Nishati EXPEDITION 570 Operation Manual

Portable solar array

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XPEDITION

ORTABLE

PERATIONS

ART

™ 570

OLAR

RRAY

ANUAL

: 225651

UMBER

Nishati, Inc.

2200 E. Williams Field Rd., Ste 200

Gilbert, Arizona 85295

703-994-2339

www.nishati-us.com

Nishati Expedition™ 570 is a 570-watt

rated ruggedized portable solar array

designed to provide power in remote

locations and expeditionary conditions.

Expedition™ 570 is fully optimized for

power

output,

deployed

ruggedness, transportability, complexity,

and cost. The system is ideal for use with

portable

solar

and

controllers and batteries as part of a

complete solar power or charging system.

Expedition™ 570 incorporates frameless,

glass-free solar panels into an integrated

case and racking system. The self-

contained, integrated design enables

simplified array deployment by one or

two individuals in just minutes. This

system is built to military ruggedization

standards and is interoperable with

commercial

and

expeditionary solar and hybrid power

systems currently in use within the U.S.

Marine Corps and U.S. Army.

December 2020

footprint,

hybrid

power

government

Revision 201208

Table of Contents

Summary of Contents for Nishati EXPEDITION 570

Page 1 Nishati Expedition™ 570 is a 570-watt rated ruggedized portable solar array designed to provide power in remote locations and expeditionary conditions. Expedition™ 570 is fully optimized for power output, deployed footprint, ruggedness, transportability, complexity, and cost. The system is ideal for use with...
Page 3: Table Of Contents
Expedition™ 570 Operations Manual Table of Contents General Information ......................1 Use of Special Text Boxes ...................... 2 Background ........................... 3 Overview ..........................4 Solar Energy Basics ........................ 5 Solar Photovoltaic (PV) Systems .....................5 Solar Insolation and Irradiance .......................5 Diffuse and Direct Solar Radiation ....................6 Solar Panel Azimuth and Tilt Angle ....................6 Solar Panels and Arrays ........................8 Solar Array Location ........................8...
Page 5 Expedition™ 570 Operations Manual Table of Figures Figure 1: Expedition™ 570 Deployed ....................4 Figure 2. Solar Panel Sub-Assembly ....................4 Figure 3: Five Expedition™ 570 Stacked on a Standard Commercial Pallet ..........5 Figure 4. Solar Declination Angle Annual Variation ................6 Figure 5. Solar Azimuth Angle ......................7 Figure 6.
Page 6: General Information
Expedition™ 570 Operations Manual General Information Part Number 225651 (4) Nishati Endurance™ 140 solar panels with Merlin™ Interconnect Contents (1) Rugged transport case with integrated solar panel and racking (1) 35-foot Wire Harness Collector Cable (16) empty sandbags Weight 88 lbs.
Page 7: Use Of Special Text Boxes
Expedition™ 570 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.
Page 8: Background
Many of these kits continue to be deployed to overseas locations in support of military operations. In 2017, Nishati introduced the Expedition™ 570 Portable Solar Array as a less complex, lower cost and more powerful alternative to the Expedition™ 420M / 450. This system maintains the man-movable, vehicle-transportable, and glass-free qualities, but delivers 570 watts of rated power in approximately one half of the Expedition™...
Page 9: Overview
Figure 1: Expedition™ 570 Deployed frequently by personnel. Expedition™ 570 consists of 4 frameless glass-free rigid 142-watt rated Nishati Endurance 140 solar modules (Figure 2) within a ruggedized case, which also serves as the base of the portable ground- mounted rack/support system. Each of the four solar panels incorporate 3 bypass diodes to mitigate power-loss from partial shading and to protect the panel against reverse current flow for a total of 12 diodes per array.
Page 10: Solar Energy Basics
Expedition™ 570 Operations Manual Figure 3: Five Expedition™ 570 Stacked on a Standard Commercial Pallet Solar Energy Basics Solar Photovoltaic (PV) Systems PV systems are designed to harvest energy directly from sunlight. PV systems often include solar panels, batteries, power control electronics, and accessories that enable power applications. Solar Insolation and Irradiance Solar insolation is the amount of solar radiation received on a given surface area during a given timeframe.
Page 11: Diffuse And Direct Solar Radiation
Expedition™ 570 Operations Manual Diffuse and Direct Solar Radiation As sunlight passes through the atmosphere, some of it is absorbed, scattered, and reflected by: • Air molecules • Dust • Forest fires • Water vapor • Pollutants • Volcanoes • Clouds The result is diffuse solar radiation, which contains less concentrated solar energy.
Page 12: Figure 5. Solar Azimuth Angle
Expedition™ 570 Operations Manual [Source: PVEducation.org] Figure 5. Solar Azimuth Angle At latitudes north of the sun’s Declination for a given day, the apparent Solar Azimuth Angle changes throughout daylight hours from east to west through true South. At latitudes south of the sun’s Declination, the apparent Solar Azimuth Angle changes from east to west through true North.
Page 13: Solar Panels And Arrays
