Solar Stik PSS-G Quick reference guide

PSS-G HEAVY
ALTERNATIVE ENERGY SYSTEM (AES)
DEPLOYMENT GUIDE
Distribution authorized to U.S. Government Agencies and their contractors in support of the
Persistent Surveillance System–Ground (PSS-G)/RAID program. Date of determination 02 February
2015. Other requests for this document shall be referred to Product Manager Electro-Optics/Infrared
Force Protection.
Revision 8. AES v. PSS-G AES
Updated:20200817

PSS-G/RAID Alternative Energy System Deployment Guide
August 2020 |Solar Stik®Inc.2 |
Contents
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
Introduction
Important Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Theory of Operation
Introduction to Alternative Energy Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
The AES Architecture, Function, and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Energy Storage—The Foundation of the AES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Minimum Battery Capacity Required for Optimal System Operation. . . . . . . . . . . . . . . . . . . . 19
System Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Models of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DC-only/Inverter (Automatic Functions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hybrid (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Load Support (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Peak Power Delivery (Manual Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
UPS (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Real-time Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
“Overload” Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Load Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lag Time and Surge Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Scaling and Modifying the AES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PRO-Verter Stacking Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Hub Stacking Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Scaling Energy Storage Capacity Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Equipment Description
PSS-G/RAID System Before AES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PSS-G/RAID with AES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operational Note about Existing UPS in PSS-G AES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AES Equipment Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Information Plates (I-Plates), Faceplates, and Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AES Component Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Li Expander Pak 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PRO-Verter 7000 AGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DC Power Hub 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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PSS-G/RAID Alternative Energy System Deployment Guide
OPERATOR INSTRUCTIONS
AES Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1. Position and Orient System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2. Organize System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3. Connect Expander Paks to Inter-Connect Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4. Connect Expander Paks to PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5. Connect PRO-Verter Power Hub 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6. Assemble PAMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7. Connect PV Panels in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8. Connect PV Array to Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9. Position PV Array for Optimal Orientation and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10. Secure the PV Arrays to the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11. Prepare the MEP-802A TQG for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12. Connect GEN COMM Cable to MEP-802A and PRO-Verter 7000 . . . . . . . . . . . . . . . . . . . . . 53
13. Install and Connect Generator Power Cable to PRO-Verter 7000 . . . . . . . . . . . . . . . . . . . . . 54
14. Verify Settings on MEP-802A for Enabling Auto Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
15. Connect the PSS-G/RAID Tower to PRO-Verter 7000 AGS . . . . . . . . . . . . . . . . . . . . . . . . . 56
16. Activate AES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
17. Set PRO-Verter Clock to Local Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
18. Initialize and Calibrate the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Raising the PSS-G/RAID Tower: PRO-Verter Load Support Function. . . . . . . . . . . . . . . . . . . . . 61
Factors That Affect Load Support Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Faults Associated with Load Support Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PRO-Verter 7000 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Overview to the User Interface Menu Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PRO-Verter Menu Map Color Coding Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Menu Map: Programming and Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FAVS Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CTRL Button Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
METER Button Menus: Read-only Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SETUP Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TECH Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Power Hub User Interface Menu Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Monitoring the Charging Status on Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
“Nuisance” Faults (Non-safety Related). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PRO-Verter 7000 Internal Operation Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Manual Generator Start and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
PRO-Verter Internal Transformer Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
PRO-Verter Monitoring Circuit or Control (LCD) Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Large Fluctuations in Power Flowing through Electrical Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 83
Generator Operating in Short Cycles (Turns On/Off Very Frequently) . . . . . . . . . . . . . . . . . . . . . 83
PRO-Verter Trouble Shooting Quick-links Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PRO-Verter User Interface Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
PRO-Verter Inverter-mode Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inverting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inverter Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

