Solar Stik G-BOSS E LIGHT User manual

|1December 2020 |Solar Stik®, Inc. PRELIMINARY
SYSTEM SETUP, OPERATION AND
MAINTENANCE MANUAL
FOR THE SOLAR STIK
G-BOSS E LIGHT
HYBRID POWER SYSTEM
Version 1.0
Updated:20201209
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

December 2020 |Solar Stik®, Inc.2 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Contents
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
Introduction to Hybrid Power Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
The HPS Flexible Open Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Important Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electric Shock Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grounding the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dust/Foreign Object Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Theory of Operation
Models of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DC-only/Inverter (Automatic Functions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hybrid (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Peak Power Delivery (Manual Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UPS (Automatic Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The HPS Architecture, Function, and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Energy Storage—The Foundation of the HPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Minimum Battery Capacity Required for Optimal System Operation . . . . . . . . . . . . . . . . . . . . . . 14
System Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Load Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Real-time Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
“Overload” Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Scaling and Modifying the HPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PRO-Verter Stacking Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Hub Stacking Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Scaling Energy Storage Capacity Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Equipment Description
The Inter-Connect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
The Standard Inter-Connect Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
24 VDC Power Distribution Module (PDM) 3000 Description . . . . . . . . . . . . . . . . . . . . . . . . . 21
PDM Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PDM Information Plate (I-Plate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
24VDC Power Hub 3500 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Hub Connection Ports and Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Hub Internal Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power Hub I-Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power Hub Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PRO-Verter S 3000 AGS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PRO-Verter Connection Ports and Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PRO-Verter Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

|3December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
PRO-Verter I-Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATOR INSTRUCTIONS
1. Identify Location for System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
a. Component Shading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
b. Minimize Potential for Water and Dust Intrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. Connect System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
G-BOSS E Light System Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inventory: Light System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
a. Connect PRO-Verter to Energy Storage Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
b. Connect PRO-Verter to AC Power Source(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compatible Generator Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
c. Connect PRO-Verter to Generator Comms Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
i. MEP-802A and MEP-831 TQG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ii. Defender 1 kW and Ranger 2 kW MPGs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
How to Connect two (2) MPGs in parallel to the PRO-Verter . . . . . . . . . . . . . . . . . . . . . . . . 39
d. Connect PRO-Verter to Power Hub 3500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
e. Connect Power Hub 3500 to PDM 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
f. Connect PDM 3000 to PDU and Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
g. Connect PV arrays to Power Hub 3500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
h. Secure PV Arrays to the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
i. Connect PRO-Verter to 120 VAC Loads (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
j. Connect Loads Requiring Regulated 28 VDC Output (Optional) . . . . . . . . . . . . . . . . . . . . . . . 45
k. Connect PV Array(s) to PRO-Verter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3. System Activation and Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
a. Activate the HPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
b. Set PRO-Verter Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
c. Program PRO-Verter to Match AC Source Output Current. . . . . . . . . . . . . . . . . . . . . . . . . . 48
Recommended generator AC Input Settings and Loads . . . . . . . . . . . . . . . . . . . . . . . . . . 48
d. Initiate System Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
What to watch for as the System is starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Generator Control Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4. PDM 3000: PDU and/or Tower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
System Deactivation
PRO-Verter Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Monitor System Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
User Interfaces and Settings
Operating the PRO-Verter User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
PRO-Verter Status and Alarm LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PRO-Verter Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Navigating “Select Group” and “Select Parameter” Menu Maps . . . . . . . . . . . . . . . . . . . . . . . 55
Parameter Groups: PRO-Verter Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Charge Curve Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Input Setting Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Input Low Limit Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input High Limit Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Other Functions Programmable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PRO-Verter Clock Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

December 2020 |Solar Stik®, Inc.4 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Stop SD Card Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Saving/Uploading Programmed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Saving Programmed PRO-Verter Parameters to SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Uploading Saved PRO-Verter Parameters from SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
PRO-Verter S 3000 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Data Log Files: Viewing Data Log Files Using Excel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
The Power Hub 3500 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Pages Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Menu Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Device List: Power Hub Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Monitoring PV Power: Current and Historical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PV Power: Understanding Reported Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Monitoring System Batteries: Current and Historical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Heat and Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Causes of Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Power Hub Internal Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Power Hub Internal Temperature Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Power Hub User Interface Settings Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TROUBLESHOOTING PROCEDURES
PRO-Verter/System Troubleshooting
Generator Fault/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Clearing PRO-Verter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
System Recovery with Overdischarged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PRO-Verter Fault Messages and Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Power Hub 3500 Troubleshooting Procedures
Power Hub Will Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Performance Issues, Causes, and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Power Hub 3500 Data Logging and Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Performance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Data Storage and Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
MicroSD Card Formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Power Hub Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Solar Charge Controller Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
MAINTENANCE INSTRUCTIONS
24VDC PRO-Verter S 3000 PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
PRO-Verter Filter Removal and Cleaning or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
24VDC Power Hub 3500 PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Power Hub Filter Removal and Cleaning or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
PDM 3000 PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Locking Component Cases to Prevent Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Transporting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Warranty and Returns
Return Material Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ABOUT SOLAR STIK, INC.
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

