybrid (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Load Support (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Peak Power Delivery (manual functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
UPS (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
The HPS Architecture, Function, and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Energy Storage—The Foundation of the HPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Minimum Battery Capacity Required for Optimal System Operation . . . . . . . . . . . . . . . . . . . . . . 17
System Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Load Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Real-time Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
“Overload” Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Load Support (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lag Time and Surge Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Scaling and Modifying the HPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PRO-Verter Stacking Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power Hub Stacking Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Scaling Energy Storage Capacity Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Equipment Description
The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The Standard Inter-Connect Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Color-coded Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Trailer Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
The Information Plate (I-Plate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

|3February 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for ATSC MS3 L0
OPERATOR INSTRUCTIONS
A. System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1. Inventory System components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2. Remove Solar Arrays, Power Hub, and 20’ Inter-Connect Cable from trailer. . . . . . . . . . . . . . . . . 28
3. Inventory 420W Expedition Solar Array-C kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. Identify locations for System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
a. Component Shading and Working Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
b. Minimize Potential for Water and Dust Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5. Connect System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
a. Connect PRO-Verter to Expander Paks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
b. Connect PRO-Verter to generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
c. Connect PRO-Verter to shelter service panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
d. Connect / Assemble Solar Arrays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
e. Connect PV Arrays to Power Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
f. Connect PRO-Verter to Power Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
g. Connect Remote Monitoring Kit to PC or LAN (RMK; optional) . . . . . . . . . . . . . . . . . . . . . 33
6. Grounding the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7. Secure the Solar Arrays to the ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
B. System Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C. System Initialization and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
D. Order of Operations: Activation and Deactivation of the System . . . . . . . . . . . . . . . . . . . . . 36
L0 Isolation of Operations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
L0-architecture Deactivation Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Steps to power down the HPS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E. Tips to Keep the System Running Safely and Smoothly. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F. L0 PRO-Verter Programming Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FAVS Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CTRL Button Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
METER Button Menus: Read-only Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
METER Button Menus continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SETUP Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TECH Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
G. Power Hub User Interface Menu Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
H. Monitoring the Charging Status on Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
I. Power Hub User Interface Menu Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
J. Hybrid System Bypass Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
K. System Breakdown and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TROUBLESHOOTING
PRO-Verter: Quick Links to Statuses, Faults, and Resolutions . . . . . . . . . . . . . . . . . . . . . . . . 55
Quick Links to PRO-Verter Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Quick Links to Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Quick Links to Other Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PRO-Verter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
The User Interface LCD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PRO-Verter Inverter-mode Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Inverting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Inverter Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

February 2020 |Solar Stik®, Inc.4 |
System Setup and Operation Manual for ATSC MS3 L0
No Inverter Comm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Unknown Mode ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PRO-Verter Charger -mode Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Absorb Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bulk Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Float Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Charger Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Silent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Secondary Scrolling Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Gen Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Gen Cool Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
PRO-Verter Charger Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 60
PRO-Verter Inverter Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AC Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Breaker Tripped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Dead Batt Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
FET Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
High Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
High Batt Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
High Volts AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Stuck Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Tfmr Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Unknown Fault ##. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PRO-Verter Internal Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Internal Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Internal Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Internal NTC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Internal Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PRO-Verter AGS Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PRO-Verter-to-Generator Communication Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Starting the Generator from the PRO-Verter User Interface . . . . . . . . . . . . . . . . . . . . . . . . 66
AGS Start Statuses Table (Meter 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Start VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
AGS Operational Statuses (Meter 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
AC In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Gen Cooldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Gen Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Manual Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
No Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Quiet Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

|5February 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for ATSC MS3 L0
Resolving AGS Operational Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
No Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Resolving AGS Faults Using the LCD User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fault Gen Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fault Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fault VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fault MaxRn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
PRO-Verter Battery Monitoring (BMK) Circuit Operational Statuses . . . . . . . . . . . . . . . . . . . . . . 72
BMK Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Think’n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
###% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Resolving BMK Faults Using the LCD User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Factory Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Unknown Fault ##. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Power-up Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fault History (Tech 04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
04B AGS Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PRO-Verter: Historical Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Auto Generator Start/Stop (AGS) Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Gen Run Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
AGS Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Days Since Gen Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Days Since 100% SOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Battery Monitor (BMK) Data (Meter 05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
BMK Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Battery SOC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DC Volts-BMK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DC Amps-BMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
AH In/Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Reset AH Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Total AH Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Minimum VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Maximum VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Days Since 100% SOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Power Hub–related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Power Hub Will Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Performance Issues, Causes and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
PV Array–related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
No Power from the PV Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Lower Than Expected Voltage from the PV Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Li Expander Pak–related Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Expander Pak Circuit Breakers Tripping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Generator-related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Testing the AGS Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Generator Having Difculty Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Generator Having Difculty Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Generator Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Generator Starts, Then Shuts Down When Load Is Transferred . . . . . . . . . . . . . . . . . . . . . . . . 82
Generator Short-cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