PSS-G/RAID Alternative Energy System Deployment Guide
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No Inverter Comm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Unknown Mode ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
PRO-Verter Charger-mode Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Absorb Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Bulk Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Float Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Charger Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Silent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Secondary Scrolling Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Gen Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Gen Cool Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PRO-Verter Charger Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 89
PRO-Verter Inverter Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
AC Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Breaker Tripped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Dead Batt Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
FET Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
High Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
High Batt Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
High Volts AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Stuck Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Tfmr Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Unknown Fault ##. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
PRO-Verter Internal Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Internal Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Internal Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Internal NTC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Internal Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
PRO-Verter AGS Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
PRO-Verter-to-Generator Communication Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Starting the Generator from the PRO-Verter User Interface . . . . . . . . . . . . . . . . . . . . . . . . 95
AGS Start Statuses Table (Meter 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Start VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
AGS Operational Statuses (Meter 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
AC In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Gen Cooldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Gen Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Manual Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
No Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Quiet Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Resolving AGS Operational Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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PSS-G/RAID Alternative Energy System Deployment Guide
No Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Resolving AGS Faults Using the LCD User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fault Gen Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fault Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Fault VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Fault MaxRn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PRO-Verter Battery Monitoring Kit (BMK) Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 101
PRO-Verter BMK Circuit Operational Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BMK Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Think’n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
###% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Resolving BMK Faults Using the LCD User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Factory Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Unknown Fault ##. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Power-up Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
PRO-Verter Historical Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Auto Generator Start/Stop (AGS) Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Gen Run Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
AGS Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Days Since Gen Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Days Since 100% SOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fault History– Inverter and AGS (Tech 04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Battery Monitor (BMK) Data (Meter 05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
BMK Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Battery SOC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DC Volts-BMK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DC Amps-BMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
AH In/Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Reset AH Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Total AH Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Minimum VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maximum VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Days Since 100% SOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Power Hub–related Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Power Hub Will Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Performance Issues, Causes and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PV Array–related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
No Power from the PV Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Lower Than Expected Voltage from the PV Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Li Expander Pak–related Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Expander Pak Circuit Breakers Tripping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SOC Disparity Among Expander Paks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Restoring SOC Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Method to Restore Expander Pak SOC Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Maintaining SOC Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Method to Maintain Expander Pak SOC Parity using Gen Exercise . . . . . . . . . . . . . . . . . . . 110
Method to Maintain Expander Pak SOC Parity using Gen 100% SOC. . . . . . . . . . . . . . . . . . 111
Energy Storage Modules—Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Terminal (End-of-life) Battery Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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Generator-related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Testing the AGS Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Generator Having Difculty Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Generator Having Difculty Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Generator Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Generator Starts, Then Shuts Down When Load Is Transferred . . . . . . . . . . . . . . . . . . . . . . . 115
Generator Short-cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Generator Fails to Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
RMK-related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
RMK Status Indicator Light Not Illuminated When PRO-Verter Powers Up . . . . . . . . . . . . . . . . . 116
Cannot Communicate with RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Status Light Stays Orange after Inserting USB Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Heat and System Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Causes of Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Keep the System Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Power Hub Overheating and Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Power Hub Temperature Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
PRO-Verter Temperature Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
PRO-Verter High-temp Generator Auto-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Charger Mode: PRO-Verter High-temp Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
MEP-802A Operation in High-altitude and Extreme Climatic Conditions. . . . . . . . . . . . . . . . . . . 121
Li Expander Pak 2400 High Internal Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
MAINTENANCE INSTRUCTIONS
AES Preventive Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Water Intrusion Prevention and Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Locking Component Cases to Prevent Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
AES Prestorage and Breakdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Breaking Down and Repacking the PAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
24VDC Expander Pak 2400 PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
24VDC PRO-Verter 7000 PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
24VDC Power Hub 2400 PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