|5December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
List of Figures
Figure 1. PRO-Verter grounding lug ............................................................................................................................... 10
Figure 2. Example-Stacking PRO-Verters ..................................................................................................................... 17
Figure 3. Example-Stacking Power Hubs ...................................................................................................................... 18
Figure 4. Connecting Li Expander Paks using Inter-Connect Strips and Inter-Connect Cables.................................... 18
Figure 5. Inter-Connect Plug .......................................................................................................................................... 20
Figure 6. PDM front ........................................................................................................................................................ 21
Figure 7. PDM left side ................................................................................................................................................... 21
Figure 8. PDM right side................................................................................................................................................. 22
Figure 9. PDM bottom .................................................................................................................................................... 22
Figure 10. PDM top, I-Plate, specs, and cautions.......................................................................................................... 23
Figure 11. Overview of Power Hub connections ............................................................................................................ 24
Figure 12. Power Hub front—DC output and communications...................................................................................... 24
Figure 13. Power Hub right side—Regulated 24 VDC input and NATO connector........................................................ 25
Figure 14. Power Hub left side—Solar-only ports .......................................................................................................... 25
Figure 15. Power Hub rear side—Air intake vent ........................................................................................................... 26
Figure 16. Power Hub I-Plate ......................................................................................................................................... 26
Figure 17. Power Hub Faceplate.................................................................................................................................... 27
Figure 18. PRO-Verter front side .................................................................................................................................... 28
Figure 19. PRO-Verter rear side...................................................................................................................................... 28
Figure 20. PRO-Verter right side..................................................................................................................................... 29
Figure 21. PRO-Verter left side....................................................................................................................................... 29
Figure 22. PRO-Verter Faceplate features...................................................................................................................... 30
Figure 23. PRO-Verter I-Plate ......................................................................................................................................... 32
Figure 24. Working-space distance for the PV Array and the PRO-Verter ..................................................................... 33
Figure 25. G-BOSS E Light connection diagram and kit inventory................................................................................ 34
Figure 26. PRO-Verter to ESM connections for G-BOSS E Light .................................................................................. 35
Figure 27. PRO-Verter(s) to AC power input connections.............................................................................................. 36
Figure 28. Compatible generator options....................................................................................................................... 36
Figure 29. MEP-831A and MEP-802A Gen Comm Cable connections ......................................................................... 37
Figure 30. Defender 1 kW and Ranger 2 kW Gen Comm Cable connections ............................................................... 38
Figure 31. Connecting two 1 kW generators in parallel with the “Y” AC power cable................................................... 39
Figure 32. PRO-Verter to Power Hub connection .......................................................................................................... 40
Figure 33. Power Hub to PDM connection..................................................................................................................... 41
Figure 34. PDM to tower and PDU connections ............................................................................................................ 42
Figure 35. Connect PV arrays to Power Hub.................................................................................................................. 43
Figure 36. PRO-Verter AC power output ports............................................................................................................... 45
Figure 37. PRO-Verter Regulated DC power output port............................................................................................... 45
Figure 38. PV array to PRO-Verter connection............................................................................................................... 46
Figure 39. PRO-Verter Power specications for PV arrays ............................................................................................ 46
Figure 40. Generator Mode Control Switches and LEDs ............................................................................................... 49
Figure 41. System metrics available in standby, charging and inverting modes............................................................ 52
Figure 42. PRO-Verter user interface power and navigation buttons............................................................................. 53
Figure 43. PRO-Verter S 3000 user interface ................................................................................................................. 54
Figure 44. LCD user interface and navigation guide ...................................................................................................... 66
Figure 45. Data views displayed in “Pages”................................................................................................................... 66
Figure 46. Device list on user interface .......................................................................................................................... 67