February 2020 |Solar Stik®, Inc.6 |
System Setup and Operation Manual for ATSC MS3 L0
Generator Fails to Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RMK-related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
RMK Status Indicator Light Not Illuminated When PRO-Verter Powers Up . . . . . . . . . . . . . . . . . . 83
Cannot Communicate with RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Status Light Stays Orange after Inserting USB Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Heat and System Derating
Causes of Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Keep the System Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Power Hub Overheating and Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Power Hub Temperature Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
PRO-Verter Temperature Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
PRO-Verter High-temp Generator Auto-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Charger Mode: PRO-Verter High-temp Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
MAINTENANCE INSTRUCTIONS
HPS Preventive Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Water Intrusion—Prevention and Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Locking Component Cases to Prevent Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SOC Disparity Among Expander Paks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Restoring SOC Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Method to Restore Expander Pak SOC Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Maintaining SOC Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Method to Maintain Expander Pak SOC Parity using Gen 100% SOC. . . . . . . . . . . . . . . . . . . 93
Energy Storage Modules – Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Life Expectancy of a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Terminal (End-of-Life) Battery Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
24VDC Expander Pak 2400 PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
24VDC PRO-Verter 5000-220 PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
24VDC Power Hub 2400 PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Clean Power Hub Air Intake Vent Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
PAM 420W PV Array PMCS and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Maximum Power (Vmp) and Open Circuit Voltages (Voc) . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Procedure to Measure PV Array Vmp with a Power Hub 2400 . . . . . . . . . . . . . . . . . . . . . . . . . 102
Navigating the User Interface Menus “View Charge Unit Status” Submenus. . . . . . . . . . . . . . . . . 103
Procedure to Measure PAM Voc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Procedure to Measure Voc of a Single PAM Quarter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ABOUT SOLAR STIK, INC.
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

|7February 2020 |Solar Stik®, Inc.
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. Example-Stacking Power Hubs ...................................................................................................................... 22
Figure 6. Connecting Li Expander Paks using Inter-Connect Strips and Inter-Connect Cables.................................... 22
Figure 7. Inter-Connect Plug .......................................................................................................................................... 24
Figure 8. System connection color coding..................................................................................................................... 25
Figure 9. System Setup Guide on the PRO-Verter I-Plate.............................................................................................. 27
Figure 10. System connection diagram.......................................................................................................................... 27
Figure 11. Solar Array transport case contents packed (left) and unpacked (right)....................................................... 28
Figure 12. Working-space distance for the Solar Arrays, Power Hub, and the trailer.................................................... 29
Figure 14. PRO-Verter to Expander Pak connections .................................................................................................... 30
Figure 13. PRO-Verter to generator connections ........................................................................................................... 30
Figure 15. PRO-Verter to shelter service panel connection ........................................................................................... 31
Figure 16. Connect negative and positive ends of the cables as shown ....................................................................... 31
Figure 17. Solar Array to Power Hub connections ......................................................................................................... 32
Figure 19. PRO-Verter to Power Hub connection .......................................................................................................... 32
Figure 18. Power Hub air intake port and vent lter....................................................................................................... 32
Figure 20. RMK external communication ....................................................................................................................... 33
Figure 21. PRO-Verter grounding lug ............................................................................................................................. 33
Figure 22. Generator control panel................................................................................................................................. 34
Figure 23. PRO-Verter LCD control panel ...................................................................................................................... 34
Figure 24. Generator Status LEDs.................................................................................................................................. 35
Figure 25. Back, Next, and Select buttons..................................................................................................................... 46
Figure 26. Power Hub User Interface ............................................................................................................................. 47
Figure 27. Hybrid Power System bypass connection .................................................................................................... 52
Figure 28. 24VDC Li Expander Pak 2400 ....................................................................................................................... 80
Figure 29. PRO-Verter temperature reports from the user interface .............................................................................. 86
Figure 30. Lock Securing the Lid of the Power Hub 2400 ............................................................................................ 90
Figure 31. Fastener locations on vent shroud (upgraded/new version) ......................................................................... 97
Figure 32. Removed vent shroud to access the louvered vent cover ............................................................................ 97
Figure 33. Replacing PRO-Verter lter (left); cleaning a PRO-Verter lter (right) ............................................................ 98
Figure 34. Removing the Power Hub air intake vent lter for cleaning .......................................................................... 99
Figure 35. View Charge Unit Status submenu navigation ............................................................................................ 103
Figure 36. Procedure to measure PAM Voc.................................................................................................................. 104
Figure 37. Procedure to measure PAM quarter panel Voc .......................................................................................... 104

