Solar Stik 24VDC PRO-VERTER 5000-120 AGS User manual

June 2020 |Solar Stik®, Inc.
OPERATOR MANUAL
FOR
24VDC PRO-VERTER
5000-120 AGS
Updated:20200618 Interactive
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
P/N 20-0104023
Version 1.0

June 2020 |Solar Stik®, Inc.2 |
24VDC PRO-Verter 5000-120 AGS Operator Manual
Contents
GENERAL INFORMATION, THEORY OF OPERATION, AND EQUIPMENT DESCRIPTION
PRO-Verter Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Use of the PRO-Verter in a System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Important Product Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Limitations on Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Theory of Operation
Models of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DC-only/Inverter (automatic functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hybrid (automatic functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Load Support (automatic functions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Peak Power Delivery (manual functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UPS (automatic functions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Selecting a Generator/Grid AC Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The Hybrid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The Load Support Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Peak Power Delivery Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Energy Storage Requirements for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Automatic Generator Start/Stop (AGS) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Testing the AGS Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AGS Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Protection Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EMI Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Circuit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Meter Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Historical Data and Fault Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Equipment Description
The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

|3June 2020 |Solar Stik®, Inc.
24VDC PRO-Verter 5000-120 AGS Operator Manual
The Inter-Connect Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connections and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
The Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Faceplate Features and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Understanding the User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Menus Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Example: How to Navigate the User Interface Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATOR INSTRUCTIONS
Power Up PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Set Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
The AC INPUT Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Setting the AC Input for “Nominal-load” Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Proper Loading and Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
“Overload” Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Load Support Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Lag Times and Surge Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
System-level Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Overview to the User Interface Menu Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Programming Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Menu Map Color Coding Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FAVS Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CTRL Button Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
METER Button Menus: Read-only Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SETUP Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TECH Button Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Quick Links to Statuses, Faults, and Resolutions Reported by the PRO-Verter . . . . . . . . . . . . . . . 46
Quick Links to PRO-Verter Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Quick Links to Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PRO-Verter LCD Screen Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
PRO-Verter Inverter Mode Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PRO-Verter Charge Mode Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PRO-Verter Charger Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 51
PRO-Verter Inverter Problems: Solutions and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . 52
PRO-Verter AGS Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PRO-Verter Battery Monitoring Kit (BMK) Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fault History (Tech 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PRO-Verter: Historical Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PRO-Verter MAINTENANCE
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Spare / Replacement Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Water Intrusion—Prevention and Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SUPPORTING INFORMATION
Restart a System with Overdischarged Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PRO-Verter/Inverter Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Remote Monitoring Kit (RMK; optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

June 2020 |Solar Stik®, Inc.4 |
24VDC PRO-Verter 5000-120 AGS Operator Manual
Section Page(s) Description Date
First published January 2019
Revision History
List of Figures
Figure 1. A PRO-Verter with an HPS ................................................................................................................................ 5
Figure 2. How a PRO-Verter works in a System............................................................................................................... 6
Figure 3. 24VDC PRO-Verter 5000-120 AGS ................................................................................................................... 7
Figure 4. PRO-Verter primary circuits............................................................................................................................. 15
Figure 5. Invert and charge mode LEDs on User Interface ............................................................................................ 19
Figure 6. AGS Status LEDs ............................................................................................................................................ 20
Figure 7. Inter-Connect Plug .......................................................................................................................................... 24
Figure 8. PRO-Verter 5000-120 AGS front exterior......................................................................................................... 25
Figure 9. PRO-Verter 5000-120 AGS left exterior........................................................................................................... 25
Figure 10. PRO-Verter 5000-120 AGS right exterior....................................................................................................... 26
Figure 11. PRO-Verter I-Plate......................................................................................................................................... 26
Figure 12. PRO-Verter Faceplate ................................................................................................................................... 27
Figure 13. LCD user interface......................................................................................................................................... 29
Figure 14. Inverter/Charger ON / OFF Buttons............................................................................................................... 29
Figure 15. PRO-Verter / System Status LEDs ................................................................................................................ 30
Figure 16. User Interface Menu Buttons......................................................................................................................... 31
Figure 17. How to start/stop a generator manually........................................................................................................ 32
Figure 18. Powering up the PRO-Verter ......................................................................................................................... 33
Figure 19. Setting the PRO-Verter clock ........................................................................................................................ 33
Figure 20. Menu buttons on the LCD user interface ...................................................................................................... 37
Figure 21. CC/CV, HOLD CV / CHG VDC charging prole ............................................................................................. 49
Figure 22. Removed vent shroud to access the louvered vent cover ............................................................................ 71
Figure 23. Replacing PRO-Verter lter (left); cleaning a PRO-Verter lter (right) ............................................................ 71
Figure 24. Location of drain plug screws in the PRO-Verter 5000 ................................................................................. 72
Figure 25. PRO-Verter Faceplate.................................................................................................................................... 73
List of Tables
Table 1. LED System Status Indicator Guide ................................................................................................................. 31
Table 2. Troubleshooting the LCD Screen ...................................................................................................................... 48
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ABOUT SOLAR STIK, INC.
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