December 2020 |Solar Stik®, Inc.6 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
List of Tables
Table 1. AC Power input settings for generators............................................................................................................ 48
Table 2. Operating Modes: Descriptions ........................................................................................................................ 51
Table 3. User Interface LED Indicators ........................................................................................................................... 54
Table 4. Programmable Parameter Groups: Descriptions .............................................................................................. 56
Table 5. Parameters for Battery Charging/Battery Protection ........................................................................................ 57
Table 6. Parameters for Grid/Generator Input Current Level, Frequency Range ........................................................... 58
Table 7. Parameters for Grid/Generator Input Low Voltage Level .................................................................................. 59
Table 8. Parameters for Grid/Generator Input High Voltage Level ................................................................................. 59
Table 9. Power Saving/Alarm/Remote Switch/Multi-function Relay/etc. ....................................................................... 60
Table 10. Local Time Clock Setting ................................................................................................................................ 60
Table 11. Instructions to Remove SD Card from PRO-Verter User Interface ................................................................. 60
Table 12. Fault Messages Symptoms and Troubleshooting........................................................................................... 74
Table 13. Symptoms and Solutions for the Most Common Power Hub Issues ............................................................. 78
Table 14. 24VDC PRO-Verter S 3000-120 PMCS........................................................................................................... 85
Table 15. 24VDC Power Hub 2400 PMCS...................................................................................................................... 87
Table 16. PDM 3000 PMCS............................................................................................................................................ 88
Revision History
Section Page(s) Description Date
First released as a PRELIMINARY DRAFT January 2020
Figure 47. Power Hub internal temperature report on user interface............................................................................. 70
Figure 48. Micro SD card port location .......................................................................................................................... 80
Figure 49. Fastener locations on vent shroud (upgraded/new version) ......................................................................... 85
Figure 50. Removed vent shroud to access the louvered vent cover ............................................................................ 85
Figure 51. Replacing PRO-Verter lter (left); cleaning a PRO-Verter lter (right)............................................................ 86
Figure 52. Cleaning the air intake lter ........................................................................................................................... 87
Figure 53. PDM 3000 bottom side ................................................................................................................................. 88
Figure 54. Steel-reinforced padlock holes...................................................................................................................... 89
Figure 55. Lock securing Power Hub lid ........................................................................................................................ 89
Figure 56. Component transportation—Wheels and handles ........................................................................................ 90

|7December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
GENERAL INFORMATION, EQUIPMENT DESCRIPTION,
AND THEORY OF OPERATION
Introduction to Hybrid Power Systems
When a portable fuel-driven power generator is the primary source of power for an application, it
must operate continuously to provide electricity to the load, even if the power requirements of
connected loads are minimal or intermittent. Fuel energy is wasted in the production of electricity
because neither the generator nor the load(s) can fully use the fuel’s potential energy. This traditional
power model is a low-efciency system.
In the high-efciency, Hybrid Power System (HPS), a battery bank supports the load. The power
for the load is drawn from the batteries only as needed. Multiple sources of power generation can
be used simultaneously to support the battery and ensure uninterrupted power to the loads. The
battery becomes the foundation of the HPS and the architecture is opened to allow multiple
technologies to operate in concert.
Generator Load
Fuel
Low-efciency
Traditional Power System
High-efciency
HPS
PRO-Verter
Generator Load
Battery
Fuel
The HPS Flexible Open Architecture
The System is comprised of modular components that integrate into a exible architecture that is
congured for an application’s specic mission requirements. If the application changes, the modular
System architecture can be modied or scaled to meet the new requirements.
Power Generation
Options
PRO-Verter
Battery
Generator Load
Fuel
HPS with Open Architecture
The introductory parts of this Manual describe Hybrid Power Systems (HPS) composed of Solar
Stik components. However, the Solar Stik architecture is modular and open allowing Operators to
integrate non-Solar Stik components as part of a HPS solution. Please contact Solar Stik Technical
Support for assistance in optimizing the integration of other components into a Solar Stik HPS.

