Solar Stik BOS 2000-120 Manual de usuario

Setup, Operation, and Maintenance Manual

for the

24VDC Li BOS 2000-120

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

SS20230123

P/N: 20-0205200

BOS 2000-120 Electrical Circuits

120 VAC circuits

Unregulated DC power input

24 VDC bus circuit

24.4–30 VDC IN/OUT

(battery expansion)

120 VAC

OUTPUT x 2

9–36 VDC INPUT

100–240 VAC INPUT

Solar Power INPUT

20 A

100 A

30 A

100 A

Solar

Charge

Controller

580 W

*30.0 V

Battery

Charger

600 W

*29.0 V

9-36VDC

Battery Charger

200 W

*28.8 V

Inverter

DC>120 VAC

2000 W

24V LiFePO4Battery

2100 Wh

24.4–30 VDC

OUTPUT

DC bus

20 A

30 A

15 A

Circuit breaker location

LED circuit activity indicator

54321

6 7

* Programmed battery charging voltage

BOS Electrical/Power Connections and Ventilation

24 VDC

30 A

~720 W

Front

Left

Right

100–240 VAC, 50-60 Hz

15 A max

600 W max

24.4–30 VDC

100 A max

3000 W max

9–36 VDC

20 A max

200 W max

33–100 VDC

30 A max

580 W max

DATA: CAN data and

comms from internal

battery.

GEN COMM: BOS control

of generator auto

start/stop.

Custom cables required.

Solar Input: Pin A (-), Pin C (+), Pin B (unused)

9–36 VDC Input: Pin A (-), Pin C (+), Pins B & D

(unused)

120 VAC

20 A

2400 W Max combined

Power Output

Power Input

Power Input/Output Data and Comms

24 VDC Output: Pin A (+), Pin B (-), Pin C

(unused)

DC output voltage is equal to DC bus voltage.

I = Air intake (vent has ﬁlter); E = Air exhaust (vent has no ﬁlter)

A. BOS setup and operation instructions,

Comm port information and operational

considerations

B. Operational specications. Provides limits

for AC and DC BOS circuits and internal

battery specications.

C. 5 VDC USB charging ports (x2) do not

transmit data (for device charging only).

D. AGS Alarm provides audible warning of

pending generator start. Alarm may be

silenced.

E. Internal battery status display reports battery

voltage, current (A), state of charge, status

(fault or OK), date, and time of day.

F. Battery status display refresh toggle switch

G. Breaker switch panel and circuit-activity

LEDs. See BOS 2000-120 Electrical Circuits

(page 2) for details.

H. Generator auto start/stop and manual-run

switch

I. The Tech ports provides programming

access to generator auto start/stop circuit.

Contact Solar Stik for further information.

J. Operational safety information

K. QR Code that links to this document

D E F

BOS 2000-120 Faceplate

Critical information on BOS setup, operation, and monitoring is provided

directly on the BOS Faceplate.

Operation Instructions

1. Ensure all breakers are OFF before connecting anything to

BOS.

2. Connect peripherals to be used as part of System (e.g.,

grid power, solar array, Novatio 1 or 2 kW generator, AC

and/or DC loads).

Note: Do not exceed load limits listed in Faceplate

Specications and elsewhere in this document.

3. Turn on BATTERY breaker to activate the BOS.

Note: BATTERY breaker must be ON for BOS to operate

properly.

4. After the battery startup info has nished, toggle Battery

DISPLAY REFRESH switch to update Battery Status

Monitor.

5. Toggle ON circuit breakers necessary to support all

connected peripherals. Green LED above breaker will

illuminate when circuit is powered.

BOS Connections and Activation BOS Charging and Discharging

Battery-only Run Times

The BOS internal battery stores 2.1 kWh of energy when fully

charged. Starting with a brand new battery, fully charged, the BOS

can support a 200 W load for ~ ten (10) hours, a 500 W load for

~ four (4) hours, or a 2000 W load for ~ one (1) hour. These times

will decrease as the internal battery ages and loses storage

capacity. This is normal for all batteries.

Low-voltage Cut Off (LVCO)

The BOS will disconnect AC loads, DC OUTPUT port and USB

charging port when the internal battery voltage drops to 24.4. If

this occurs, charge BOS immediately. Power will return to loads

automatically when battery voltage is > 25.4.

BOS Charging

Connect active AC and/or DC power source(s). Toggle ON

corresponding power input breakers.