PV Array PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Maximum Power (Vmp) and Open Circuit Voltages (Voc). . . . . . . . . . . . . . . . . . . . . . . . . 131
Procedure to Measure PV Array Vmp with a Power Hub 2400 . . . . . . . . . . . . . . . . . . . . . . . 131
Navigating the User Interface Menus “View Charge Unit Status” Submenus . . . . . . . . . . . . . . 132
Procedure to Measure PV Array Voc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Procedure to Measure Voc of a Single PV Array Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 133
SUPPORTING INFORMATION
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Temperature Operating Range for Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Temporary Bypass of the AES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Configuring the MEP-802A to Support 120 VAC and 240 VAC Loads Simultaneously . . . . . . . . . . . 137
Monitoring Output Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Reconfiguring AES Components for a 24 VDC Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Spin-lock Inter-Connect Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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PSS-G/RAID Alternative Energy System Deployment Guide
Warranty and Returns
Return Material Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
ABOUT SOLAR STIK, INC.
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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List of Figures
Figure 1. The Solar Stik Alternative Energy System powering a RAID Tower................................................................. 12
Figure 2. PRO-Verter ground lug .................................................................................................................................... 15
Figure 3. AES in operation.............................................................................................................................................. 23
Figure 4. Example-Stacking PRO-Verters ...................................................................................................................... 24
Figure 5. Example-Stacking Power Hubs ...................................................................................................................... 25
Figure 6. Connecting Li Expander Paks using Inter-Connect Strips and Inter-Connect Cables.................................... 25
Figure 7. The PRO-Verter 7000 I-Plate ........................................................................................................................... 30
Figure 8. Expander Pak features .................................................................................................................................... 31
Figure 9. PRO-Verter 7000 AGS features and controls................................................................................................... 32
Figure 10. PRO-Verter 7000 AGS front exterior.............................................................................................................. 33
Figure 11. PRO-Verter 7000 AGS right exterior.............................................................................................................. 33
Figure 12. PRO-Verter 7000 AGS left exterior ................................................................................................................ 34
Figure 13. Power Hub Faceplate description ................................................................................................................. 35
Figure 14. Power Hub front exterior ............................................................................................................................... 35
Figure 15. Power Hub right exterior ............................................................................................................................... 36
Figure 16. Power Hub left exterior.................................................................................................................................. 36
Figure 17. Power Hub rear exterior ................................................................................................................................ 36
Figure 18. Inter-Connect Plug ........................................................................................................................................ 38
Figure 19. AES components and connections ............................................................................................................... 39
Figure 20. Working-space radius for the AES ................................................................................................................ 40
Figure 21. Component arrangement ............................................................................................................................. 41
Figure 22. Connect Expander Paks using Inter-Connect Strips and leashes and stow the Inter-Connect Strips ......... 42
Figure 23. Expander Pak to PRO-Verter 7000 AGS connection .................................................................................... 43
Figure 24. Power Hub 2400 to PRO-Verter 7000 AGS connection ................................................................................ 43
Figure 25. PAM components .......................................................................................................................................... 44
Figure 26. Sandbag (left) and tent stake (right) .............................................................................................................. 44
Figure 27. Unrolling and standing up the PV panel support rack................................................................................... 45
Figure 28. Unfolding and attaching the panels............................................................................................................... 45
Figure 29. Seating the panels from the top down ......................................................................................................... 45
Figure 30. Connecting H4 PV panel leads...................................................................................................................... 46
Figure 31. Connect negative (-) and positive (+) ends of the cables as shown.............................................................. 46
Figure 32. Loose panel lead wires (A) versus tucked and protected wires and connectors (B)..................................... 46
Figure 33. Six (6) PAMs connecting to the solar-only input ports of the Power Hub 2400 ........................................... 47
Figure 34. Connecting PV arrays to the Power Hub 2400 solar-only ports.................................................................... 47
Figure 35. Adjusting PV panel angle .............................................................................................................................. 48
Figure 36. Securing the PV arrays with sandbags.......................................................................................................... 50
Figure 37. Impenetrable surface – twelve (12) sandbags............................................................................................... 50
Figure 38. Securing the PV arrays with tent stakes........................................................................................................ 50
Figure 39. PAMs deployed without ground securing: No stakes and no sandbag ........................................................ 51
Figure 40. Bent or broken U-shaped catches and latches along the side of the panel ................................................. 51
Figure 41. Improvised repair: Panel secured to stand with a bolt .................................................................................. 51
Figure 42. Panel bent and creased................................................................................................................................. 51
Figure 43. Location of generator .................................................................................................................................... 52
Figure 44. Generator berm deployment and re extinguisher........................................................................................ 52
Figure 45. Generator batteries........................................................................................................................................ 52
Figure 46. Oil dipstick location ....................................................................................................................................... 52
Figure 47. Motor coolant ................................................................................................................................................ 52
Figure 48. TQG fuel location........................................................................................................................................... 52

