160315 PAM Expedition (AISPCA) Operations Manual w: NSN...

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ABSTRACT!AISPCA! is! a! 420! Watt! solar! array!designed! as! a! drop! in! replacement! for!fielded! and! other! future! expeditionary!power! systems! that! require! renewable!energy.! ! ! AISPCA! is! 48! percent! the!weight! and! 32! percent! the! storage!volume!of! the!original! Integrated!Solar!Panel! Case! Assembly! (ISPCA)! fielded!with! the! Ground! Renewable!Expeditionary! Energy! Network! System!(GREENS).! AISPCA! provides! portable,!effective,!and!rugged!solar!energy.!

!ADVANCED!INTEGRATED!!

SOLAR!PANEL!CASE!ASSEMBLY!(AISPCA)!

OPERATIONS!MANUAL!!!

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! !Nishati,!Inc.!8201!Greensboro!Drive,!Suite!300!McLean,!Virginia!22102!303T906T3838!www.nishatiTus.com!Patents:!www.nishatiTus.com/patents!

April!2015!Copyright!©!2015!All!Rights!Reserved!Revision!140910!Drawing!217303!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

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AISPCA!Operations!Manual!!

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Contents'General!Information!.....................................................................................................................................!2!

National!Stock!Numbers!(NSN)!....................................................................................................................!3!

USE!of!Special!Text!Boxes!.............................................................................................................................!4!

Background!..................................................................................................................................................!5!

Overview!......................................................................................................................................................!6!

Solar!Energy!Basics!.......................................................................................................................................!7!

Photovoltaic!(PV)!Systems!........................................................................................................................!7!

Solar!Insolation!Considerations!................................................................................................................!7!

Diffuse!and!Direct!Solar!Radiation!...........................................................................................................!7!

Solar!Panels,!Modules,!and!Arrays!...........................................................................................................!9!

Safely!Locating!Solar!Arrays!.....................................................................................................................!9!

AISPCA!System!Components!......................................................................................................................!10!

Solar!Array!Operation!–!Set!Up!..................................................................................................................!11!

Unrolling!and!Erecting!Stand!..................................................................................................................!11!

Securing!Stand!with!Sandbags!and!Stakes!.............................................................................................!12!

Attaching!Solar!Panels!............................................................................................................................!13!

Electrically!Connecting!Solar!Panels!.......................................................................................................!14!

Adjusting!Solar!Panel!Angle!for!Location!and!Time!of!Year!...................................................................!15!

Connecting!Solar!Array!to!Charge!Controller!.........................................................................................!16!

Solar!Array!Operation!–!Disassembly!and!Packing!for!Transport!...............................................................!17!

Disconnecting!Solar!Array!from!Charge!Controller!................................................................................!17!

Disconnecting!Connectors!......................................................................................................................!17!

Electrically!Disconnecting!Solar!Panels!..................................................................................................!17!

Fold!and!Detach!Solar!Panels!.................................................................................................................!18!

Remove!Sandbags!(and!Empty)!and!Tent!Stakes,!if!Used!......................................................................!19!

Roll!Stand!...............................................................................................................................................!19!

Pack!Components!in!Transport!Case!......................................................................................................!20!

Preventive!Maintenance!Checks!and!Services!...........................................................................................!22!

Quick!Reference!Card!.................................................................................................................................!24!


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General'Information'

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Weight!(Stowed!Configuration)! ! ! 73.5!pounds!(lbs.)!

Stowage!Volume! ! ! ! 4.15!cubic!feet!(Cu.!Ft.)!

Stowed!Dimensions!(Outside!Dimensions)! 47”!x!16.5”!x!9.1”!

Max.!Deployed!Footprint! ! ! 39.9!ft2!(@!30°!deployment!angle)!

Max!Power! ! ! ! ! 420!Watts!

Open!Circuit!VoltageT!Voc!(each!solar!panel)! 15.66!VDC!

Short!Circuit!Current!T!Isc!(each!solar!panel)! 8.96!AMPS!(A)!

Open!Circuit!Voltage!–!Voc! ! ! 62.64!VDC!(Solar!Array!T!4!panels!in!series)!

Storage!Temperature! ! ! ! T25°!to!160°!F!

Operating!Temperature!! ! ! T4°!to!140°!F!


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National'Stock'Numbers'(NSN)'!

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AISPCA OEM)Part)Number OEM)CAGE)Code NSN U/I

Technical)description,)Length,)Width,)))))))))))))))))))))))))))))))))))))))))))))

Height,)Weight),)specs,)etc)Alternative*Integrated*Solar*

Panel*Case*Assembly*217551 75CR6 6117<01<641<0930 ea.

