Solar Stik PRO-VERTER S 3000 User manual

|1December 2020 |Solar Stik®, Inc. PRELIMINARY
OPERATION AND MAINTENANCE
MANUAL
FOR THE
PRO-VERTER S 3000
Version 1.0
Updated:20201209
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Item # 20-0104029

December 2020 |Solar Stik®, Inc.2 |
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
Contents
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
Introduction to Hybrid Power Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HPS Flexible Open Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Important Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grounding a PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Theory of Operation
Models of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DC-only/Inverter (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hybrid (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Peak Power Delivery (Manual Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UPS (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selecting a Generator/Grid AC Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Energy Storage Requirements for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DC Voltage: Master Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRO-Verter Circuits and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Load Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Real-time Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
“Pass-through” Power and the Internal AC Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Qualifying AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Charge Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Invert Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transfer of Loads From Grid/Generator Input to Inverter (Batteries) . . . . . . . . . . . . . . . . . . . . . . 19
Transfer of Loads From Inverter (Batteries) to Grid/Generator . . . . . . . . . . . . . . . . . . . . . . . . . 19
Solar Charging and Solar Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Automatic Generator Start/Stop (AGS) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AGS Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling Fan Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Protection Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dead-battery System Recovery Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Derating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Historical Data and Fault Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Circuit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Equipment Description
The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

|3December 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
The Standard Inter-Connect Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PRO-Verter S 3000 AGS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PRO-Verter Connection Ports and Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PRO-Verter Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PRO-Verter I-Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATOR INSTRUCTIONS
1. Minimize Potential for Water and Dust Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2. How to Connect System Components to PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
a. How to Connect PRO-Verter to Energy Storage Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 31
b. How to Connect PRO-Verter to AC Power Source(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compatible Generator Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
c. How to Connect PRO-Verter to Generator Comms Cables . . . . . . . . . . . . . . . . . . . . . . . . . 33
i. MEP-802A and MEP-831 TQG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ii. Defender 1 kW and Ranger 2 kW MPGs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
How to Connect two (2) MPGs in parallel to the PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . 35
d. How to Connect PRO-Verter to Power Hub 3500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
e. How to Connect Power Hub 3500 to PDM 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
f. How to Connect PRO-Verter to 120 VAC Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
g. How to Connect Loads Requiring Regulated 28 VDC Output . . . . . . . . . . . . . . . . . . . . . . . . 38
h. How to Connect PV Array(s) to PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
i. How to Set PRO-Verter Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
j. How to Program PRO-Verter to Match AC Source Output Current . . . . . . . . . . . . . . . . . . . . . . 41
Recommended generator AC Input Settings and Loads . . . . . . . . . . . . . . . . . . . . . . . . . . 41
k. Starting a Generator with PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PRO-Verter Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating the PRO-Verter User Interface
PRO-Verter Status and Alarm LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
PRO-Verter Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Navigating “Select Group” and “Select Parameter” Menu Maps . . . . . . . . . . . . . . . . . . . . . . . . 46
Parameter Groups: PRO-Verter Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Charge Curve Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Input Setting Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Input Low Limit Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input High Limit Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Other Functions Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
PRO-Verter Clock Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Stop SD Card Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Saving/Uploading Programmed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Saving Programmed PRO-Verter Parameters to SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Uploading Saved PRO-Verter Parameters from SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
PRO-Verter S 3000 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Data Log Files: Viewing Data Log Files Using Excel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TROUBLESHOOTING PROCEDURES
Clearing PRO-Verter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
System Recovery with Overdischarged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PRO-Verter Fault Messages and Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

December 2020 |Solar Stik®, Inc.4 |
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
MAINTENANCE, SECURITY, AND TRANSPORT
24VDC PRO-Verter S 3000 PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
PRO-Verter Filter Removal and Cleaning or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Locking Component Cases to Prevent Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transporting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Warranty and Returns
Return Material Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ABOUT SOLAR STIK, INC.
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