120–240 VAC Charging: 600 W; minimum charge time from

empty is ~ 3.5 h. If AC power source is a Novatio generator, follow

directions on BOS Faceplate.

Solar Charging: 580 W max; minimum charge time from empty

is ~ 3.5 h. Charging will begin when sufcient sunlight is present.

Solar power charging speed is a function of connected solar array

power output.

9–36 VDC Charging: 200 W; minimum charge time from empty is

~ 10 h.

Internal battery is charged fully when charging current approaches

zero (0) A (see battery status sections of this document).

• For information on expanding BOS 2000 energy storage

capacity, contact Solar Stik.

• Do not connect lead-acid batteries to BOS.

• The BOS should be shaded from direct sun exposure and

sheltered from the elements as much as possible during

operation.

• Keep the case lid and connector covers closed when not

in use to prevent water and dust intrusion.

• Check the integrity of electrical connectors on a monthly

basis.

• Do not block air vents on case exterior. Clean or replace

air lters form optimum cooling.

Notice

A. During normal operation, the display is updated automatically at intervals of three (3) minutes. The DISPLAY REFRESH

momentary toggle switch can be pressed and held to update the display during normal operation. The REFRESH DISPLAY switch

must be pushed and held until the home page is completely repopulated. If the button is released too soon, the display will not

populate. If this happens, wait ve (5) seconds, press and hold button until home page is repopulated.

B. A timestamp for the last “refresh” is updated and displayed, whether it occurred automatically or by pushing the refresh button.

C. The SOC is reported visually by a ve-segment “fuel gauge”. Each segment represents 20% increments up to 100%.

D. Nominal voltage = 26.4 VDC; voltage @ 100% SOC ≈ 30.4 VDC; voltage @ 0% SOC ≈ 20.0 VDC.

E. The net current (A) with respect to the batter is positive when the BOS internal battery is charging and negative when discharging.

F. If/when a battery fault occurs, the word “FAULT” appears in the upper right corner of the display. If the fault is unattended for

three (3) minutes, “FAULT” appears in large font, lling the screen. If the fault is not corrected within 60 minutes, the BOS will

enter storage mode even with the POWER switch in the ON position.

Additional information about the fault can be found on the second “page” (diagnostic screen) of the Battery Status Display, which is

accessed by toggling the Display Refresh switch twice.

Battery net

current +in/-out

Battery voltage

Timestamp of

last refresh

SOC

Indicator.

5-segment

Status

OK/FAULT

0-20% 21-40%

41-60% 61-80% 81-100% A

Battery Status Display Home Screen

An exclamation mark (“!”) will appear in the

left-most bar when SOC drops to 0% (top

left).

If/when an internal battery fault occurs,

the word “FAULT” appears in the upper

right corner of the display. If the fault is

unattended for three (3) minutes, “FAULT”

appears in large font, lling the screen (left).

If the fault is not cleared within 60 minutes,

the BOS will enter storage mode even with

the POWER switch in the ON position.

Additional information about the fault(s) can

be found on the second page of the Battery

Status Monitor (diagnostic screen).

Diagnostic Screen

To access the diagnostic screen, toggle the refresh switch once to

refresh display then a second time for the diagnostic screen. The image

below is an example of the information on the diagnostic screen that is

present when the BOS 2000 is operating normally. The SOC value range

of a new BOS will narrow as the battery cycles.

Battery Warnings and Faults Notiﬁcations

A. Battery serial number

B. CAN address for Battery

Status Monitor

C. CAN bus termination

status of battery

D. CAN address of battery

E. State of health

F. State of charge

Battery Status Monitor

Startup Screens

1. Firmware version and date

2. CAN bus auto-termination status

3. CAN bus communication operational

4. Connecting to battery comms

5. Battery serial number

Screen 1

Screen 2

These two screens scroll by automatically

during startup, before the nal status

screen is populated. This is the

location where the rmware version is

documented. For more information on

the rmware, contact Solar Stik Technical

Support.

Notiﬁcations and Faults

Notications and fault details are found on the diagnostic screen. To access the diagnostic screen, toggle the refresh switch once to

refresh the display, then a second time for the diagnostic screen.

Notiﬁcations

Battery Ofﬂine – This notication indicates that the Battery Status Monitor lost communication with the battery. It may have taken

itself ofine to protect from overdischarge. Toggle the POWER switch to clear the notication. If the notication doesn’t clear, apply a

charging source for at least two (2) minutes. If this fails to clear the notication, contact Solar Stik.