Solar*Panel*Assemblies*for*

GREENS*Gen*II

AISPCA)SLD3 OEM)Part)Number OEM)CAGE)Code NSN U/I


Height,)Weight),)specs,)etc)

Solar*Panel*Assembly 217286 75CR66117<01<647<3613

ea.

105W*Solar*Panel*Assy,*PAM*

Expedition

Structure*Assembly*Roll*

Stand 217230 75CR66117<01<646<8414

ea.

Structure*Assembly,*PAM*

Expedition

Transport*Case*Assembly 217276 75CR66130<01<646<8114

ea.

Transport*Case*Assembly,*

PAM*Expedition

Wire*Harness*Collector*

Cable 217179 75CR66150<01<646<8450

ea.

Wire*Harness,*420W*PAM*

Expedition

Sand*Bags 217100*Item*6 813498105<00<142<9345

ea.

Polypropylene*Desert*Tan*

San*Bag

Stakes 217100*Item*4 0JKN0 834<01<563<9937 ea. 262581739

AISPCA)Maintenance OEM)Part)Number OEM)CAGE)Code NSN U/I


Height,)Weight),)specs,)etc)PIO*Replacement*Kit*with* 217277 75CR6 5340<01<646<8477 ea PIO*Replacement*Assembly

Longeron*Trim*and*Drill*<*01 217271<01 75CR6 5340<01<647<0338 ea Longeron*Trim*and*Drill*<01

Longeron*Trim*and*Drill*<*02 217271<02 75CR6 5340<01<646<8439 ea Longeron*Trim*and*Drill*<*02

Cross*Strap*Upper,*Front*

Batten 217235 75CR65340<01<646<8449

ea

Cross*Strap*Upper,*Front*

Batten

Cross*Strap*Angle*Adjust,*

Battens

217232<01/<02*

(5*each) 75CR65340<01<646<8455

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Cross*Strap*Angle*Adjust,*

Battens

Sandbag*Straps*front*and*

rear 217263 75CR63940<01<646<8497

ea

Sandbag*Straps*Front*and*

Rear

Cover,*structure*assembly 217264 75CR6 8145<01<646<8474 ea Cover,*PAM*Structure

Batten*Assembly 217231 75CR6 ea.

Batten*Assembly,*420W*

Structure

Front*Batten,*Structure 217268 75CR6 5340<01<646<9493 ea. Front*Batten,*PAM*Structure

Rear*Batten,*Structure 217269 75CR6 5340<01<646<8443 ea. Rear*Batten,*PAM*Structure

Slide*Latch*Assembly N/A 75CR6 ea.

Solar*Panel*Slide*Lock*

Assembly

Positive*Panel*Connector H4CFC4D* Amphenol ea

Positive*Amphenol*H4*PV*

Connector

Negative*Panel*Connector H4CMC4D Amphenol ea

Negative*Amphenol*H4*PV*

Connector

Large*Head*Blind*Rivet PTTL606 Hanson*Rivet 5320<01<647<8547 ea. Large*Head*Blind*Rivet

Solar*Panel*Slide*Latch*

Assembly

Redundant*part*

with*slide*latch*

assembly*above

MC4*Assembly*Tool B00BCWZFN2 6YBD35120<01<647<0353

ea.

Tool*used*to*diconnect*H4*

panel*connectors


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USE'of'Special'Text'Boxes'!

WARNING!

A'procedure,'practice,'or'condition'that'may'result'in'injury'or'death'if'not'carefully'observed'or'followed.!

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CAUTION'

A'procedure,'practice,'or'condition'that'may'damage'equipment'if'not'carefully'observed'or'followed.!

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NOTE'

A'procedure,'practice,'or'condition'that'is'essential'to'emphasize.!

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Background'!!!!!!!!In!2010,!the!Marine!Corps!(USMC)!led!the!development!and!deployment!of!renewable!energy!systems!to!support!combat!operations!in!Afghanistan.!One!of!the!most!successful!systems!deployed!during!this!timeframe!was!the!Ground!Renewable!Expeditionary!Energy!Network!System!(GREENS).!!The!GREENS!is!a! hybrid! renewable! energy! system! that! is! man!movable! and! vehicle! transportable! that! incorporates!more! than! 1.6! kW!of! solar! panels,! energy! storage,! and! power! electronics! to! provide! round! the! clock!power!for!combat!systems.!!!!Powered!by!the!sun,!GREENS!provides!an!average!continuous!output!of!300!Watts!T!enough!to!power!a!small!patrol!base,!company!outpost,!remote!communications!relay!station!and!sensors!around!the!clock!without!the!need!for!battery!or!fuel!resupply.!GREENS!proved!that!renewable!energy!systems!increase!combat!effectiveness!by!reducing!the!need!for!logistics!resupply!of!fuel!and!batteries.!!AISPCA!is!the!direct!result!of!the!lessons!learned!from!the!first!deployment!of!renewable!energy!systems!to!combat.! !The! initial!solar!panels!deployed!with!GREENS!were!commercial!off!the!shelf!systems!that!were! fragile,! large,! and! heavy! and! not! particularly! suited! for! an! expeditionary! environment.! ! This!feedback!resulted!in!the!development!of!the!Portable!Array!Module!(PAM™)!Expedition!which!began!as!a! Small! Business! Innovation! Research! (SBIR)! program! out! of! the! Office! of! Naval! Research! (ONR)! in!collaboration! with! the! United! States! Marine! Corps.! ! The! ONR! SBIR! was! awarded! to! Composite!Technology! Development,! Inc.! (CTD)! who! led! the! development! of! PAM™! Expedition,! which! is! now!licensed!to!Nishati!Inc.!Figure!1!shows!AISPCA!and!the!GREENS!Controller!and!Batteries.!