December 2020 |Solar Stik®, Inc.8 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Important Safety Information and Instructions
This manual contains important instructions that must be followed during the installation and
operation of the System. Read all instructions and information contained in this manual.
Thoroughly read and understand the operator manual for each of the components in this System
PRIOR to assembly and use of this System. Important information regarding the safe setup and use
of each component and this System is contained in each of the operator manuals. DO NOT begin
assembly or use of this System without rst reading and understanding the individual operator
manuals.
While the System components are designed for indoor/outdoor operation, the user interface (control
panels) must not be exposed to rain, snow, moisture, or liquids. Close and latch and/or lock the
cases when the components are unattended.
Exercise caution when handling or operating the System. Live power may be present.
Safety Information Labels
Your safety and the safety of others is very important.
Many important safety messages have been provided in this manual and directly on the System
components. Always read and obey all safety messages.
This is the safety alert symbol. This symbol is an alert to potential hazards that can cause
death or injury. All safety messages will follow the safety alert symbol and the word
“DANGER”, “WARNING”, or “CAUTION”. These words are dened as:
DANGER Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
All safety messages will describe what the potential hazard is, how to reduce the chance of injury,
and what can happen if the instructions are not followed.

|9December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Fire Hazard
Fire Types
Class A fire - Fires in ordinary combustibles such as wood, paper, cloth, trash, and plastics.
Class B fire - Fires in ammable liquids such as gasoline, petroleum, oil, and paint.
Class C fire - Fires involving energized electrical equipment such as motors, transformers, and
appliances. Remove the power source and the class C re becomes a class A or B re.
Recommended Fire Extinguisher
NSN 4210-00-288-7219 Fire Extinguisher, Carbon Dioxide, 10 lb
Carbon dioxide is a liqueed gas, which is highly effective ghting class B and C res. These
extinguishers are ideal for areas where contamination and/or cleanup are a concern, such as data
processing centers, labs, and telecommunication rooms.
Using the Fire Extinguisher
When using the extinguisher on a re, remember PASS:
Pull the pin.
Aim the nozzle or hose at the base of the re from a safe distance.
Squeeze the operating lever to discharge the re extinguishing agent.
Sweep the nozzle or hose from side to side until the re is out. Move forward or around the re as
the re diminishes.
Watch the area for reignition until the cause has been xed.
Use Sweeping Motion
WARNING
Only CO2(carbon dioxide) re extinguishers should
be used with this equipment.
These additional cautionary steps will ensure
your safety:
• System components should not be operated in
standing water.
• Close and latch the component lids if it is
precipitating.
• System cables should not be routed through
standing water.
• Cable connections should remain dry.
• Unused ports on System components should
be covered when not in use to reduce the
possibility of water intrusion.

December 2020 |Solar Stik®, Inc.10 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Grounding the PRO-Verter at the grounding lug is an important
safety measure. The PRO-Verter and the generator (if included)
should be bonded to an earth grounding rod. When the
generator is running, the AC neutral and equipment ground
automatically are bonded internally at the generator. When
running off battery, the AC neutral and equipment ground are
automatically bonded internally at the PRO-Verter.
If the System is ever connected to grid power, the AC neutral
must be bonded to the earth ground at the main breaker panel
of the grid power. Any generator connected to the System must
have a neutral-to-ground bond.
Grounding the System
PRO-Verter Grounding Lug
Figure 1. PRO-Verter grounding lug
Electric Shock Hazard
WARNING
Standing water around the electrical equipment and/or intrusion of water into the System
components can increase the risk of electrical shock.
DON’T LET THIS BE YOU!
HIGH VOLTAGE: System components, PV
arrays, and generators may produce lethal
line voltages. Extreme care should be taken
to protect against electrocution. Always work
with another person in case an emergency
occurs. Disconnect power before performing
maintenance. Wear safety glasses whenever
working on any part of a system that requires
exposure to mechanical or direct electrical
contacts.
WARNING
The System is NOT GFCI protected.

|11December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Environmental and Handling Precautions
All Solar Stik components are ruggedized, yet there are a few things the operator can do to prevent
failures and prolong the operational life of the Solar Stik System.
Wind
It is imperative to properly secure the PV
panels to the ground using sandbags so they
do not become dangerous projectiles in high
winds.
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.