|5December 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
List of Figures
Figure 1. PRO-Verter grounding lug ............................................................................................................................... 10
Figure 2. PRO-Verter circuits.......................................................................................................................................... 15
Figure 3. Inter-Connect Plug .......................................................................................................................................... 23
Figure 4. PRO-Verter front .............................................................................................................................................. 24
Figure 5. PRO-Verter rear ............................................................................................................................................... 24
Figure 6. PRO-Verter right side....................................................................................................................................... 25
Figure 7. PRO-Verter left side......................................................................................................................................... 25
Figure 8. PRO-Verter Faceplate features........................................................................................................................ 26
Figure 9. PRO-Verter I-Plate ........................................................................................................................................... 28
Figure 10. System connection diagram.......................................................................................................................... 30
Figure 11. PRO-Verter to ESM connections................................................................................................................... 31
Figure 12. PRO-Verter(s) to AC power input connections.............................................................................................. 32
Figure 13. Compatible generator options....................................................................................................................... 32
Figure 14. MEP-831A and MEP-802A Gen Comm Cable connections ......................................................................... 33
Figure 15. Defender 1 kW and Ranger 2 kW Gen Comm Cable connections ............................................................... 34
Figure 16. Connecting two 1 kW generators in parallel with the “Y” AC power cable................................................... 35
Figure 17. PRO-Verter to Power Hub connection .......................................................................................................... 36
Figure 18. Power Hub to PDM connection..................................................................................................................... 37
Figure 19. PRO-Verter AC power output ports............................................................................................................... 38
Figure 20. PRO-Verter Regulated DC power output port............................................................................................... 38
Figure 21. PV array to PRO-Verter connection............................................................................................................... 39
Figure 22. PRO-Verter Power specications for PV arrays ............................................................................................ 39
Figure 23. Generator mode control switches and LEDs................................................................................................. 42
Figure 24. Generator Status LED blinking pattern legend.............................................................................................. 42
Figure 25. PRO-Verter user interface power and navigation buttons............................................................................. 44
Figure 26. PRO-Verter S 3000 user interface ................................................................................................................. 45
Figure 27. Fastener locations on vent shroud (upgraded/new version) ......................................................................... 61
Figure 28. Removed vent shroud to access the louvered vent cover ............................................................................ 61
Figure 29. Replacing PRO-Verter lter (left); cleaning a PRO-Verter lter (right)............................................................ 62
Figure 30. Steel-reinforced padlock holes...................................................................................................................... 63
Figure 31. Lock securing Power Hub lid ........................................................................................................................ 63
Figure 32. Component transportation: Wheels and handles.......................................................................................... 64

December 2020 |Solar Stik®, Inc.6 |
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
List of Tables
Table 1. AC Power input settings for generators............................................................................................................ 41
Table 2. Operating Modes: Descriptions ........................................................................................................................ 43
Table 3. User Interface LED Indicators ........................................................................................................................... 45
Table 4. Programmable Parameter Groups: Descriptions .............................................................................................. 47
Table 5. Parameters for Battery Charging/Battery Protection ........................................................................................ 48
Table 6. Parameters for Grid/Generator Input Current Level, Frequency Range ........................................................... 49
Table 7. Parameters for Grid/Generator Input Low Voltage Level .................................................................................. 50
Table 8. Parameters for Grid/Generator Input High Voltage Level ................................................................................. 50
Table 9. Power Saving/Alarm/Remote Switch/Multi-function Relay/etc. ....................................................................... 51
Table 10. Local Time Clock Setting ................................................................................................................................ 51
Table 11. Instructions to Remove SD Card from PRO-Verter User Interface ................................................................. 51
Table 12. Fault Messages Symptoms and Troubleshooting........................................................................................... 57
Table 13. 24VDC PRO-Verter S 3000-120 PMCS........................................................................................................... 61
Revision History
Section Page(s) Description Date
First released as a PRELIMINARY DRAFT January 2020

|7December 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
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 or energy storage module (ESM) 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
HPS Flexible Open Architecture
The HPS is comprised of modular components that integrate into a exible architecture congured
for an application’s specic mission requirements. If the application changes, the modular HPS
architecture can be modied or scaled to meet the new requirements.
Power Generation
Options
PRO-Verter
Battery
Generator Load
Fuel
HPS with Open Architecture
The introductory parts of this manual describe Hybrid Power Systems composed of Solar Stik
components. However, the Solar Stik architecture is modular and open, allowing Operators to
integrate non-Solar Stik components as part of a Hybrid Power System solution. Please contact
Solar Stik Technical Support for assistance in optimizing the integration of other components into a
Solar Stik Hybrid Power System.

December 2020 |Solar Stik®, Inc.8 |
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
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.

|9December 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
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.