Figure!1:!AISPCA!integrated!with!GREENS!Controller!and!Battery!

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Overview'AISPCA!is!a!ruggedized!solar!energy!harvesting!system!compatible!with!the!USMC’s!GREENS!as!well!as!other!future!USMC!hybrid!energy!systems!(Figure!2).!!AISPCA!is!designed!for!operational!conditions!that!are! routinely! encountered! in! the! field! in! any! environment! and! climate! conditions.! This! equipment! is!intended!for!transport!by!military!ground,!air!and!sea!vehicles!and!to!be!easily!moved!frequently!by!one!or!two!personnel.!!!

AISPCA!consists!of!four!triTfold!solar!panels,!a!lightweight!rollable!stand;!sandbags!(empty)!and!stakes!to!stabilize!the!system!in!the!wind,!and!one!35’!power!collector!cable.!All!assemblies!listed!are!shipped!in!a!single! waterproof! and! rugged! transport! case! with! external! dimensions! of! 47.20”! x! 16.50”! x! 9.20”!occupying!a!volume!of!4.15!cubic! feet! (Figure!3).! !The!weight!of! the!system! is! less! than!75! lbs.! in! the!transport!case.!The! lightweight!rollable!stand!can!be!used!to!angle!the!panels!towards!the!sun!at!45°,!30°,!or!0°!as!needed!to!maximize!energy!capture.!

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!Figure!2:!AISPCA!Deployed!Configuration!

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Figure!3:!AISPCA!Packed!into!Rugged!Transport!Case!


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Solar'Energy'Basics'Photovoltaic'(PV)'Systems'PV!systems!are!designed!to!harvest!energy!directly!from!sunlight.!They! include!solar!panels,!batteries,!power!control!electronics,!and!accessories!that!support!power!needs!for!many!applications.!

Solar'Insolation'Considerations'Solar!irradiance!is!a!measure!of!the!power!per!unit!area!on!the!Earth’s!surface!produced!by!the!sun!often!measured!in!Watts!per!square!meter!(W/m2).!Although!the!energy!output!of!the!Sun!is!fairly!constant,!solar!irradiance!varies!significantly!from!one!place!to!another!and!changes!throughout!the!year.!The!solar!radiance!is!an!instantaneous!power!density!in!units!of!kW/m2.!The!solar!radiance!varies!throughout!the!day!from!0!W/m2!at!night!to!a!maximum!of!about!1000!W/m2.

Direct!solar!insolation!is!the!solar!radiation!energy!per!unit!area!during!a!given!time!often!measured!in!Kilowatts!hour!per!square!meter!per!day![kWh/(m2Tday)]. The!amount!of!insolation!received!at!the!surface!of!the!Earth!is!controlled!by!the!angle!of!the!sun,!the!state!of!the!atmosphere,!altitude,!geographic!location,!and!time!of!year.

PV!cells!harvest!solar!rays!and!produce!direct!current!(DC).!PV!cells!are!combined!together!to!create!modules!to!increase!the!total!power!output.!These!modules!are!most!productive!when!the!panels!face!directly!into!the!sun!(i.e.!are!as!close!to!perpendicular!to!the!sun’s!rays!as!practical).!Two!factors!affect!the!angle!at!which!the!sun’s!rays!strike!a!solar!panel:!