Expedition™ 570 Operations Manual If the solar panels have an adjustable tilt angle, adjust as follows: • Winter – latitude plus fifteen degrees • Summer – latitude minus fifteen degrees Figure 6. Tilt Angle Determination Solar Panels and Arrays Solar panels, also referred to as solar modules, are made up of multiple electrically connected solar cells. Solar arrays, in turn, consist of a several solar panels, which are electrically connected in series, parallel, or a combination of series and parallel circuits.
Page 14: Expedition™ 570 System Components
Expedition™ 570 Operations Manual Expedition™ 570 System Components Expedition™ 570 is composed of the following components shown in Figure 8. Figure 8: Expedition™ 570 Components Copyright © 2020 All Rights Reserved Revision 201208...
Page 15: Solar Array Operation - Set Up
Expedition™ 570 Operations Manual Solar Array Operation – Set Up 1. Opening the Case and Orienting the Solar Array 1a. Lay the Expedition™ 570 solar array on the ground or other flat solid surface with the Case Bottom to the ground side. The Case Bottom is slightly deeper than the Case Top and distinguished by carrying handles and butterfly latches around the case exterior perimeter.
Page 16: Figure 10. Un-Stow Solar Panel Assemblies And Lock The Solar Panel Support Tubes In Place
Expedition™ 570 Operations Manual 2. Erecting the Solar Panels 2a. Starting with either the Case Top or Bottom, unclasp the Solar Panel Storage Straps by slipping the strap loop of each of the front straps free from the rear strap “E” hooks. Raise the folded panels and grasp the Solar Panel Support Tube as it swings free.
Page 17: Figure 12. Secure The Solar Panel Assembly Support Straps
Expedition™ 570 Operations Manual 3. Securing the Solar Panels 3a. Secure all four Support Straps by stretching the straps just enough to join them and sliding the upper strap loop over the open end of the opposing lower strap “E” hook. (Figure 12) Figure 12.
Page 18: Figure 14. Four Series (4S) Electrical Configuration (Standard)
Solar Panel Assembly into the other in the event of a voltage mismatch between them caused by differential sun exposure or a malfunction. Nishati offers an optional diode-protected ‘Y’ cable for the 2s/2p configuration.
Page 19: Figure 15. Two Series / Two Parallel (2S/2P) Electrical Configuration
Expedition™ 570 Operations Manual Figure 15. Two Series / Two Parallel (2s/2p) Electrical Configuration Negative (Female) H4 Connector Positive (Male) H4 Connector Figure 16. Making Electrical Connections CAUTION Prior to connecting the Expedition™ 570 to a solar charge controller or other power electronics, verify that controller/electronics are rated to accept at least the open-circuit voltage and short- circuit current for the selected wiring configuration.
Page 20: Figure 17. Wire Harness Collector Cable Ends
Expedition™ 570 Operations Manual 5. Connecting Expedition™ 570 to a Solar Controller (Standard Configuration) 5a. After connecting the solar panel electrical connectors in a 4s configuration there will be two unconnected wires, one a positive (male) connector and one a negative (female) connector. A best practice for cable management is to make connections so that the free ends originate from the lower solar panels as shown in Figure 14.
Page 21: Figure 18. Example Expedition™ 570 Configuration With Power Electronics And Energy Storage
Expedition™ 570 Operations Manual Figure 18. Example Expedition™ 570 Configuration with Power Electronics and Energy Storage Copyright © 2020 All Rights Reserved Revision 201208...
Page 22: Solar Array Operation - Stowing And Packing For Transport
Expedition™ 570 Operations Manual Solar Array Operation – Stowing and Packing for Transport 1. Disconnecting Solar Array from Charge Controller WARNING Do not disconnect solar panel electrical connectors under load, disconnecting under load could cause damage, death, or injury. 1a. On the solar controller, turn off solar panel circuit breakers to stop the flow of electricity from the solar panels into the controller prior to disconnecting any cables.
Page 23: Figure 20. Disconnect The Solar Panel Assembly Support Straps
Expedition™ 570 Operations Manual 4. Fold Down Solar Panels and Stow Cables 4a. Disconnect all four Support Straps by unhooking from E-Hook clasp and lay the Lower straps outboard on the ground and clear of the panel stowage area within the case. (Figure 20) Figure 20.
Page 24: Figure 21. Stow Solar Panel Assemblies
Expedition™ 570 Operations Manual Figure 21. Stow Solar Panel Assemblies Rear Strap “E” Hooks Figure 22. Secure Solar Panel Assemblies CAUTION Failure to properly secure the solar panels within the case may cause damage during transit and, if done repeatedly, is likely to degrade panel performance over the life of the panel. Copyright ©...
Page 25: Figure 23. Re-Combine The Case Top And Bottom
Expedition™ 570 Operations Manual 5. Re-combine and Secure the Case 6a. Lift and rotate the Case Top to place the open side onto the Case Bottom’s open side, aligning the case tongue and groove lip and taking care to avoid pinching fingers (Figure 23). Figure 23.
Page 26: Preventive Maintenance Servicing And Checks
If any of these conditions exist, remove the affected Solar Panel Assembly from Service and contact Nishati for replacement components. 2. Clean Solar Panel Surface to Maximize Performance Though the Expedition™...
Page 27: Figure 25. Shade Solar Panel Sub-Assemblies One Pair At A Time
Figure 25. Shade Solar Panel Sub-Assemblies One Pair at a Time NOTE If a Solar Panel Assembly fails the bypass diode check, remove the assembly (two solar panels) from the array, replace with a properly functioning assembly, and contact Nishati for a replacement Solar Panel Assembly. Copyright © 2020...

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