December 2020 |Solar Stik®, Inc.10 |
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
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 a PRO-Verter
PRO-Verter Grounding Lug
Figure 1. 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.

|11December 2020 |Solar Stik®, Inc.
Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
Environmental and Handling Precautions
All Solar Stik components are ruggedized, yet there are a few things the operator can do to prevent
failures and prolong the operational life of the Solar Stik System.
Wind
It is imperative to properly secure PV panels
(if used) to the ground using sandbags so
they do not become dangerous projectiles in
high winds.
Water
If outdoor operation is necessary, the lid
should be closed and latched. During
operation, the case should be placed upright,
especially during inclement weather. The
lid should be open only to access operator
controls and closed at all other times.
Impact
The PRO-Verter 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.

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Operator and Maintenance Manual for the PRO-Verter S 3000
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Theory of Operation
Models of Operation
Depending on the application, there are several operational models that can be congured using a
PRO-Verter:
DC-only/Inverter (Automatic Functions)
Operating conditions: All power generated is from DC generators and AC loads are supported by
the PRO-Verter’s Invert 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.
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/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 state of charge (SOC).
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 the application in which it is to be used. It is possible for the Operator to alter any of the
programmed settings for Hybrid, Load Support, Peak Power Delivery, or UPS Models when
changes to operating conditions and system architecture are necessary. Consult the System
Deployment Guide for details.

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Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
Selecting a Generator/Grid AC Source
PRO-Verters can be used with grid/utility or generator AC power sources and can be easily
programmed to work with the amperage limits of both the AC source circuits and the AC load
circuits. Once programmed, the PRO-Verter effectively calculates and then regulates how much
power is delegated between these circuits to prevent overload conditions while maintaining
(prioritizing) the load.
Acceptable generators/grid AC sources for use with a single PRO-Verter should provide power
between 1 kW and 10 kW, and ALL source AC power must provide consistent, pure, sine wave AC
output. The PRO-Verter will not accept modied sine wave AC, or “dirty”, power. Fluctuations in
voltage or frequency during operation may have an adverse affect on PRO-Verter functions.
Many factors should be considered when selecting a generator for use with a PRO-Verter, including:
• Auto-start/stop capability
• Physical size
• Weight
• Fuel consumption
• AC output rating
If a particular generator is desired based on the application, then one of the following power models
will likely be used:
• Hybrid Model: The peak AC load should not exceed the maximum continuous AC output of both
the PRO-Verter and AC power source (i.e., Peak Load AC ≤ AC Source + PRO-Verter AC).

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Operator and Maintenance Manual for the PRO-Verter S 3000
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• Load Support Model: The peak AC load should not exceed the PRO-Verter maximum
continuous AC power output (i.e., Peak Load AC ≤ PRO-Verter AC). The peak AC load can
exceed the AC power source maximum continuous AC output up to 150% for brief periods (i.e.,
Peak Load AC ≥ Source AC).
• Peak Power Delivery Model: The peak AC load exceeds the PRO-Verter continuous AC output
up to 150% (i.e., Peak Load AC ≥ PRO-Verter AC).
Note: Several programmable settings may affect the ability of the PRO-Verter to operate with
a particular generator or grid AC power source. Surges and/or overloads can occur at the AC
source when the transfer switch engages, causing it to shut down or overload. Consult Solar Stik
Technical Support when conguring the PRO-Verter programming for a particular AC source.
Energy Storage Requirements for Operation
PRO-Verters require connection to an active 24 V battery circuit to operate. They CANNOT be used
directly between an AC source and an AC load without a battery connected to it. PRO-Verters are
compatible with both lead-acid and lithium battery chemistries.
DC Voltage: Master Metric
The PRO-Verter has an intelligent brain that uses one primary data point for most of its critical
operating decisions: battery (bus) DC voltage.
The Inter-Connect Circuit communicates VOLTAGE! Voltage is the one value that triggers all of the
events in the PRO-Verter. If it can’t read the battery voltage, it can’t perform its critical role. Make
sure all system conguration diagrams are followed and setup is complete before attempting to
operate the PRO-Verter.
DC voltage is the safest and most reliable “trigger” mechanism for controlled functions such as
external generator start/stop, charging rates and inverter modes, and load prioritization/sharing.
Battery voltage can also be universally used to accurately determine SOC, at both fully “charged”
and “discharged” thresholds for ALL battery chemistries. This allows the Operator to choose
from multiple chemistry options when conguring energy storage that is compatible with mission
requirements, logistics, and cost.
Voltage is also used to determine battery health, correct system sizing, conguration management,
and troubleshooting. It also affects both historical and real-time performance data.