|5June 2020 |Solar Stik®, Inc.
24VDC PRO-Verter 5000-120 AGS Operator Manual
GENERAL INFORMATION, THEORY OF OPERATION,
AND EQUIPMENT DESCRIPTION
PRO-Verter Introduction
The primary function of a Portable Remote Operation – Inverter/Charger (PRO-Verter) is to serve
as the central power management device in a circuit where both alternating current (AC) and direct
current (DC) are present and being used.
A PRO-Verter is designed specically for operation between energy-storage batteries (DC) and
a fuel-driven generator or utility-grid (AC) power. When being used with a portable fuel-driven
generator and a bank of batteries, it creates a “hybrid” power system (HPS) that allows energy
storage technologies to play a critical role in applications where any combination of the following is
necessary:
• Backup power for critical loads when the primary power source fails
• Reducing generator burdens (fuel consumption, wet-stacking, maintenance, or logistic support)
• Durations of “silent” operation are critical
• Use of renewable power generation is desirable
• Less reliance on grid-utility power is desirable (peak shaving)
• Temporary replacement of inadequate grid or generator power during periods of peak power
demand (peak power delivery)
A PRO-Verter is a modular, portable component of the HPS architecture, and its exible function
and design allows the operator to use it with technologies that collectively meet the specic mission
requirements in an application.
All PRO-Verters are “Plug & Play”-compatible with the Inter-Connect circuit and can be used with
additional PRO-Verters (PRO-Verter “stacking”) when high-power or multiple load voltages are
required.
AC and DC cables for a PRO-Verter are sold separately, as they must be correct for the voltage type
and their current-carrying ability.
Figure 1. A PRO-Verter with an HPS

June 2020 |Solar Stik®, Inc.6 |
24VDC PRO-Verter 5000-120 AGS Operator Manual
Use of the PRO-Verter in a System
The PRO-Verter provides specic capabilities for the system in which it is employed, but systems
vary in accordance with the operator’s requirements; consequently, not every feature in the PRO-
Verter may be used for an application.
The PRO-Verter is delivered fully programmed at the factory for the customer’s system and
application, and only minor programming adjustments are usually needed in the eld.
Most of the features/functions are controlled by programming at the user interface. This manual
provides an overview of the core feature/functions and capabilities of the PRO-Verter along with
a complete overview of the menu options, but there are many functional properties within the
programming menus that are not covered.
The PRO-Verter programming can be easily adjusted for changing conditions. If the system
architecture is altered (changes to system functions) or if the operational environment changes
(climate), programming can be manipulated accordingly.
Please consult the specic System Operator Manual for information on how the PRO-Verter is
programmed for its specic role in a particular system.
PRO-Verter 5000
Li Expander Pak 2400
Solar Arrays 24VDC Power Hub 2400
Grid Power
DC
DC
DC
AC
AC
AC
Loads
Generator
Figure 2. How a PRO-Verter works in a System
PROVERTER 5000

|7June 2020 |Solar Stik®, Inc.
24VDC PRO-Verter 5000-120 AGS Operator Manual
Figure 3. 24VDC PRO-Verter 5000-120 AGS
Shown with AMMPS Auto Generator Start and
Remote Monitoring Kit (Item # 20-0702604)
Important Product Safety Information and Instructions
This manual contains important safety instructions that must be followed during the installation and
operation of the 24VDC PRO-Verter 5000-220 AGS. Read all instructions and safety information
contained in this manual.
While the PRO-Verter is 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 equipment is unattended.
The PRO-Verter is not eld serviceable. If repair is needed, contact your eld service representative
(FSR) for assistance in diagnosis and identication of the proper repair and parts.
Exercise caution when handling or operating equipment. Live power may be present.