February 2020 |Solar Stik®, Inc.8 |
System Setup and Operation Manual for ATSC MS3 L0
Revision History
Section Page(s) Description Date
First Published 20 Apr 2018
PRO-Verter
Programming
29-37 Update PRO-Verter programming to CC/CV 30 Oct 2018
All Most Major Update 27 Nov 2019
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. Symptoms and Solutions for the Most Common Power Hub Issues ............................................................... 78
Table 5. Battery Status LED Color and Corresponding Condition ................................................................................. 80
Table 6. 24VDC Li Expander Pak 2400 PCMS ............................................................................................................... 96
Table 7. 24VDC PRO-Verter 5000-120 PMCS................................................................................................................ 97
Table 8. 24VDC Power Hub 2400 PMCS........................................................................................................................ 99
Table 9. PV Array PMCS............................................................................................................................................... 100

|9February 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for ATSC MS3 L0
Figure 1. MS3 L0 HPS
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. Fuel energy is wasted in the production of electricity
because neither the generator nor the load(s) can fully use the fuel’s potential energy. This traditional
power model is a low-efciency system.
In the high-efciency, Hybrid Power System (HPS), a battery bank supports the load. The power
for the load is drawn from the batteries only as needed. Multiple sources of power generation can
be used simultaneously to support the battery and ensure uninterrupted power to the loads. The
battery becomes the foundation of the HPS and the architecture is opened to allow multiple
technologies to operate in concert.
Generator Load
Fuel
Low-efciency
Traditional Power System
High-efciency
HPS
PRO-Verter
Generator Load
Battery
Fuel
Power Generation
Options
PRO-Verter
Battery
Generator Load
Fuel
The Hybrid Power System Flexible Open Architecture
The System is comprised of modular components that integrate into a exible architecture that is
congured for an application’s specic mission requirements. If the application changes, the modular
System architecture can be modied or scaled to meet the new requirements.
HPS with Open Architecture

February 2020 |Solar Stik®, Inc.10 |
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 congured for operation with
compact Yanmar YDG5500 diesel-fuel generator. The generator is rated for lower output than the
peak AC power requirement. Only the PRO-Verter’s inverter function can meet the peak-power
delivery requirement of the AC loads.
Peak-Power Loads Defined
1. Mast and Payload Raising/Lowering—The deployment of the L0 mast requires up to 10 kW (43 A
at 230 VAC) at peak load.
2. Environmental Control Units (ECUs)—The ECUs on the L0 requires up to 8050 W (35 A @ 230
VAC) at peak load.
ECU Soft-starts
The ECUs on the L0 have been congured with soft-start kits, which reduce the surge loads of
the compressor, allowing them to operate within the limits of the generator during normal hybrid
functions.
Sequential Deployment
Raising the mast with payload requires 100% of the PRO-Verter’s capability, and since the PRO-
Verter is the only AC source capable of raising the L0 mast with its payload, it should be used
exclusively when performing this step. The generator should not be used.
Once the mast and payload are fully deployed, the remaining L0 systems and payloads can be
activated, and the system can be returned to normal hybrid mode with the generator engaged as
necessary to support normal L0 operations.
L0 Hybrid Power Function Overview
The Solar Stik Hybrid System is designed to provide constant, quality sine-wave AC power to the
L0 platform, using a 12 kWh battery bank, a Yanmar diesel-fuel generator, and a photovoltaic (PV)
array to meet the daily power requirements of the L0. Both power generation sources (Yanmar and
PV) must produce enough power on a daily basis to be used by the loads, although they will both
provide power under different conditions:
• The Yanmar generator only operates when the PRO-Verter commands it to, based on
programming.
• The PV array only generates power when exposed to sunlight.
The PRO-Verter is programmed at the factory for use in the L0 application. It is possible to alter the
programmed settings for special conditions or changes in system conditions or application. Contact
Solar Stik Technical Support for assistance.
The Remote Monitoring Kit (RMK) transmits Hybrid Power System information in real time from the
PRO-Verter over any LAN or internet gateway.