•! Direction!/!azimuth!•! Tilt!angle!'Diffuse'and'Direct'Solar'Radiation'Solar!radiation!that!reaches!the!earth!is!composed!of!direct!and!diffuse!solar!radiation.!Direct!solar!radiation!travels!on!a!straight!line!from!the!sun!down!to!the!surface!of!the!earth.!Diffuse!radiation!describes!the!sunlight!that!has!been!scattered!by!molecules!and!particles!in!the!atmosphere!but!that!has!still!made!it!down!to!the!surface!of!the!earth.!When!the!sky!is!clear!and!the!sun!is!very!high!in!the!sky,!direct!radiation!is!around!85%!of!the!total!insolation!striking!the!ground!and!diffuse!radiation!is!about!15%.!As!the!sun!goes!lower!in!the!sky,!the!percent!of!diffuse!radiation!keeps!going!up!until!it!reaches!40%!when!the!sun!is!10°!above!the!horizon.!However,!this!ratio!can!vary!due!to!many!factors!including:!

•!Air!molecules! •!Water!vapor!!!! •!Clouds! ! •!Dust!•!Pollutants! ! •!Forest!fires! ! •!Volcanoes! ! •!Latitude!

The!sum!of!the!diffuse!and!direct!solar!radiation!is!called!global!solar!radiation.!Atmospheric!conditions!can!reduce!direct!radiation!by!10%!on!clear,!dry!days!and!by!100%!during!thick,!cloudy!days.!


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Azimuth!is!the!horizontal!direction!expressed!as!the!angular!distance!between!the!direction!of!a!fixed!point!and!the!direction!of!the!object.!In!PV!terms,!it!is!the!sun’s!apparent!location!east!and!west!of!true!south!(northern!hemisphere)!or!true!north!(southern!hemisphere).!See!Figure!4.!

To!optimize!power!output!in!most!areas,!solar!panels!should!be!aligned!to!face!true!south!(not!magnetic!south)!in!the!northern!hemisphere!and!true!north!in!the!southern!hemisphere.!

Depending!on!location!and!topography,!it!can!be!beneficial!to!align!the!panels!somewhat!away!from!true!north!(or!true!south)!to!compensate!for!local!effects.!For!example;!if!the!solar!panels!are!located!in!a!valley!with!mountains!to!the!west!that!obscure!the!sun!in!the!late!afternoon,!it!may!be!beneficial!to!face!the!solar!panels!a!little!to!the!east!and!collect!extra!power!during!the!morning!and!maximize!the!exposure!of!the!solar!panels!to!the!sun!during!the!day.!This!will!compensate!for!losing!power!in!the!afternoon!from!the!shade!caused!by!the!mountains.!

NOTE'

If'the'environmental'effects'and'proper'azimuth'are'uncertain,'the'system'should'remain'facing'true'south'(in'the'northern'hemisphere)'or'true'north'(in'the'southern'hemisphere).'

Tilt!angle!refers!to!the!PV!panel’s!vertical!angle!relative!to!the!ground.!Optimum!tilt!angle!is!a!function!of!the!sun’s!elevation!relative!to!the!horizon!at!the!location!of!interest!on!the!earth!and!the!time!of!year.!Once!a!panel!is!aligned!to!the!proper!azimuth,!the!tilt!angle!is!determined!by!two!factors!that:!latitude(and(time(of(year.!

For!a!fixed!solar!panel!system!with!a!fixed!azimuthal!direction,!a!general!year!round!rule!is!to!set!tilt!angle!equal!to!the!latitude.!For!example;!at!the!north!and!south!poles,!the!latitude!will!equal!90°.!At!45°!North!or!South!latitude!the!tilt!angle!of!the!solar!panels!should!be!45°,!and!at!the!equator!the!solar!panels!should!be!laid!flat!on!the!ground.!Figure!5!summarizes!this.!To!compensate!for!time!of!year,!if!the!solar!panels!have!an!adjustable!tilt!angle,!adjust!as!follows:!

•! Winter!–!latitude!plus!fifteen!degrees!!

•! Summer!–!latitude!minus!fifteen!degrees!!

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Figure!5:!Tilt!Angle!Determination.!

!Figure!4:!Azimuth!vs.!True!South.!


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Solar'Panels,'Modules,'and'Arrays'

Solar! modules! are! made! up! of! a! number! of! electrically!connected! PV! or! solar! cells.! Solar! panels! consist! of! a! several!solar! modules,! which! are! connected! with! series! and! parallel!circuits.!Figure!6!shows!a!solar!panel.!!

Most!solar!panels!operate!at!relatively!low!voltage!and!amperage.!Depending!on!load!requirements,!multiple!solar!panels!can!be!used!together,!creating!a!solar(array,!to!reach!the!desired!energy!production.!This!allows!tailored!solar!energy!production,!which!can!match!the!type!of!load!requirements!that!exist.!AISPCA!is!a!solar!array,!which!has!a!total!output!capacity!of!420!Watt!at!about!48!volts!at!about!8.75!amps.!

WARNING'

Solar'systems'are'silent'energy'systems.'Always'assume'live'voltage'is'present.'

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WARNING!