June 2020 |Solar Stik®, Inc.8 |
24VDC PRO-Verter 5000-120 AGS Operator Manual
Limitations on Liability
Since the use of this manual and the conditions or methods of operation, use, and maintenance of
this product are beyond the control of Solar Stik, this company does not assume responsibility and
expressly disclaims liability for loss, damage, or expense—whether direct, indirect, consequential, or
incidental—arising out of or anyway connected with such operation, use, or maintenance.
Due to continuous improvements and product updates, the images shown in this manual may not
exactly match the unit purchased.
This equipment CAN BE USED FOR CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER
MEDICAL EQUIPMENT or devices; however, without limiting the generality of the foregoing, Solar
Stik makes no representations or warranties regarding the use of the System in connection with life
support systems or other medical equipment devices.
Safety Information Labels
Your safety and the safety of others is very important.
Always read and obey all safety messages.
This is the safety alert symbol. This symbol alerts you to potential hazards that can kill you or
hurt you and others. All safety messages will follow the safety alert symbol and the word
“DANGER”, “WARNING”, or “CAUTION”. These words are dened as:
DANGER Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of
injury, and tell you what can happen if the instructions are not followed.
WARNING

|9June 2020 |Solar Stik®, Inc.
24VDC PRO-Verter 5000-120 AGS Operator Manual
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 Solar Stik 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.

June 2020 |Solar Stik®, Inc.10 |
24VDC PRO-Verter 5000-120 AGS Operator Manual
Electric Shock Hazard
DON’T LET THIS BE YOU!
HIGH VOLTAGE: System components, solar
arrays, and generators may have lethal line
voltages. Extreme care should be taken to protect
against electrocution.
Always:
• Work with another person in case an
emergency occurs.
• Disconnect power before performing
maintenance.
• Wear safety glasses whenever working on any
part of a System that requires exposure to
mechanical or direct electrical contacts.
WARNING
The 24VDC PRO-Verter 5000-120 AGS is NOT GFCI protected.
WARNING
Standing water around the electrical equipment and/or intrusion of water into the
System components can increase the risk of electrical shock.

|11June 2020 |Solar Stik®, Inc.
24VDC PRO-Verter 5000-120 AGS Operator Manual
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 product.
Water
If outdoor operation is necessary, the lids
of all components should be closed and
latched whenever possible. Lids should only
be open 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 reduce efciency and
life expectancy. Shade products (except PV
arrays) to prevent the negative effects of
extreme heat.

June 2020 |Solar Stik®, Inc.12 |
24VDC PRO-Verter 5000-120 AGS Operator Manual
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 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 run-time 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/Grid AC
output, but less than the Inverter AC output rating.
In the Load Support model, 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/grid AC source during brief/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/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 their SOC.

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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 usually pre-programmed at the factory for use in the application in which it is to
be used. It is possible for the Operator to alter any of the programmed settings 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.
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 to 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. (See
Troubleshooting AC Problems)
Many factors should be considered when selecting a specic 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:
The 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 and PRO-Verter AC)

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The 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 source maximum continuous AC output up to 130%
(i.e., Peak Load AC ≥ Source AC).
The 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 in order for it 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.
A minimum of four (4) energy storage modules (i.e. Expander Paks or Power Paks) must be present
and functioning for the PRO-Verter to be able to operate at its rated power.
DC Voltage
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 that 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, and also affects both historical and real-time performance data.

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24VDC PRO-Verter 5000-120 AGS Operator Manual
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
Support Circuits
• BMK – “Battery Monitor” circuit
• AGS – “Automatic Generator Start/Stop” circuit
Recovery Circuit
• AC-powered System Recovery (overdischarged batteries)
NATO Circuit –
• DC Load or Battery Charging circuit
Both the primary and the support circuit functions of the inverter/charger are managed by native
programming, which can be easily adjusted through settings made at the User Interface.
If the PRO-Verter is connected to an over-discharged battery, the recovery circuit enables the PRO-
Verter to restore the battery to service using a 240 VAC power source such as a generator or grid
utility. This circuit is not programmable and is an Optional Feature.
The NATO port allows connection of a NATO 24V DC circuit to the Hybrid System’s 24V bus. This
can be in support a 24V DC load or to allow charging from an external 24V DC source.
Figure 4. PRO-Verter primary circuits
Charging Inverting
Auto Generator Start/Stop
OR
Loads
Power
Generation
Energy
Storage

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24VDC PRO-Verter 5000-120 AGS Operator Manual
Load Prioritization
The PRO-Verter has a “one-track mind” when it comes to managing power – In every operation
mode 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 state of charge (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. Photovoltaic, 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 the 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 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).
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