|11February 2020 |Solar Stik®, Inc.
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.
Thoroughly read and understand the operator manual for each of the components in this System
PRIOR to assembly and use of this System. Important information regarding the safe setup and use
of each component and this System is contained in each of the operator manuals. DO NOT begin
assembly or use of this System without rst reading and understanding the individual operator
manuals.
While the System components are designed for indoor/outdoor operation, the User Interface (control
panels) must not be exposed to rain, snow, moisture, or liquids. Close and latch and/or lock the
cases when the components are unattended.
Exercise caution when handling or operating the System. Live power may be present.
Safety Information Labels
Your safety and the safety of others is very important.
Many important safety messages have been provided in this manual and directly on the System
components. Always read and obey all safety messages.
This is the safety alert symbol. This symbol is an alert to potential hazards that can cause
death or injury. 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 describe what the potential hazard is, how to reduce the chance of injury,
and what can happen if the instructions are not followed.

February 2020 |Solar Stik®, Inc.12 |
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 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.
Use Sweeping Motion
WARNING
Only CO2(carbon dioxide) re extinguishers should
be used with this equipment.
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.

|13February 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for ATSC MS3 L0
Grounding the PRO-Verter at the grounding lug is an important
safety measure. The PRO-Verter and the generator (if included)
should be bonded to an earth grounding rod. When the
generator is running, the AC neutral and equipment ground
automatically are bonded internally at the generator. When
running off battery, the AC neutral and equipment ground are
automatically bonded internally at the PRO-Verter.
If the System is ever connected to grid power, the AC neutral
must be bonded to the earth ground at the main breaker panel
of the grid power. Any generator connected to the System must
have a neutral-to-ground bond.
Grounding the System
PRO-Verter Grounding Lug
Figure 2. PRO-Verter grounding lug
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.
DON’T LET THIS BE YOU!
HIGH VOLTAGE: System components, PV
arrays, and generators may produce 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
The System is NOT GFCI protected.

February 2020 |Solar Stik®, Inc.14 |
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.
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. As a general rule, 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 and
life expectancy. Shade components (except
PV panels) to prevent the negative effects of
heat.

|15February 2020 |Solar Stik®, Inc.
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 congured using a
PRO-Verter.
Note: The PRO-Verter settings used in each model of operation are unique and not
interchangeable. The PRO-Verter must be programmed specically for the model of operation in
which the System is functioning. Damage to System components may occur if a PRO-Verter is
not properly programmed for the model of operation in which the System is functioning.
DC-only/Inverter (Automatic Functions)
Operating conditions – All power generated is from DC generators, and AC loads are supported by
the PRO-Verter’s Inverter function using energy stored in batteries.
Hybrid (Automatic Functions)
Operating conditions: The “Continuous Load” AC power requirement is LESS than the individual
inverter or generator/grid AC power output ratings.
In the Hybrid Model, the PRO-Verter serves as the primary power management device in a System,
using either inverter AC power or generator/grid AC power to maintain the load. In the Hybrid
Model, the batteries will cycle regularly to mitigate generator runtime and logistical support often
associated with operation in remote locations. Hybrid systems also provide the operator with a
exible architecture that allows for the addition of multiple power sources, such as renewable power
generation.
Load Support (Automatic Functions)
Operating conditions: The “Surge Load” AC requirement is MORE than the generator or grid AC
output, but less than the inverter AC output rating.
The Load Support Model allows the use of a smaller generator based on total loads operating over
24-hour period rather than a larger generator that is required for the “peak” loads, which may only
last for a brief period. The PRO-Verter can be used to provide supplemental “surge” AC power to
a generator or grid AC source during brief or intermittent periods while allowing the “continuous”
loads to be supported in the Hybrid Model.
Peak Power Delivery (manual functions)
Operating conditions: The “Peak Load” AC requirement is MORE than the PRO-Verter AC
continuous output ratings.
In the Peak Power Delivery Model, the PRO-Verter combines generator or grid AC power with
Inverter AC power to support “peak” AC for brief periods. This mode can only be supported for
limited durations and is directly dependent on the total battery capacity and battery SOC.