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PSS-G/RAID Alternative Energy System Deployment Guide
Figure 49. GEN COMM cable connection between the PRO-Verter 7000 AGS and the MEP-802A TQG ................... 53
Figure 50. PRO-Verter 7000 AGS to MEP-802A TQG AC power connection ................................................................ 54
Figure 51. MEP-802A control panel ............................................................................................................................... 55
Figure 52. MEP-802A door closed ................................................................................................................................ 55
Figure 53. Power connections from the PRO-Verter 7000 AGS to the PSS-G/RAID Tower ......................................... 56
Figure 54. Li Expander Pak 2400 power switch activation ............................................................................................ 57
Figure 55. PRO-Verter 7000 AGS audible alarm switch ................................................................................................. 57
Figure 56. PRO-Verter Power switch.............................................................................................................................. 57
Figure 57. Set PRO-Verter Clock.................................................................................................................................... 58
Figure 58. Generator status LED ................................................................................................................................... 59
Figure 59. Raising a Tower ............................................................................................................................................. 61
Figure 60. Menu buttons on the LCD user interface ...................................................................................................... 65
Figure 61. Back, Next, and Select buttons..................................................................................................................... 74
Figure 62. Power Hub user interface.............................................................................................................................. 75
Figure 63. 24VDC Li Expander Pak 2400 ..................................................................................................................... 108
Figure 64. PRO-Verter temperature reports from the user interface ............................................................................ 119
Figure 65. Lock Securing the Lid of the Power Hub 2400 ........................................................................................... 124
Figure 66. Packing up the PAMs .................................................................................................................................. 125
Figure 67. Fastener locations on vent shroud (upgraded/new version) ....................................................................... 127
Figure 68. Removed vent shroud to access the louvered vent cover .......................................................................... 127
Figure 69. Replacing PRO-Verter lter (left); cleaning a PRO-Verter lter (right) .......................................................... 128
Figure 70. Removing the Power Hub air intake vent lter for cleaning ........................................................................ 129
Figure 71. View Charge Unit Status submenu navigation ............................................................................................ 132
Figure 72. Procedure to measure PV Array Voc ........................................................................................................... 133
Figure 73. PV array panel positive and negative cables/terminals............................................................................... 133
Figure 74. Case placard ............................................................................................................................................... 134
Figure 75. AES wired to the PSS-G Tower ................................................................................................................... 136
Figure 76. Conguration for temporary bypass of the AES.......................................................................................... 136
Figure 77. TQG 120 and 240 VAC output settings ....................................................................................................... 137
Figure 78. TQG voltage and current gauges ............................................................................................................... 137
Figure 79. AES DC-only conguration.......................................................................................................................... 138
Figure 80. Inter-Connect plug diagram......................................................................................................................... 139
Figure 81. Connector assembly.................................................................................................................................... 139