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24VDC PRO-Verter 5000-120 AGS Operator Manual
INPUT (FAVS 03) 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 for @ 120 VAC or 13.6 A @ 220 VAC (=3000 Watts).
“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, and once it has been qualied (approximately 15 seconds in duration), the switch engages
and incoming AC power is transferred directly to the load. The PRO-Verter is designed to ensure
that 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 that the 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 other condition based on application requirements.
The transfer switch is directly controlled by the inverter function, but it ONLY reacts to the presence
of incoming AC power from a generator or grid-utility. The switch ensures that 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 inverter function is engaged, the transfer switch is also engaged. The transfer switch is disabled if
the Inverter function is off.
Transfer time between incoming AC and Inverter mode is ~16ms when using 60Hz, which is usually
fast enough to support computers, servers, and other critical loads, however, the “effective” transfer
switch time may be prolonged if the frequency is lower (i.e., 50Hz) and/or if the VAC DROPOUT
(Charger Setup menu) is set too low for the loads to be sustained (the voltage drops below a load’s
minimum voltage requirement AND the transfer switch causes an interruption in AC to the load.
When using the PRO-Verter with critical loads, the VAC DROPOUT should be set to UPS MODE.
The disadvantage of a higher VAC Dropout setting is that smaller generators (or large generators
with an unstable output) may nuisance transfer. This happens commonly when powering loads that
are larger than the generator can handle—causing the generator’s output voltage to constantly fall
below the inverter’s input VAC dropout threshold.
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 invert 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 certain
thresholds, such as the VAC DROPOUT setting.
If the AC waveform itself distorts during operation, it may cause certain PRO-Verter functions to
retard (de-rate) or cease. For example, if the Field Effect Transistors (FETS) and the EMI lter are
pushed beyond their design limits by poor AC power, it may result in a FET OVERLOAD or FET
OVERTEMP faults, 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. During this qualication phase, the
CHARGER (“CHG”) LED will blink rapidly. Once the AC voltage is accepted, the AC transfer relay
closes passing AC power to the load, and then CHARGE function begins, indicated by a steady-on
“CHG” LED at the User Interface, and the LCD will show “CHARGING”.
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.
When entering CHARGE mode, the PRO-Verter uses battery voltage to determine the charging
stage. If the battery voltage is low, the charger begins Bulk charging. If the voltage is high enough,
the charger will skip the Bulk and Absorb charge stages and go directly to Float charging.
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. The “CHG” LED will
blink when this protection is engaged.

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24VDC PRO-Verter 5000-120 AGS Operator Manual
LEDs on the User Interface
indicate when the PRO-Verter
is inverting or charging
Figure 5. Invert and charge mode LEDs on User Interface
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 inverter (“INV”) LED indicator at the User Interface will be steady-on when AC power is
available, while inverting, or in standby.
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
circuit to go into “standby” mode (green INV LED remains on). 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.
Only a manual deactivation of the inverter function will cause the LED to turn off. If the inverter
function is not engaged, then AC power will only be available when the PRO-Verter is connected to
an active AC source, and it is passing power through to the AC load. It is recommended that this
function always remain on.
The inverter circuit has extensive protection circuitry to shut down the inverter under certain fault
conditions. The red FAULT LED will be steady-on and the associated error message will be shown
on the LCD.
Automatic Generator Start/Stop (AGS) Function
The AGS circuit is used to start/stop an external generator, controlling it based on AGS
programming that is made for the application in which the PRO-Verter is being used.
Generator function can be triggered by singular or multiple conditions, including:
• Battery state-of-charge (SOC)
• Time of day
• Peak shaving
• Quiet time

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24VDC PRO-Verter 5000-120 AGS Operator Manual
When the AGS is active during hybrid operation, it might 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 the following information to the
operator:
• The Ready LED indicates when the AGS has power and is ready for normal operation.
• The Status LED indicates when the AGS system is initiating a generator start sequence. This
happens when the Test button (on the AGS) has been pressed and released, or a programmed
condition has triggered the AGS to autostart the generator.
Blinking green LED indicates that the generator start sequence has begun.
Steady-on green LED Indicates the generator has started successfully and is providing the
Gen Run sense signal/voltage to the AGS module.
Steady-on RED LED Indicates a fault condition in which the generator either has not
started, or has not provided the correct run gen sense signal/voltage to the AGS module –
after four (4) start attempts
• See also Table 1.
Testing the AGS Function
There is a red AGS TEST button at the AGS interface that can be used to conrm that all wiring
from the generator to the AGS module is correct and the AGS circuit is congured correctly for a
particular generator. When pressed, the STATUS LED on the AGS module will blink green indicating
the AGS has initiated an automatic generator start/stop sequence.
Once the generator starts, view the STATUS LED and ensure it turns solid green (indicating the
generator has started successfully and is providing the gen run sense signal to the AGS module). It
should run for approximately 30-60 seconds before automatically turning off.
AGS Audible Alarm
The PRO-Verter has an audible warning that signals the generator has initiated the autostart
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.
Figure 6. AGS Status LEDs