December 2020 |Solar Stik®, Inc.12 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Theory of Operation
Models of Operation
Depending on the application, there are several operational models that can be congured using a
PRO-Verter.
Note: The PRO-Verter settings used in each model of operation are unique and not
interchangeable. The PRO-Verter must be programmed specically for the model of operation in
which the System is functioning. Damage to System components may occur if a PRO-Verter is
not properly programmed for the model of operation in which the System is functioning.
DC-only/Inverter (Automatic Functions)
Operating conditions: All power generated is from DC generators, and AC loads are supported by
the PRO-Verter’s Inverter function using energy stored in batteries.
Hybrid (Automatic Functions)
Operating conditions: The “Continuous Load” AC power requirement is LESS than the individual
Inverter or Generator/Grid AC power output ratings.
In the Hybrid model, the PRO-Verter serves as the primary power management device in a System,
using either inverter AC power or generator/grid AC power to maintain the load. In the Hybrid
Model, the batteries will cycle regularly to mitigate generator runtime and logistical support often
associated with operation in remote locations. Hybrid systems also provide the operator with a
exible architecture that allows for the addition of multiple power sources, such as renewable power
generation.
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 state of charge (SOC).

|13December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
UPS (Automatic Functions)
Operating conditions: A PRO-Verter connects critical AC loads directly to grid utility or prime AC
power when it is available, and provides backup power for the load by supplying inverter AC (using
energy from a connected battery bank) when the grid utility or prime AC source is interrupted.
In the UPS Model, “peak shaving” and the use of renewable power sources are also possible by
connecting a Power Hub.
Note about PRO-Verter Model Programming: The PRO-Verter is programmed at the factory for
use in the application in which it is to be used. It is possible for the Operator to alter any of the
programmed settings when operating conditions change and/or System architecture changes are
necessary. To learn more, contact Solar Stik Technical Support.
The HPS Architecture, Function, and Operation
The Solar Stik Hybrid Power System (HPS) incorporates three technologies that comprise a network:
• Energy storage
• Power management
• Power generation
The PRO-Verter, Power Hub, and Expander Paks are designed to operate in concert and provide
uninterrupted pure sine wave AC and DC power to the loads. It is a powerful solution for the
following conditions:
1. The generator requires protection from adverse operating conditions.
2. Grid or generator AC power sources are not present or only intermittently available.
3. Power requirements for the load may exceed an existing power source’s daily power output,
requiring multiple power sources to operate in concert to meet the daily demand
4. The reduction of fuel-driven generator “runtime” is necessary, due to logistics concerns or to
simply to reduce the cost burdens of operating a generator.
It is important to follow two rules when conguring power generation and energy storage
technologies to serve in an application:
1. The power generated over 24 hours must be greater than or equal to the power consumed
2. The energy storage capacity must be able to power the load over 24 hours (with no recharging)
Energy Storage—The Foundation of the HPS
Operating a generator may have signicant cost burdens (logistics, support, etc.). The HPS alleviates
those cost burdens by redirecting the nancial investment into a battery-based platform.
Batteries in a hybrid system are designed to “cycle”. A full cycle is dened as one complete
discharge and recharge over a specic period of time. With every cycle that occurs, the HPS is
providing a return on the nancial investment.

December 2020 |Solar Stik®, Inc.14 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
All batteries have a cycle life and therefore should be considered the “consumable” part of the HPS.
The health of the battery can directly affect the function of the HPS over time, so proper cycling and
cell-health management practices are strongly encouraged.
See additional information about the Expander Paks: Energy Storage Modules – Supplemental
Information.
Minimum Battery Capacity Required for Optimal System Operation
A HPS will function most efciently when proper balance is achieved within the System’s architecture
(Energy Storage, Power Management, and Power Generation). The central power management
device is the PRO-Verter, so any components that are connected to it need to be rated for the
amount of power that will be processed by it.
For example, the PRO-Verters can require extremely high current (amperage) from the battery bank
when AC loads require power from the inverter, but it can also push high current into the bank when
it is in charge mode.
Each Expander Pak has a built-in circuit breaker that will trip at a value less than the maximum rated
current to/from the PRO-Verter. For this reason, multiple Expander Paks must be connected to a
PRO-Verter for the System to function at its rated power. The combined values of the Expander
Pak circuit breakers must be greater than the rated inverter/charger current required from the
PRO-Verter.
In the HPS, the PRO-Verter 5000 inverter can require up to 200 A from the batteries, and the charger
has a rated output of 110 A. Four (4) 24VDC Expander Paks is the MINIMUM number required to
support the inverter’s full inverter output and be charged effectively and safely when the PRO-Verter
5000 is in charge mode.
Connecting an insufcient number of Expander Paks (energy storage modules, or ESMs) to a PRO-
Verter will result in a situation where the batteries are charged or discharged too quickly:
• Charging LiFePO4Expander Paks too quickly may result in an articially high battery voltage
reading and signal the PRO-Verter to turn off the generator before the batteries are actually
charged sufciently.
• Discharging LiFePO4Expander Paks too quickly may cause the battery temperature to rise to
a point that the battery management system (BMS) disconnects the batteries from the whole
System.
Refer to the “Minimum Battery Capacity Recommendations” on the PRO-Verter I-Plate to ensure
trouble-free operation.
System Cycling
During normal operation, the generator runs only to charge the ESMs and support the load while
doing so; the batteries and generator will cycle 1–2 times daily.