Battery Voltage Low – “Battery voltage low” notication occurs when the BOS battery voltage falls below 20 VDC. It is only a

notication. It does not cause the battery to shut off. This notication automatically clears after charging brings voltage to > 20 VDC.

Faults

The battery may report one or more faults at a time on the diagnostic screen. If a condition other than the ones shown below appears,

contact Solar Stik for assistance. Faults place the BOS 2000 into Protected mode until the fault is corrected and the BOS returns to

Operational mode. If the fault is not cleared in 60 minutes, the BOS 2000 will enter Storage mode even if the POWER switch remains

in the ON position.

Faults reported on diagnostic screen and solutions

Fault Name Value Exceeded Clear Value

Critical Cell Overvoltage for 2

minutes Max Cell V > 4.2000 V Max Cell V < 3.8000 V

Critical Cell Undervoltage Cell Voltage < 2.00 V @ < 120 A

discharge (battery voltage < 16.0 VDC)

Automatically clears fault one time after 2-minute delay. If fault occurs again

without charging battery for 2 minutes, must clear by charging for 2 minutes or

toggling the POWER switch ON>OFF>ON.

Critical Cell Temp High Max Cell Temp > 169 ºF (76 ºC) Reduce Cell Temp to < 149 ºF (65 ºC)

Critical Board Temp High Max Elec Temp 1 or 2 > 248 ºF (120 ºC) Reduce Max Elec Temp to < 194 ºF (90 ºC)

Hardware Overload Current > 3000 A 2-minute cool down, followed by toggling the POWER switch ON>OFF>ON

Fast Software Overload Current > 1500A 30 ms 2-minute cool down, followed by toggling the POWER switch ON>OFF>ON

Software Overload Max Elec Temp 3 > 275 ºF (135 ºC) 2-minute cool down, followed by reducing Elec Temp 3 to < 194 ºF (90 ºC)

BOS Internal Battery Troubleshooting

Frequent visual monitoring of BOS 2000 Battery Status Display is the best method to ensure each battery is operating normally. If a

NOTIFICATION or FAULT is displayed on the screen take the prescribed corrective action to clear it.

The Battery Status Monitor will display the last status acquired before the POWER switch was turned OFF. However, battery voltage

will decrease during storage due to self-discharge. Toggle ON the POWER switch to update in-storage battery status.

In-storage BOS Internal Battery Status Information

MAINTENANCE CHARGING INSTRUCTIONS

Never store a BOS in a discharged state! Charge BOS fully before placing in storage.

Never store a BOS with the BATTERY switch in the ON position.

Temperature-dependent Self-discharge

The self-discharge rate increases as storage temperature increases. If the BOS is stored at temperatures above 90 ºF (32 ºC), then

intervals between maintenance checks and / or charges should be reduced to three (3) months.

In-storage Battery Status rRefresh: Voltage, SOC, and SOH

When the BOS BATTERY switch is OFF, the Battery Status Monitor will continue to report the last-recorded battery status; it does not

refresh automatically during storage. The Battery Status Monitor must be refreshed to report the current status while in storage.

1. Toggle ON BOS BATTERY switch.

2. The Battery Status Monitor Screen will populate with up-to-date information. This will take ~ one (1) min. with the several startup

tests/results displayed before the Status Monitor is populated.

3. Check voltage and SOC on Home screen

4. Toggle the REFRESH DISPLAY switch again to move to the Diagnostic Screen to check SOH.

In-storage Charging

If charging at any temperature lower than 68 ºF (20 ºC) the internal battery may need to heat to charge optimally. The internal heater

may require 650 W. The AC charging source provides 600 W, so the BOS internal battery may use stored energy in addition to the

AC power source to heat itself, effectively draining the battery instead of charging. This situation will be apparent if the Battery Status

Monitor reports a negative current value during the initial phase of charging and when there is no other load connected to the BOS.

1. Connect a power source to the BOS 2000. AC power will charge fastest, then solar power, then power supplied from 9–36 VDC

sources. Note: If the BOS battery was previously overdischarged, it will need to be connected to the charge source for at least two

(2) minutes, or power-cycled (toggling POWER switch ON>OFF>ON) before charge current will begin to ow.

2. Enable the charging source and allow the BOS to charge. Remember, the battery may heat itself before charging if the BOS internal

battery is colder than 68 ºF (20 ºC).

3. The BOS 2000 should continue to charge, balance, and taper until it reaches the voltage setpoint at less than 0.5 A. At this point

the BOS 2000 can be considered to be fully charged.

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