February 2020 |Solar Stik®, Inc.16 |
System Setup and Operation Manual for ATSC MS3 L0
UPS (Automatic Functions)
Operating conditions: A PRO-Verter connects critical AC loads directly to grid utility or prime AC
power when it is available, and provides backup power for the load by supplying inverter AC (using
energy from a connected battery bank) when the Grid utility or prime AC source is interrupted.
In the UPS Model, “peak shaving” and the use of renewable power sources are also possible by
connecting a Power Hub.
Note about PRO-Verter Model Programming: The PRO-Verter is programmed at the factory for
use in the application in which it is to be used. It is possible for the Operator to alter any of the
programmed settings when operating conditions change and/or 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
• Power generation
The PRO-Verter, Power Hub, and Expander Paks are designed to operate in concert and provides
uninterrupted pure sine wave AC and DC power to the loads. The HPS is a powerful solution for the
following conditions:
1. The generator requires protection from adverse operating conditions.
2. Grid or generator AC power sources are not present or only intermittently available.
3. Power requirements for the load may exceed an existing power source’s daily power output,
requiring multiple power sources to operate in concert to meet the daily demand
4. The reduction of fuel-driven generator “runtime” is necessary, due to logistics concerns or to
simply to reduce the cost burdens of operating a generator.
It is important to follow two rules when conguring power generation and energy storage
technologies to serve in an application:
1. The power generated over 24 hours must be greater than or equal to the power consumed
2. The energy storage capacity must be able to power the load over 24 hours (with no recharging)
Energy Storage—The Foundation of the HPS
Operating a generator may have signicant cost burdens (logistics, support, etc.). The HPS alleviates
those cost burdens by redirecting the nancial investment into a battery-based platform.
Batteries in a hybrid system are designed to “cycle”. A full cycle is dened as one complete
discharge and recharge over a specic period of time. With every cycle that occurs, the HPS is
providing a return on the nancial investment.

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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.
See additional information about the Expander Paks: Energy Storage Modules – Supplemental
Information.
Minimum Battery Capacity Required for Optimal System Operation
A HPS will function most efciently when proper balance is achieved within the System’s architecture
(energy storage, power management, and power generation). The central power management device
is the PRO-Verter, so any components connected to it need to be rated for the amount of power that
will be processed by it.
For example, the PRO-Verter can require extremely high current (amperage) from the battery bank
when AC loads require power from the inverter, but it can also push high current into the bank when
it is in charge mode.
Each Expander Pak has a built-in circuit breaker that will trip at a value less than the maximum rated
current to/from the PRO-Verter. For this reason, multiple Expander Paks must be connected to a
PRO-Verter for the System to function at its rated power. The combined values of the Expander
Pak circuit breakers must be greater than the rated inverter/charger current required from the
PRO-Verter.
In the HPS, the PRO-Verter 5000 inverter can require up to 200 A from the batteries, and the charger
has a rated output of 110 A. Four (4) 24VDC Expander Paks is the MINIMUM number required to
support the inverter’s full inverter output and be charged effectively and safely when the PRO-Verter
5000 is in charge mode.
Connecting an insufcient number of Expander Paks (energy storage modules, or ESMs) to a PRO-
Verter will result in a situation where the batteries are charged or discharged too quickly:
• Charging LiFePO4Expander Paks too quickly may result in an articially high battery voltage
reading and signal the PRO-Verter to turn off the generator before the batteries are actually
charged sufciently.
• Discharging LiFePO4Expander Paks too quickly may cause the battery temperature to rise to
a point that the battery management system (BMS) disconnects the batteries from the whole
system.
Refer to the “Minimum Battery Capacity Recommendations” on the PRO-Verter I-Plate to ensure
trouble-free operation.
System Cycling
During normal operation, the generator runs only to charge the ESMs and support the load while
doing so; the batteries and generator will cycle 1–2 times daily.