|15December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Load Prioritization
When the HPS is fully functioning, providing power to the load is always prioritized over other functions.
If renewable DC generators (i.e., PV arrays, wind, etc.) are producing power, it is immediately directed to
to the load once it ows into the HPS. The batteries will ONLY begin to charge once the DC generation
exceeds the demand from the load.
During periods of peak renewable DC generation, it may be exclusively used to support the load while
excess energy charges the batteries simultaneously. This function reduces the demand on the batteries,
prolongs battery-operation time, and promotes healthy cycling of the battery.
This same function also occurs when the HPS is connected to an AC source. If the HPS is connected to
an active generator or grid-utility, the load is always supported FIRST before any AC is used for charging
the HPS batteries. If the PRO-Verter is controlling a connected generator and the battery bank reaches
a low SOC, the PRO-Verter can be programmed to auto-start the generator to keep AC owing to the
load,charging the connected batteries only after the load is fully supported by the generator.
Real-time Load Management
When connected to an active AC source, the PRO-Verter can automatically adjust (in real time) its battery
charging rate to keep the total load value under the AC INPUT setting value.
If the load is dynamic, the PRO-Verter can make immediate adjustments and keep the total load on the
AC source from exceeding the value of the AC INPUT setting while still maintaining a 100% load at the
external AC source (generator or grid utility).
It is incumbent on the Operator to ensure the sum of all loads does not exceed the limit of the AC source
(generator or grid-utility) or the connections or circuit protections in the network. The AC INPUT (FAVS
03) setting should be set to the same value of the maximum AC output rating of the source. For example,
if the generator is rated for 3000 W continuous output, then the AC INPUT should be set for 25 Amps*
(25 A @ 120 VAC = 3000 W)
*See Lag Times and Surge Rates
The overall health of the HPS can be determined by the amount of cycling that occurs in a 24-hour
period. If the HPS cycles more than twice daily, or is experiencing irregular cycling, there are several
factors that may be causing it:
• Excessive load
• Inadequate battery capacity
• Heat-derated performance
• Disparity in battery SOC
Consult the troubleshooting sections for more details on causes of irregular or excessive cycling.

December 2020 |Solar Stik®, Inc.16 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
“Overload” Conditions
Overloading of the System can occur under the following conditions:
• Load AC power demand is greater than the inverter’s rated output.
• Load AC and DC power demand is greater than the connected AC source (generator or grid/
utility).
• Load AC power demand is greater than the AC INPUT setting, which may cause the PRO-Verter
to disconnect from the AC source when in pass-through (charging) mode.
• Load AC and DC power demand is greater than the output of the connected AC source
(generator or grid utility), causing it to shut down.
In each of these scenarios, the solution is simply a reduction in the total load demand (AC and DC).
Use the AC and DC METERS to conrm the load is reduced to prescribed levels and proceed with
normal operation.

|17December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Scaling and Modifying the HPS
When expanding or modifying the HPS architecture, scaling and stacking may be used to provide
additional capabilities that may exceed the ability of any one component to handle.
Scaling
• Power generation and energy storage can be modied in accordance with changes in load
requirements. Additional generation sources should be selected based on availability of
resources, logistics and the local environment (fuel-driven generator, wind, fuel cell, etc.).
• Additional energy storage modules can be of a different form factor but must be of the same
chemistry and voltage and have compatible charge and discharge current capabilities etc.
Stacking
• Capabilities can be added (or removed), including advanced power distribution and management
modules, stacking of generators with PRO-Verters, Power Hubs and more.
Consult the individual product manuals for additional information about scaling and stacking.
Note: When scaling or modifying the HPS architecture, it should be done so with all components in
the HPS completely inactive and OFF. The Initialization and Calibration step must be repeated once
the modications have been made.
PRO-Verter Stacking Example
Stacking PRO-Verters, of the same or different types, provides a mechanism to power a wide variety
of AC loads from the same system. The dashed-line box surrounds the stacked PRO-Verters.
Figure 2. Example-Stacking PRO-Verters
PRO-Verter
7000-120 AGS
Inter-Connect Strip
Inter-Connect Strip
Communication Cable
Generator AC Power Cable
Li Expander Pak 2400
(x5)
Li Expander Pak 2400
(x5)
Legend
DC Solar Circuit
Inter-Connect
AC Load Circuit
AC Supply Power Cord
Communication Cable
direction of flow energy or comm
PRO-Verter
5000-220
120 VAC
Loads
220 VAC
Loads

