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Nishati AISPCA Operation Manual

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A
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DVANCED!
NTEGRATED!
P
C
OLAR!
ANEL!
ASE!
O
PERATIONS!
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Nishati,!Inc.!
8201!Greensboro!Drive,!Suite!300!
McLean,!Virginia!22102!
303T906T3838!
www.nishatiTus.com!
Patents:!www.nishatiTus.com/patents!
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ABSTRACT!
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AISPCA! is! a! 420! Watt! solar! array!
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designed! as! a! drop! in! replacement! for!
fielded! and! other! future! expeditionary!
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power! systems! that! require! renewable!
A
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energy.! ! ! AISPCA! is! 48! percent! the!
SSEMBLY
weight! and! 32! percent! the! storage!
(AISPCA)!
volume! of! the! original! Integrated! Solar!
M
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Panel! Case! Assembly! (ISPCA)! fielded!
ANUAL!
with!
Expeditionary! Energy! Network! System!
(GREENS).! AISPCA! provides! portable,!
effective,!and!rugged!solar!energy.
!
the!
Ground!
Renewable!
April!2015!
Copyright!©!2015!All!Rights!Reserved!
Revision!140910!
Drawing!217303!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!

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Summary of Contents for Nishati AISPCA

  • Page 1 AISPCA! is! a! 420! Watt! solar! array! designed! as! a! drop! in! replacement! for! fielded! and! other! future! expeditionary! DVANCED! NTEGRATED! power! systems! that! require! renewable! energy.! ! ! AISPCA! is! 48! percent! the! OLAR! ANEL! ASE! SSEMBLY weight! and! 32! percent! the! storage!

  • Page 3: Table Of Contents

    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!........................! 1 0 Solar!Array!Operation!–!Set!Up!........................! 1 1 Unrolling!and!Erecting!Stand! ........................! 1 1 Securing!Stand!with!Sandbags!and!Stakes!.....................! 1 2 Attaching!Solar!Panels! ..........................! 1 3 Electrically!Connecting!Solar!Panels! .......................! 1 4 Adjusting!Solar!Panel!Angle!for!Location!and!Time!of!Year!..............! 1 5...

  • Page 4: General!Information

    AISPCA!Operations!Manual! General'Information' 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!ft !(@!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!

  • Page 5: National!Stock!Numbers!(Nsn)

    AISPCA!Operations!Manual! National'Stock'Numbers'(NSN)' Technical)description,)Length,) OEM)Part) AISPCA OEM)CAGE)Code Width,))))))))))))))))))))))))))))))))))))))))))))) Number Height,)Weight),)specs,)etc) Alternative*Integrated*Solar* Solar*Panel*Assemblies*for* 217551 75CR6 6117<01<641<0930 Panel*Case*Assembly* GREENS*Gen*II Technical)description,)Length,) OEM)Part) AISPCA)SLD3 OEM)CAGE)Code Width,))))))))))))))))))))))))))))))))))))))))))))) Number Height,)Weight),)specs,)etc) 105W*Solar*Panel*Assy,*PAM* 6117<01<647<3613 Solar*Panel*Assembly 217286 75CR6 Expedition Structure*Assembly*Roll* Structure*Assembly,*PAM* 6117<01<646<8414 Stand 217230 75CR6 Expedition Transport*Case*Assembly,* 6130<01<646<8114 Transport*Case*Assembly 217276...

  • Page 6: Use!Of!Special!Text!Boxes

    AISPCA!Operations!Manual! USE'of'Special'Text'Boxes' WARNING A'procedure,'practice,'or'condition'that'may'result'in'injury'or'death'if'not'carefully'observed'or' followed. CAUTION' A'procedure,'practice,'or'condition'that'may'damage'equipment'if'not'carefully'observed'or' followed. NOTE' A'procedure,'practice,'or'condition'that'is'essential'to'emphasize.

  • Page 7: Background

    AISPCA!Operations!Manual! 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!

  • Page 8: Overview

    AISPCA!Operations!Manual! 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.!!! Figure!2:!AISPCA!Deployed!Configuration! 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°,!

  • Page 9: Solar!Energy!Basics

    AISPCA!Operations!Manual! 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/m ).!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/m .!The!solar!radiance!varies! throughout!the!day!from!0!W/m !at!night!to!a!maximum!of!about!1000!W/m 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/(m Tday)]. 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!
  • Page 10 AISPCA!Operations!Manual! 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.! Figure!4:!Azimuth!vs.!True!South.! 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!! Figure!5:!Tilt!Angle!Determination.! Summer!–!latitude!minus! •! fifteen!degrees!!