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Load Prioritization
When the HPS is fully functioning, providing power to the load is always prioritized over other functions.
If renewable DC generators (i.e., PV arrays, wind, etc.) are producing power, it is immediately directed to
to the load once it ows into the HPS. The batteries will begin to charge ONLY when the DC generation
exceeds the demand from the load.
During periods of peak renewable DC power production, it may be exclusively used to support the load
while excess energy charges the batteries simultaneously. This function reduces the demand on the
batteries, prolongs battery operation time, and promotes healthy cycling of the battery.
This same function also occurs when the HPS is connected to an AC source. If the HPS is connected to
an active generator or grid utility, the load is always supported FIRST before any AC is used for charging
the HPS batteries. If the PRO-Verter is controlling a connected generator and the battery bank reaches a
low state-of-charge, the PRO-Verter can be programmed to auto-start the generator to keep AC owing
to the load, charging the connected batteries only after the load is fully supported by the generator.
Real-time Load Management
When connected to an active AC source, the PRO-Verter can automatically adjust (in real time) its battery
charging rate to keep the total load value under the AC INPUT setting value.
If the load is dynamic, the PRO-Verter can make immediate adjustments and keep the total load on the
AC source from exceeding the value of the AC INPUT setting while still maintaining a 100% load at the
external AC source (generator or grid utility).
It is incumbent on the Operator to ensure the sum of all loads does not exceed the limit of the AC source
(generator or grid utility) or the connections or circuit protections in the network. The AC INPUT (FAVS 03)
setting should be set to the same value of the maximum AC output rating of the source. For example, if
the generator is rated for 3000 W continuous output, then the AC INPUT should be set for 25 A* (25 A @
120 VAC = 3000 W)
*See Lag Times and Surge Rates
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:
• Excessive load
• Inadequate battery capacity
• Heat-derated performance
• Disparity in battery SOC
Consult the troubleshooting sections for more details on causes of irregular or excessive cycling.

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“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).
• Load AC power demand is greater than the AC INPUT setting, which may cause the PRO-Verter
to disconnect from the AC source when in pass-through (charging) mode.
• Load AC and DC power demand is greater than the output of the connected AC source
(generator or grid utility), causing it to shut down.
In each of these scenarios, the solution is simply a reduction in the total load demand (AC and DC).
Use the AC and DC METERS to conrm the load is reduced to prescribed levels and proceed with
normal operation.
Load Support (If Equipped)
Load Support function is used to support two models of operation:
1. Load Support Model
2. Peak Power Model
Load Support is an automatic function of the PRO-Verter that combines power from a generator or
grid AC source with the inverter’s AC output to briey support high AC loads that exceeds the AC
source’s or the PRO-Verter’s rated AC power output.
It is typically used in operations where the PRO-Verter is connected to a generator or Grid AC
power source that is rated for LESS AC output than the inverter output power rating of the PRO-
Verter.
It automatically engages once the load exceeds the AC INPUT setting (FAVS 03), and because it
requires power from the batteries, it should only be used if the excessive loads are brief in duration
and intermittent in scope.
For Load Support to function, the PRO-Verter must be connected to an active AC power source. It
cannot engage if there is no active external AC power source.
The PRO-Verter can also be congured to perform Load Support as a manual intervention method
when conditions warrant. This is also referred to as the Peak Power Model.
Consult the PRO-Verter I-Plate to determine if the PRO-Verter is equipped with the Load Support
feature and for specic instructions on manual engagement of Load Support for a particular
application.

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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.
A PRO-Verter should be paired with an appropriately rated generator, but if it is paired with a smaller
generator, the AC INPUT setting must be set to limit the AC power the PRO-Verter will expect from
the AC source. In this scenario, it is possible for the PRO-Verter to put up to 130% load on the AC
source (generator or grid utility), which can occur when charging mode is engaged and a sudden AC
surge is demanded by the load. Since the PRO-Verter can’t determine in advance how much power
will be demanded at the time of the surge, it can only “react” to the surge condition. It may take up
to 1 full second for the PRO-Verter to react, and this period is known as “lag time”. Lag time results
in 130% of the AC INPUT setting being demanded from a generator for up to 1 second.
If the generator can’t handle 130% surge, it will likely crash the System in the following ways:
• The generator AC output voltage may drop below the VAC DROPOUT setting in the PRO-Verter.
• The generator AC contactor (if present) or circuit breaker may open, causing a loss of AC at the
PRO-Verter.
• If the generator has an electronic protection circuit, it may cause the unit to shut down entirely.
All of these issues are resolved by dropping the AC INPUT setting less than 130% of the output
rating of the connected AC source.
Figure 3. Hybrid Power System in Operation