Solar'energy'systems'should'be'handled'like'other'power'generation'equipment'and'shall'not'be'located'near'flammable'materials'or'close'to'tents'or'shelters.!

'Safely'Locating'Solar'Arrays'Solar!arrays!shall!be!located!away!from!flammable!materials!and!away!from!tents!or!shelters.!!In!very!rare!cases!solar!energy!systems!have!been!known!to!cause!fires!due!to!internal!electrical!failures.!It!is!important!to!handle!solar!energy!systems!with!the!care!required!for!high!power!generating!and!electrical!equipment.!

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!Figure!6:!Solar!Panel.!


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AISPCA'System'Components'!!AISPCA!is!composed!of!the!components!shown!in!figure!7.!

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#" Descrip*on"

1" Tri&fold"Solar"Panel"

2" Rollable"Stand"

3" Canvas"Cover"with""Quick"Look"Instruc@ons"

4" Sandbag"Straps"&"Tent"Stake"Loops"(front"and"back)"

5" Longeron"

6" Transport"Case"

7" Rolled"Stand"

8" Folded"Solar"Panels"

9" 12"Sandbags"&""10"Tent"Stakes""(not"shown)"

10" Front"and"Rear"BaOens"

11" Upper"Cross"Strap"

12" Collector"Cable"

13" Opera@ons"Manual"

14" Transport"Case"Packing"Guide"

15" Canvas"Sand"Cover"with"Quick"Look"Instruc@ons"

16" PIO"Integrated"Electrical"Connec@on"Quick"Disconnect""

2 5

11

10

6

7 8 12

13 14

16

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!!35”!@

!45°

3

1

4

17


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Solar'Array'Operation'–'Set'Up'Unrolling'and'Erecting'Stand'1.!!Remove!stowed!AISPCA!stand!

from!case!(Figure!8)!

!Figure!8:!Rolled!Stand!Stored!in!Transport!Case!

2.! Unroll!of!the!AISPCA!stand!!!(figure!9).!

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!Figure!9:!Unroll!AISPCA!Stand!!

3.! Lift!the!unrolled!stand!and!erect!the!‘A’!frame!structure!as!shown!in!Figure!10.!!

•! Place!array!on!ground!with!unobstructed!view!of!the!Southern!sky!in!Northern!latitudes!and!Northern!sky!in!Southern!latitudes.!

•! Stand!is!shown!at!the!45°!tilt!angle!relative!to!the!ground!

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!Figure!10:!Erected!stand!facing!the!optimum!

direction!for!solar!energy!capture!

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Securing'Stand'with'Sandbags'and'Stakes'

WARNING'

Failure'to'properly'secure'solar'array'to'surface'with'sandbags'could'result'in'damage,'death,'or'injury'in'high'winds.'As'appropriate'tent'stakes'can'be'used'along'with'sandbags'

1.! Secure!solar!array!to!surface!by!placing!12!sandbags!on!the!AISPCA!front!and!rear!sand!bag!straps!(Figure!11).!Tent!stakes!can!also!be!used!to!supplement!sand!bags.!!!To!secure!with!sandbags,!one!sandbag!shall!be!placed!on!each!of!the!four!sandbag!straps!in!the!front,!under!where!the!solar!panels!attach,!and!two!sandbags!shall!be!placed!on!each!of!the!four!sandbag!straps!in!the!rear.!A!total!of!12!sandbags!are!required!to!properly!secure!the!AISPCA!solar!array!in!high!winds.!Sandbags!shall!weigh!a!minimum!of!50!lbs.!

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!!Figure!11:!Secure!the!AISPCA!stand!with!12!sandbags!!

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Attaching'Solar'Panels'

WARNING'

Failure'to'properly'attach'solar'panels'could'result'in'damage'or'injury'in'high'winds.'

1.!!Secure!solar!panels!to!the!AISPCA!stand!by!sliding!the!solar!panel!top!hooks!onto!top!hook!posts!on!the!stand.!Then!secure!the!lower!portion!of!the!solar!panel!by!putting!the!slide!latch!posts!through!the!openings!in!the!slide!latches!and!secure!the!slide!latches!as!shown!Figures!12!and!by!following!the!procedure!below.!

!Figure!12:!Secure!Solar!Panels!to!AISPCA!stand!using!top!hook!and!slide!latch!connections!

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The!following!procedure!is!recommended!for!attaching!the!solar!panels!to!the!stand�

1.! Remove!one!triTfold!solar!panel!from!the!transport!case!and!attach!it!to!the!appropriate!side!of!the!erected!rollable!stand.!�

2.! Keeping!the!solar!panel!folded,!engage!the!two!top!hooks!on!either!side!of!the!solar!panel!onto!the!upper!most!support!posts!on!the!erected!stand!(Figure!13),!unfold!the!solar!panel!and!engage!the!four!slide!latches,!to!secure!the!solar!panel!to!the!rollable!stand!as!shown!figure!14.�

3.!!!!Repeat!for!the!three!remaining!solar!panels.!