  • Page 11: Solar!Panels,!Modules,!And!Arrays

    AISPCA!Operations!Manual! 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! Figure!6:!Solar!Panel.! 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.'...

  • Page 12: Aispca!System!Components

    AISPCA!Operations!Manual! AISPCA'System'Components' !AISPCA!is!composed!of!the!components!shown!in!figure!7.! #" 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"...

  • Page 13: Solar!Array!Operation!-!Set

    AISPCA!Operations!Manual! 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).! 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! Figure!10:!Erected!stand!facing!the!optimum! angle!relative!to!the!ground! direction!for!solar!energy!capture!

  • Page 14: Securing!Stand!With!Sandbags!And!Stakes

    AISPCA!Operations!Manual! 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! Figure!11:!Secure!the!AISPCA!stand!with!12!sandbags! 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.!

  • Page 15: Attaching!Solar!Panels

    AISPCA!Operations!Manual! 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! 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!14:!Engage!four!slide!latches!to!secure!the! Figure!13:!Engage!solar!panel!top!hooks! solar!panel.! onto!the!upper!support!posts.!

  • Page 16: Electrically!Connecting!Solar!Panels

    AISPCA!Operations!Manual! 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.! Figure!15:!AISPCA!wired!for!48!Volt.! Operation! 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.' Figure!16:!Positive!Connector.! Figure!17:!Negative!Connector.!

  • Page 17: Adjusting!Solar!Panel!Angle!For!Location!And!Time!Of!Year

    AISPCA!Operations!Manual! 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.!

  • Page 18: Connecting!Solar!Array!To!Charge!Controller

    AISPCA!Operations!Manual! 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.! Location! collector! cable! Figure!20:!AISPCA!Connection!of!solar!panels!to!GREENS!Controller.!

  • Page 19: Solar!Array!Operation!-!Disassembly!And!Packing!For!Transport

    AISPCA!Operations!Manual! 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.!! Figure!21:!Disconnect!Solar!Panels!by!Pressing!PIO.! 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.!

  • Page 20: Fold!And!Detach!Solar!Panels

    AISPCA!Operations!Manual! 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!22:!Unlatch! the!4!slide!latches.!! Figure!24:!Solar!Panel!Second!Fold.! Figure!23:!Solar!Panel!First!Fold.! Figure!26:!Remove!Solar!Panel!by!sliding! Figure!25:!Folded!Solar!Panel!Ready!for! the!Top!Hook!off!the!Support!Posts.! Removal.!

  • Page 21: Remove!Sandbags!(And!Empty)!And!Tent!Stakes,!If!Used

    AISPCA!Operations!Manual! 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!28:!Roll!Longerons!neatly!and!uniformly! Figure!27:!Start!Rolling!Stand!Using!Pre] to!make!it!easier!to!pack!into!transport!case.! Rolled!Longerons.! Figure!29:!When!stand!is!fully!rolled,!wrap!with! Figure!30:!Fully!rolled!stand!ready!for! integrated!cover!and!secure!Velcro!straps.! packing!into!transport!case.!

  • Page 22: Pack!Components!In!Transport!Case

    AISPCA!Operations!Manual! 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.
  • Page 23 AISPCA!Operations!Manual! Figure!31:!Schematic!of!Packing!Arrangement!for!Solar!Arrays!and!Rolled!Stand!in!Transport!Case.! Figure!32:!First!solar!panel!placed!into! Figure!33:!Second!solar!panel!placed!into! transport!case!with!junction!box!face!up! the!transport!case!with!junction!box!face! towards!wheel!end!of!case.! down!away!from!wheel!end!of!case.!! Figure!34:!Case!with!4!solar!panels!and! rollable!stand!packed,!ready!for!loading!of! Figure!35:!Labels!in!case!showing!how!to! route!solar!panel!wires.!! stakes,!sandbags,!and!collector!cable.!

  • Page 24: Preventive!Maintenance!Checks!And!Services

    AISPCA!Operations!Manual! 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.!
  • Page 25 AISPCA!Operations!Manual! 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! Diode!Direction! Multimeter! Multimeter! Multimeter! Setting! Negative!Lead! Positive!Lead! 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.!

  • Page 26: Quick!Reference!Card

    AISPCA!Operations!Manual! Quick'Reference'Card'...

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