December 2020 |Solar Stik®, Inc.18 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
PV Array (x6)
Figure 3. Example-Stacking Power Hubs
PV Array (x6)
Power Hub
Power Hub
Legend
DC Solar Circuit
Inter-Connect
direction of flow energy or comm
PRO-Verter
Power Hub Stacking Example
Stacking Power Hubs, of the same or different types, provides a mechanism to add DC power
sources to a system. The dashed-line box surrounds the stacked Power Hubs.
Scaling Energy Storage Capacity Example
Plug & Play architecture allows expansion or contraction of battery capacity when conditions
warrant.
Use Inter-Connect Strips and Inter-Connect Cables to create a “bank” of Li Expander Paks (Figure
26). Note: Do not mix battery chemistries in a System battery bank.
If a System needs to be downsized, due either to reductions in the load or simply to reallocate
energy storage resources to other locations, then Li Expander Paks can be removed from service in
accordance with reductions in runtime requirements.
Figure 4. Connecting Li Expander Paks using Inter-Connect Strips and Inter-Connect Cables
24VDC PRO-Verter
Inter-Connect Strip 7
24VDC Li Expander Pak 2400s
24VDC Li Expander
Pak 1300s
Inter-Connect Cables

|19December 2020 |Solar Stik®, Inc.
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Equipment Description
The Inter-Connect System
The System is comprised of three (3) distinct types of technologies:
• Energy storage
• Power management
• Power generation
All of the individual components that operate in these categories utilize a unique connection
architecture known as the Inter-Connect Circuit.
The Inter-Connect Circuit is the connection framework of the System’s DC power network. It uses
a simple, polarized, locking connection that is common throughout the architecture. All power
management, energy storage, and power generation components are compatible with the Inter-
Connect Circuit.
Using a common, polarized connector allows rapid “Plug & Play” scaling of components, adaptation
of capabilities within the architecture, technology refreshment, and swapping of components when
conditions warrant. It also ensures that there is no unsafe way to make connections.
Circuit Breaker Protections
The Inter-Connect network is protected from overloads and short circuits through a network of circuit
breakers strategically placed throughout the circuit. It ensures the potential for a reverse polarity
connection within the circuit is minimized. If a problem occurs in a leg of the Inter-Connect Circuit,
the affected leg will disconnect from the primary network, leaving the other circuits functioning. If a
major failure occurs in the circuit, then the entire network will shut down for System and Operator
protection.
Operate with Voltage
The Inter-Connect Circuit communicates simple battery voltage to all components on the network,
allowing them to independently coordinate their respective functions. Battery voltage is used to
trigger actions such as Automatic Generator Start/Stop (AGS) function, power distribution timing,
and more. Therefore, the proper setup of the Inter-Connect Circuit is critical to properly communicate
voltage to all points in the System and to ensure all of the components operate together to provide
seamless power to the load.
Optimize with Data
Data collection for a System occurs through the Inter-Connect network. Power management devices
such as Power Hubs and PRO-Verters meter voltage, current and time through the circuit, providing
critical real-time data the operator can use to troubleshoot and verify System performance. Data
collection enables programming/architectural changes to optimize performance based on evolving
conditions.

December 2020 |Solar Stik®, Inc.20 |
System Setup and Operation Manual for the Solar Stik G-BOSS E Light HPS
PRELIMINARY
Figure 5. Inter-Connect Plug
The Standard Inter-Connect Plug
• Polarized
• 200 A maximum current
• 24 VDC connection only
• Mechanically “locks” into place
• Rotate knob clockwise to lock,
counterclockwise to release
• Can be repaired or modied in the eld