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List of Tables
Table 1. Terrain Type and Ground-securing Method ...................................................................................................... 50
Table 2. PRO-Verter LED Indicator Status...................................................................................................................... 64
Table 3. Charge Status Indicator—LED Status............................................................................................................... 75
Table 4. List of Faults and Source(s) of Problem............................................................................................................ 82
Table 5. Troubleshooting the User Interface LCD Screen............................................................................................... 85
Table 6. Symptoms and Solutions for the Most Common Power Hub Issues ............................................................. 106
Table 7. Battery Status LED Color and Corresponding Condition ............................................................................... 108
Table 8. 24VDC Li Expander Pak 2400 PCMS ............................................................................................................. 126
Table 9. 24VDC PRO-Verter 5000-120 PMCS.............................................................................................................. 127
Table 10. 24VDC Power Hub 2400 PMCS.................................................................................................................... 129
Table 11. PV Array PMCS............................................................................................................................................. 130
Table 12. Product Weights and Dimensions................................................................................................................. 134
Table 13. Product Operating Temperature Range ........................................................................................................ 134

|11August 2020 |Solar Stik®Inc.
PSS-G/RAID Alternative Energy System Deployment Guide
Revision History
Description Date
First released as Revision 4 Apr 2015
Revision 5 Dec 2015
Revision 6 Apr 2016
Updated Revision 7
• PHS&T to UN3481 from UN3480
• Added Li Expander Pak in-storage maintenance charging interval and
protocol update (PMCS)
• Added RMK LAN images and claried instructions
• Claried PRO-Verter 7000 Load Support Mode
• Updated PRO-Verter 7000 Settings
Sep 2016
Version 8 Updates
• Updated 24VDC Li Expander Pak 2400 Preventive Maintenance Checks and
Service (PMCS) including In-Storage Maintenance Charging Requirements
updates; consolidated PMCS with similar but scattered information on the
24VDC Li Expander Paks
• PRO-Verter 7000 Settings updated to CC/CV charging prole
Nov 2017
Version 9 Updates
• Updated entire manual to current standards and state of understanding
• Removed appendices that represented now-complete component TMs
• Version to be uploaded to web portal for secure, remote download
Apr 2020

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Introduction
Thank you for choosing the Solar Stik®PM EO/IR Alternative Energy System (AES).
“Early adopters” are largely responsible for the success or failure of any new technology as it enters
the marketplace. As such, we value your feedback, as well as any suggestions that you may have.
The Solar Stik AES was specically congured for operation with the PSS-G and RAID platforms for
the PM Electro-Optics/Infrared Payloads and Force Protection (PM EO/IR Payloads FP). However, it
is not limited to the exclusive scope of those applications.
Before setting up, please take the time to thoroughly study this manual. It will make operation easier,
safe, and more productive!
This document is subject to frequent revisions based on user feedback and program ofce
requirements, so please check the revision date to make sure you are using the latest information
available.
Figure 1. The Solar Stik Alternative Energy System powering a RAID Tower
GENERAL INFORMATION, EQUIPMENT DESCRIPTION,
AND THEORY OF OPERATION

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PSS-G/RAID Alternative Energy System Deployment Guide
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.

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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.

|15August 2020 |Solar Stik®Inc.
PSS-G/RAID Alternative Energy System Deployment Guide
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
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.
Figure 2. PRO-Verter ground lug

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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.

|17August 2020 |Solar Stik®Inc.
PSS-G/RAID Alternative Energy System Deployment Guide
Theory of Operation
Introduction to Alternative Energy 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, Alternative Energy System (AES), 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 AES 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
AES
PRO-Verter
Generator Load
Battery
Fuel
Power Generation
Options
PRO-Verter
Battery
Generator Load
Fuel
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.
AES with Open Architecture

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August 2020 |Solar Stik®Inc.18 |
The AES Architecture, Function, and Operation
The Solar Stik AES 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 AES 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 AES
Operating a generator may have signicant cost burdens (logistics, support, etc.). The AES 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 AES is
providing a return on the nancial investment.
All batteries have a cycle life and therefore should be considered the “consumable” part of the AES.
The health of the battery can directly affect the function of the AES 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.

|19August 2020 |Solar Stik®Inc.
PSS-G/RAID Alternative Energy System Deployment Guide
Minimum Battery Capacity Required for Optimal System Operation
The AES 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 AES, 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.
The overall health of the AES can be determined by the amount of cycling that occurs in a 24-hour
period. If the AES 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 state of charge (SOC)
Consult the troubleshooting sections for more details on causes of irregular or excessive cycling.

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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.