Figure!13:!Engage!solar!panel!top!hooks!onto!the!upper!support!posts.!

!Figure!14:!Engage!four!slide!latches!to!secure!the!solar!panel.!


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Electrically'Connecting'Solar'Panels'

WARNING'

Do'not'disconnect'solar'panel'electrical'connector'under'load,'disconnecting'under'load'could'cause'damage,'death,'or'injury.'

1.! Electrically!connect!the!four!solar!panels!as!required!to!meet!the!system!voltage!requirements.!!

2.! For!48!Volt!operation,!as!is!used!for!GREENS,!all!four!solar!panels!are!connected!in!series!as!shown!in!figure!15.!

3.! Figures!16!and!17!show!the!positive!and!negative!ends!of!the!electrical!connectors,!respectively.!!!

4.! Securely!connect!the!positive!and!negative!connectors!to!make!a!good!connection!between!solar!panels!as!shown!in!figures!16!and!17.!

WARNING'

Failure'to'properly'secure'electrical'connectors'could'result'shock'hazard'to'personnel.'

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Figure!15:!AISPCA!wired!for!48!Volt.!Operation!

Figure!16:!Positive!Connector.! Figure!17:!Negative!Connector.!


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!!

Adjusting'Solar'Panel'Angle'for'Location'and'Time'of'Year'!1.!!Use!the!levers!on!the!back!of!the!stand!to!adjust!solar!

array!tilt!angle!to!0°,!30°,!or!45°!(figure!18).!Use!of!an!appropriate!tilt!angle!will!maximize!solar!energy!capture!depending!on!latitude,!time!of!year,!and!local!topography!as!described!in!Solar!Energy!Basics!section.!�

!

!Figure!18:!Adjust!AISPCA!stand!angle!

!•! The!angle!of!the!solar!panels!relative!to!the!sun!can!be!adjusted!using!the!5!adjusting!levers!on!the!

back!of!the!solar!array!stand.!•! Flip!the!levers!down!for!45°!angle!(see!figure!19).!•! Flip!the!levers!up!for!30°!angle!(see!figure!19).!•! Lay!the!solar!panels!and!rollable!stand!assembly!flat!on!the!ground!for!0°!angle.!•! When!adjusting!the!angle!of!the!solar!panels,!it!may!be!necessary!to!adjust!the!position!of!the!stand,!

which!may!require!moving!sandbags!and!stakes.!!

! 'Figure!19:!Lever!for!Setting!Solar!Panel!Angle.!


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Connecting'Solar'Array'to'Charge'Controller'

WARNING'Do'not'disconnect'solar'panel'electrical'connector'under'load,'disconnecting'under'load'

could'cause'damage,'death,'or'injury.'

1.! After!connecting!the!solar!panel!electrical!connectors!in!series!there!should!be!two!unconnected!wires,!one!at!each!end!of!the!solar!array!stand.!One!will!be!a!positive!connector!and!one!will!be!a!negative!connector.!

2.! Remove!the!collector!cable!from!the!transport!case.!3.! Connect!the!end!of!the!cable!with!two!separate!connectors!to!the!appropriate!mating!

unconnected!wires!on!either!end!of!the!stand.!4.! Connect!the!end!of!the!cable!with!the!single!connector!to!the!charge!controller.!Figure!20!shows!

the!configuration!that!should!be!used!for!the!GREENS!system.!

!

!

!

!

! !

Figure!20:!AISPCA!Connection!of!solar!panels!to!GREENS!Controller.!

Location!of!collector!cable!


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Solar'Array'Operation'–'Disassembly'and'Packing'for'Transport'Disconnecting'Solar'Array'from'Charge'Controller'

WARNING'

Do'not'disconnect'solar'panel'electrical'connector'under'load,'disconnecting'under'load'could'cause'damage,'death,'or'injury.'

1.! On!the!system!controller!turn!off!the!solar!panels!to!stop!the!flow!of!electricity!from!the!solar!panel!prior!to!disconnecting!any!cables.!When!using!the!GREENS!controller,!turn!off!circuit!breakers!J3,!J4,!J5,!and!J6.!If!this!is!not!possible,!carefully!disconnect!the!collector!cable!from!the!charge!controller.!

Disconnecting'Connectors''1.! The!same!connectors!are!used!to!connect!the!collector!cable!to!the!solar!array!as!well!as!to!

interconnect!the!solar!panels!on!the!solar!array.!!

2.! To!disconnect!solar!panel!connectors!squeeze!the!tabs!on!both!sides!of!the!negative!connector!and!gently!pull!the!two!sides!of!the!connector!apart!as!shown!in!figure!21.!!