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Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
PRO-Verter Circuits and Functions
A PRO-Verter is the central power management device (i.e., the “brain”) for a hybrid or high-
efciency electrical system. At its core, the PRO-Verter has a combination inverter/charger, which
operates in concert with its supporting circuits to provide the operator with a multifaceted solution
and seamless power for an application:
Primary Circuits
• Inverter – Transforms DC from a battery to AC for use by a load
• Charger – Converts AC from generator or grid to DC for charging batteries
• Photovoltaic (PV) – Optimizes and regulates DC power from PV panels to charge batteries
Support Circuits
• DC Voltage – “Battery monitor” circuit
• AGS – “Automatic generator start/stop” circuit
Recovery Circuits
• AC-powered System recovery (overdischarged batteries)
• PV-mediated System recovery (overdischarged batteries)
NATO Circuit
• DC load or battery charging circuit
28 VDC Regulated Output Circuit
• Low-wattage, voltage-sensitive DC loads
Both the primary and the support circuit functions of the PRO-Verter are managed by native
programming, which can be adjusted via user interfaces.
If the PRO-Verter is connected to an overdischarged battery, the recovery circuit enables the PRO-
Verter to restore the battery to service using a 120 VAC power source such as a generator or grid/
utility. This circuit is not programmable and is an optional feature. Active PV panels may also be
used to recover a System with overdischarged batteries.
The NATO port allows connection of a NATO 24V DC circuit to the HPS’s 24 V bus. This can be in
support of a 24 VDC load or to allow charging from an external 24 VDC source.
Figure 2. PRO-Verter circuits
Auto Generator Start/Stop
AND/OR
120 VAC
Loads
Voltage-sensitive
DC Loads
PVEnergy
Storage

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Load Prioritization
The PRO-Verter has a “one-track mind” when it comes to managing power—in every model of
operation it is entirely focused on maintaining constant power to the load. This function is key to
understanding how the PRO-Verter behaves. It makes decisions and executes actions based on
a real-time operating conditions, which include:
• Total amount of power available to the PRO-Verter
• Total power needed to support the load
• Battery SOC
• Temperature
• User programming for special conditions
PRO-Verters can be used with grid/utility or generator AC power and can be easily adjusted to
work with the amperage limits of both the AC load circuit and the external AC power source.
Limitations can be programmed into the PRO-Verter, and once done, it effectively calculates
and then regulates how much power is delegated between the circuits, preventing “overload”
conditions while maintaining (prioritizing) the load.
If there are dynamic changes in the load, the PRO-Verter can instantly increase or decrease
current ow to both the load and batteries simultaneously while maintaining a 100% load at the
generator (AC Input).
If a PRO-Verter is being used with other external DC power sources (i.e., PV, wind, vehicular,
fuel cells, etc.), all incoming power will be directed (prioritized) to the load, reducing DC owing
from the batteries, prolonging battery-operation time, and reducing need for AC from a grid/
utility or generator source.
If a PRO-Verter is being used with a fuel-driven generator, the AGS circuit can be used to
control the generator when the battery SOC is low. Once the battery SOC reaches a determined
point, the PRO-Verter AGS circuit will start the generator, ensuring (prioritizing) power to the
load. In effect, the PRO-Verter uses a connected generator as the last line of defense against
mission failure.
With load prioritization, the load will always be the rst to receive AC, with the balance of
electrical output from a grid/utility or generator converted to “potential energy”, which is stored
in the batteries to be used during periods where the grid source is unavailable or the generator
is off.
Real-time Load Management
When connected to an active AC power 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 power source from exceeding the value of the AC Input setting while still maintaining a 100%
load at the external AC power source (generator or grid/utility).