!

!

!

! !

!

Electrically'Disconnecting'Solar'Panels'!1.! Prior!to!disconnecting!the!solar!panels!be!certain!they!are!not!connected!to!the!charge!controller!

and!generating!power.!2.! Disconnect!wires!interconnecting!the!solar!panels!(total!of!4!connectors).!!3.! Figure!21!shows!the!solar!panel!interconnect!cables!being!disconnected.!!4.! Disconnected!cables!should!remain!free!for!folding!and!detaching!the!solar!arrays!from!the!stand.!

!

! !

Figure!21:!Disconnect!Solar!Panels!by!Pressing!PIO.!


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Fold'and'Detach'Solar'Panels'!

1.! Remove!each!solar!panel!one!at!a!time.!2.! Unlatch!the!4!slide!latches!used!to!attach!the!solar!panel!to!the!

rollable!stand!as!shown!in!figure!22.!3.! Fold!the!solar!panel!from!the!bottom,!bending!the!two!folds!of!the!triT

fold!panel!as!shown!in!figures!23,!24,!and!25.!4.! Now!lift!the!folded!solar!panel!off!the!rollable!stand!by!sliding!the!

panel!upwards!disengaging!the!top!hooks!figure!26.!

!

!

!

!

! !

Figure!23:!Solar!Panel!First!Fold.! Figure!24:!Solar!Panel!Second!Fold.!

Figure!25:!Folded!Solar!Panel!Ready!for!Removal.!

!

Figure!26:!Remove!Solar!Panel!by!sliding!the!Top!Hook!off!the!Support!Posts.!

!

Figure!22:!Unlatch!the!4!slide!latches.!!!


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Remove'Sandbags'(and'Empty)'and'Tent'Stakes,'if'Used'!

1.! If!the!rollable!stand!is!secured!with!stakes,!pry!the!stakes!from!the!ground,!remove!excess!dirt!and!debris.!!!

2.! Remove!and!empty!the!sandbags,!fold!all!the!empty!sandbags!except!one.!!3.! Place!all!other!empty!and!folded!sandbags!and!stakes!into!the!remaining!unfolded!sandbag!for!

storage.!!

Roll'Stand'!

1.! Lift!the!stand!up!to!collapse!the!‘A’!frame!structure!and!lay!the!stand!on!the!ground!with!solar!panel!attachment!side!facing!the!ground!and!the!rollable!longerons!facing!up!(figure!27).!

2.! Starting!from!the!end!of!the!stand!with!the!preTrolled!longerons,!roll!the!stand!toward!the!other!end.!Try!to!keep!the!longerons!rolling!in!a!neat!and!uniform!roll,!which!makes!it!easier!to!pack!into!the!transport!case!(figure!28).!

3.! When!the!stand!is!fully!rolled,!wrap!it!with!the!integrated!cover!and!secure!the!cover!with!the!three!Velcro!straps!(figures!29!and!30).!

!

! !

Figure!27:!Start!Rolling!Stand!Using!Pre]Rolled!Longerons.!

Figure!28:!Roll!Longerons!neatly!and!uniformly!to!make!it!easier!to!pack!into!transport!case.!

Figure!30:!Fully!rolled!stand!ready!for!packing!into!transport!case.!

Figure!29:!When!stand!is!fully!rolled,!wrap!with!integrated!cover!and!secure!Velcro!straps.!


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Pack'Components'in'Transport'Case'CAUTION'

Failure'to'properly'package'solar'panels'will'result'in'failure'or'difficulty'to'close'the'AISPCA'case'lid'and'may'result'in'damage'to'solar'panels.!

1.! Figure!31!depicts!packaging!of!the!solar!array!into!the!transport!case.!!

a.! Packing!solar!panels:!the!solar!panels!can!be!packed!in!any!order,!but!they!must!be!packed!per!the!following!instructions!and!as!shown!in!figure!31.!

b.! First!solar!panel!packed!must!have!the!junction!box!face!up!on!the!wheel!side!of!the!case!(figure!32).!

c.! Second!solar!panel!must!have!the!junction!box!side!face!down!and!away!from!the!wheel!end!of!the!case!(figure!33).!

d.! Third!solar!panel!packed!must!have!the!junction!box!face!up!to!the!wheel!side!of!the!case!!e.! Fourth!solar!panel!must!have!the!junction!box!face!down!and!away!from!the!wheel!end!of!the!

case!(figure!34).!!2.! All!solar!panel!cables!must!be!routed!into!“Wire!Storage!Area”!as!directed!by!the!labels!in!the!case!