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Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
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 setting should be set to the same value of the maximum AC power output rating of the source.
For example, if the generator is rated for 3000 watts continuous output, then the AC Input should be
set for 25 amps @ 120 VAC.
“Pass-through” Power and the Internal AC Transfer Switch
The PRO-Verter employs a high-speed transfer switch that enables it to toggle between incoming
AC power when it is available (i.e., when the generator is on or it is connected to grid/utility power)
and inverter power when necessary (using energy from the batteries).
When AC power is available at the PRO-Verter’s AC input, it is rst “qualied” by the PRO-Verter to
make sure it is acceptable (i.e., within the programmed limits of quality) to pass on to a connected
load. Once it has been qualied, the switch engages and incoming AC power is transferred directly
to the load. The PRO-Verter is designed to ensure the load is always supported FIRST before it does
anything else with the incoming power (load prioritization).
The primary benet of using a transfer switch is simple: it maximizes the efciency of the system
while keeping constant power to the load:
• If the PRO-Verter is controlling a generator, the transfer switch allows it to maximize the load
on the generator (for optimal engine operation), and it also ensures all of the fuel (i.e., “energy”)
consumed in the generator engine is utilized—for direct load support and/or to charge a
connected battery bank (storing energy for later use).
• If the PRO-Verter is being used with grid/utility power, the transfer switch allows the PRO-Verter
to control multiple conditions under which power is harvested, including time of day, peak
shaving, or another condition based on application requirements.
The transfer switch is directly controlled by the Invert function, but it ONLY reacts to the presence
of incoming AC power from a generator or grid/utility. The switch ensures the AC output of the
PRO-Verter is always active, whether the PRO-Verter is inverting or passing power through from an
external source (generator or grid).
If the Invert function is engaged, the transfer switch is also engaged. The transfer switch is disabled
if the Invert function is off.
Transfer time between incoming AC and Inverter mode is ~16 ms, and less than 1 ms from inverter
to the AC input source, which is usually fast enough to support computers, servers, and other
critical loads.
Note: When switching from Inverter mode to Standby mode, the PRO-Verter waits approximately
15 seconds as it qualies the incoming AC, ensuring the AC source is clean and stable before
transferring the load.

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Qualifying AC Input Power
The PRO-Verter must only be used with AC sources that generate or provide pure sinusoidal
waveforms with voltage and frequency that meet minimum standards.
When an active AC source is connected to the PRO-Verter, it will “qualify” the power before passing
it through to the load and initiating the battery charging sequence. If the PRO-Verter detects poor
quality AC power, then the PRO-Verter may reject it and remain in Inverter mode.
Once AC has been accepted, it will not automatically reject the AC input power if it falters or morphs
during operation. It can, however, be programmed to reject the power of it falls below or goes over
certain thresholds, such as those programmed in the Input Low and Input High settings.
If the AC waveform itself distorts during operation, it may cause certain PRO-Verter functions to
retard (derate) or cease. For example, if the eld effect transistors (FETs) and the EMI lter are
pushed beyond their design limits by poor AC power, it may result in a Heat Sink Overheat fault,
which will cause either retardation of charging functions or a failure to provide AC power to the load.
Charge Function
Whenever an AC source is connected to the AC Input, the PRO-Verter automatically begins
monitoring for acceptable AC voltage and power quality. Once the AC voltage is accepted, the AC
transfer relay closes, passing AC power to the load and beginning the Charge function.
The PRO-Verter is equipped with a logic-controlled, multi-stage battery charger. It actively monitors
battery voltage and SOC, using this information to control the amount of power used to charge the
batteries in real time. Voltage and current are independently controlled so that maximum charge
current is always applied to the batteries, reducing charging times. This maximizes the real power
available from the AC power source (grid/utility or generator), which translates into less power
wasted and less dependence on external power sources.
The automatic, multi-stage charger in the PRO-Verter provides Bulk, Absorb, Float, and Full Charge
stages, ensuring complete recharging and monitoring of the batteries without damage due to over/
under charging. There is also a constant current/constant voltage (CC/CV) option for use with
certain types of lithium batteries.
If the PRO-Verter is being operated in high-heat environments, it can “throttle back” its charging
amperage rate to prevent overheating of the internal transformer or FET board.
Invert Function
The PRO-Verter’s Invert function transforms DC from a connected battery into pure sine wave AC
power for an AC load. When 24 volts DC is available from a connected battery, the PRO-Verter
automatically engages its inverter circuit functions, and AC power is immediately available for the
load. The user interface home screen will indicate the PRO-Verter is inverting.
When AC power is available from a grid/utility or generator source, the PRO-Verter is programmed
to defer the load (via the transfer switch) onto the external source, which will cause the inverter