(figure!35).!3.! Place!the!rolled!stand!on!top!of!the!solar!panels!as!shown!in!figure!35.!4.! Insert!the!sandbag!containing!the!other!folded!sandbags!and!tent!stakes!into!case!on!top!of!solar!

panels.!5.! Neatly!coil!the!collector!cable!and!place!into!the!case!on!top!of!solar!panels!

!!!

CAUTION'

Failure'to'secure'tent'stakes'in'sandbags'could'cause'damage'to'solar'panels'during'shipping.!


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! !

Figure!35:!Labels!in!case!showing!how!to!route!solar!panel!wires.!!

!

!

!

!

!

! !

Figure!31:!Schematic!of!Packing!Arrangement!for!Solar!Arrays!and!Rolled!Stand!in!Transport!Case.!

Figure!32:!First!solar!panel!placed!into!transport!case!with!junction!box!face!up!

towards!wheel!end!of!case.!

Figure!33:!Second!solar!panel!placed!into!the!transport!case!with!junction!box!face!

down!away!from!wheel!end!of!case.!!

Figure!34:!Case!with!4!solar!panels!and!rollable!stand!packed,!ready!for!loading!of!

stakes,!sandbags,!and!collector!cable.!


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Preventive'Maintenance'Checks'and'Services'!

1.! Tools!Required!There!are!no!specialty!tools!required!for!the!preventive!maintenance!or!service!of!AISPCA!

2.! Before!Operations!Checks!and!Services!Before!operation!begins,!always!check!for!!

•! Physical!damage!•! Ensure!that!the!solar!panels!are!securely!attached!to!the!stand!•! The!stand!is!secured!to!the!ground!with!a!minimum!of!12!sandbags!•! All!electrical!connections!are!firmly!connected.!!•! In!addition!for!efficient!and!safe!operation,!verify!that!the!bypass!diodes!on!all!panels!are!

functional!using!one!of!the!two!test!methods!described!below.!

3.! Verifying!that!panel!bypass!diodes!are!functional.!Test!Method!1:!AISPCA!is!connected!to!a!GREENS!controller.!

a.! With!solar!array!connected!to!GREENS!controller.!b.! Fold!each!of!the!4!solar!panels!one!at!a!time!and!note!the!change!in!output!power!on!

the!GREENS!controller!(figure!36).!c.! With!a!working!bypass!diode,!the!output!power!should!drop!only!by!about!20!to!30%.!If!

the!bypass!diode!is!not!operational!the!output!power!will!drop!close!to!0.!!!

For!example!if!all!four!panels!are!producing!350!watts,!then!3!panels!with!a!working!diode!on!the!shaded!panel!should!product!around!250!watts.!If!the!power!goes!to!zero!(or!close!to!it),!the!bypass!diode!on!the!shaded!panel!is!not!functioning!properly.!

d.! If!a!panel!fails!remove!that!panel!from!the!array!and!replace!with!working!panel.!!

Figure!36:!Fold!one!panel!at!a!time!to!shade!it!from!the!sun!to!determine!whether!the!bypass!diode!on!the!shaded!panel!is!functioning!properly.!

!! !


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Test!Method!2:!When!AISPCA!is!not!connected!to!a!Solar!Controller!a.! Bypass!diode!can!be!easily!tested!using!a!digital!multimeter!with!diode!testing!capability!b.! For!each!individual!panel,!test!is!conducted!by!probing!solar!panels!HCT4!connectors!

(see!procedure!in!Table!1!and!expected!multimeter!reading!in!figure!37)!c.! It!is!important!that!the!panel!is!shaded!or!turned!away!from!light!or!the!sun!during!this!

test!in!order!to!achieve!accurate!readings!d.! If!a!panel!fails!remove!that!panel!from!the!array!and!replace!it!with!working!panel!

!!!Table!1:!Procedure!for!Verifying!Bypass!Diode!are!Functioning!with!a!Multimeter!Multimeter!Setting!

Diode!Direction! Multimeter!Negative!Lead!

Multimeter!Positive!Lead!

Multimeter!Reading!

Diode!Test! Forward! Panel!Negative! Panel!Positive! Out!of!Limits!(OL)!Diode!Test! Reverse! Panel!Positive! Panel!Negative! Should!read!less!

than!0.2V!!

! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!(a)! ! ! !!!!!!!!!!!!(b)!Figure!37:!Multimeter!used!to!test!diode!function.!In!Figure!37(a)!negative!lead!to!negative!connector!and!positive!lead!to!positive!connector!shows!‘out!of!limits!(OL).!In!Figure!37(b),!negative!lead!to!positive!connector!and!positive!lead!to!negative!connector!shows!a!value!of!less!than!0.2V.!

!


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Quick'Reference'Card'

!

160315 PAM Expedition (AISPCA) Operations Manual w: NSN...

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