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Operator and Maintenance Manual for the PRO-Verter S 3000
PRELIMINARY
circuit to go into Standby mode. In Standby mode, the inverter circuit is not actively providing power
from the batteries to the loads; rather, the loads connected to the inverter are powered directly
using the external AC power (pass-through power). However, if power from the external AC source
is interrupted, the inverter senses these conditions and immediately starts inverting to maintain AC
output to the loads.
Transfer of Loads From Grid/Generator Input to Inverter (Batteries)
When the PRO-Verter is operating in Charge mode, the phase and frequency of AC input power are
tracked continuously. If AC input power fails or is disconnected, the load will be transferred within 16
ms to the inverter at the same phase and frequency as the AC input power that was disconnected.
Transfer of Loads From Inverter (Batteries) to Grid/Generator
When grid/generator power becomes available, its voltage and frequency are checked to determine
if they are within the programmed limits. If so, the output voltage of the inverter is synchronized
with the grid/generator through phase locked loop (PLL). This synchronization process takes few
seconds. Once synchronization is completed, the load is transferred instantly (within 1 ms) to
the grid/generator at zero crossing of the voltage waveform for seamless transfer and for better
protection of transfer relay contacts.
Solar Charging and Solar Prioritization
Charging the HPS Expander Paks can be supplemented by connecting a PV array to the PRO-
Verter. The maximum PV current must not exceed 50 A. The value of the PV current is displayed as
“EXTERNAL”, the bottom line of the user interface.
The net bulk charging current fed to the battery bank is as follows:
• Net Bulk Charging Current fed to the battery bank = Adjusted Bulk Charging Current from the
PRO-Verter charger + Current available from the PV array.
The measured value of the charging current received from the PV array is monitored by the control
circuitry of the PRO-Verter charger. The amount of bulk charging current produced by the internal
battery charger is adjusted in real time to satisfy the following condition:
• Internal Bulk Charging Current = Programmed Value of “Bulk Current” – External Charging
Current
For example, if “Bulk Current” in the PRO-Verter is programmed to 40 A and the PV array is
generating 15 A, the PRO-Verter charger will reduce its current from 40 A to 25 A so the net charging
current is equal to the programmed value of 40 A.

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Automatic Generator Start/Stop (AGS) Function
The AGS circuit is used to start/stop an external generator, controlling it based on battery voltage.
When the AGS is active during hybrid operation, it should only start/stop a generator as a last line of
defense to ensure continuity of power is available to the load when the batteries are at low SOC.
The Generator Status LEDs located on the Faceplate provide real-time generator function
information to the Operator.
AGS Audible Alarm
The PRO-Verter has an audible warning that signals the generator has initiated the auto-start
protocol and is about to start. This provides Operators standing or working on or around the
generator with an opportunity to take precautions before it auto starts. This function can be disabled
for silent operations.
Soft Start
The PRO-Verter incorporates a “soft start” feature that provides advantages and protections. When
the PRO-Verter powers up, it starts in Invert mode. The soft start allows the output voltage to ramp
up gradually from around 48 VAC to 120 VAC in about 200 ms. This dampens the high inrush current
and concomitant voltage drop of inductive loads like motors. This will result in less mechanical
stress, less wear and tear, and increased lifetime of the PRO-Verter and the loads.
Cooling Fan Operation
The PRO-Verter contains two (2) variable-speed internal cooling fans that are controlled
automatically. The speed of these fans is determined either by the PRO-Verter internal temperature
or by the load on the transformer.
Two (2) additional cooling fans are integrated PRO-Verter case and turn on when the PRO-Verter is
powered up. They remove heat from the case interior.
Protection Circuits
The PRO-Verter is protected against fault conditions using protection circuits in the form of
magnetic/thermal circuit breakers. During normal usage, it will be rare to see any faults; however, if
a condition occurs that is outside the normal operating parameters, the PRO-Verter will shut down
and attempt to protect itself, the battery bank, and the AC loads. If there is a condition that causes
the inverter to shut down, it will be reected as a fault on the LCD user interface. (Refer to the PRO-
Verter Fault Diagnosis section to help diagnose and clear the fault condition.)
Note: Circuit breakers will vary among PRO-Verters according to customer requirements and
connection ratings.