Nishati Expedition 570 User manual

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

portable solar and hybrid power

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 government

expeditionary solar and hybrid power

systems currently in use within the U.S.

Marine Corps and U.S. Army.

EXPEDITION™570

PORTABLE SOLAR ARRAY

OPERATIONS MANUAL

PART NUMBER:225651

Nishati, Inc.

2200 E. Williams Field Rd., Ste 200

Gilbert, Arizona 85295

703-994-2339

www.nishati-us.com

December 2020

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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

Expedition™ 570 System Components ................................................................................... 9

Solar Array Operation –Set Up ............................................................................................ 10

Solar Array Operation –Stowing and Packing for Transport ................................................. 17

Preventive Maintenance Servicing and Checks..................................................................... 21

Provisioning Information ..................................................................................................... 23

Expedition™ 570 Operations Manual

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Expedition™ 570 Operations Manual

iii

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. Tilt Angle Determination ......................................................................................................8

Figure 7. Four-panel Solar Array .........................................................................................................8

Figure 8: Expedition™ 570 Components ..............................................................................................9

Figure 9. Unlatch, lay out and orient the Expedition™ 570 Case Top and Bottom ...............................10

Figure 10. Un-stow Solar Panel Assemblies and lock the Solar Panel Support Tubes in place ..............11

Figure 11. Rotate the solar panels into position. ...............................................................................11

Figure 12. Secure the Solar Panel Assembly Support Straps ...............................................................12

Figure 13. Sandbag the Case Top and Bottom ...................................................................................12

Figure 14. Four Series (4s) Electrical Configuration (Standard) ...........................................................13

Figure 15. Two Series / Two Parallel (2s/2p) Electrical Configuration .................................................14

Figure 16. Making Electrical Connections ..........................................................................................14

Figure 17. Wire Harness Collector Cable Ends....................................................................................15

Figure 18. Example Expedition™ 570 Configuration with Power Electronics and Energy Storage .........16

Figure 19. Disconnect Solar Panels by Squeezing the PIO tabs ...........................................................17

Figure 20. Disconnect the Solar Panel Assembly Support Straps ........................................................18

Figure 21. Stow Solar Panel Assemblies ............................................................................................19

Figure 22. Secure Solar Panel Assemblies..........................................................................................19

Figure 23. Re-combine the Case Top and Bottom ..............................................................................20

Figure 24. Secure the Case Latches ...................................................................................................20

Figure 25. Shade Solar Panel Sub-Assemblies One Pair at a Time .......................................................22

Expedition™ 570 Operations Manual

General Information

Part Number 225651

Contents (4) Nishati Endurance™ 140 solar panels with Merlin™ Interconnect

(1) Rugged transport case with integrated solar panel and racking

(1) 35-foot Wire Harness Collector Cable

(16) empty sandbags

Weight 88 lbs.

Outside Dimensions 43” x 38.37” x 6.75”

Stowage Volume 6.4 cubic feet (cu. ft.)

Max Deployed Footprint 22.9 ft2(@ 35° deployment angle)

Rated Solar Power Capacity 570 Watts

PV Efficiency >19%

Open Circuit Voltage 79.6V DC (Solar Panels Wired in Series)

Short Circuit Current 9.0 Amps (A)

Operating Temperature -4° to 140° F

Storage Temperature -25° to 160° F

Weatherproofing IP67: Protected from dust / water (to 1m immersion for 30 min)

Wind Certification 50 MPH for 30 minutes with 800lbs. (400 lbs. per side)

Gust to 70 MPH when secured with 800 lbs. (400 lbs. per side)

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.

NOTE

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

Expedition™ 570 Operations Manual

Background

The Nishati Expedition™ 420M Portable Solar Array, also known as the Advanced Integrated Solar Panel

Case Assembly (AISPCA), replaced conventional glass solar panels in hardened transit cases that were

originally fielded by military services. The 420-watt rated Expedition™ 420M/AISPCA dramatically

improved transportability in expeditionary operations, reducing the system weight by 52% and the

volume by 68%, while eliminating the more fragile and reflective glass and maintaining the solar

performance. Since 2015, Nishati has delivered approximately 4,500 Expedition™ 420, and its 450-watt

rated obsolescence replacement Expedition™ 450, to the U.S. Marine Corps, U.S. Army, and other

government agencies to meet remote power requirements. 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™ 420M/450 footprint when deployed. The Expedition™ 570 is much easier to deploy

and pack up and the simplified design improves manufacturability, field supportability and cost.

Expedition™ 570 Operations Manual

Overview

Expedition™ 570 (Figure 1) is a ruggedized

portable solar array that is compatible with

a range of ruggedized commercial-off-the-

shelf (COTS) solar, renewable, and hybrid

energy systems used by the U.S. Marine

Corps, U.S. Army, and other military,

government, and commercial systems.

Expedition™ 570 is designed for the harsh

operational and environmental conditions

encountered in the field. This equipment is

intended for transport by military ground,

air, and sea vehicles and to be moved

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.

Solar panels are joined in pairs by a hinge assembly and the

pairs deploy side by side supported by the integrated rack and

case system at a 35fixed angle. In the standard system

configuration, the four solar modules are connected

electrically in series. An option to connect each pair in series

and then connect the pairs in parallel is available for working

with solar controllers that are unable to accept the series

open-circuit voltage of 79.6V. Each module pair with racking

folds down to fit within their respective case halves, which

then clasp together to form the transport configuration. (16)

sandbags (empty) and one 35-foot Export Power Cable are

included with the standard kit. Tie down straps and stakes may be added to the kit as an option. The

system is equipped with multiple carrying handles to permit single or two-person movement and two-

person lift.

The complete system measures 43.0” x 38.4” x 6.75” in the transport configuration and weighs 88 lbs. The

system deploys in a surface area of less than 23 ft2(86” x 38.4”). Systems can be stacked up to eight high

for palletized transport and can be stacked vertically on their edge for trailer or other space-constrained

transport provided there is a means to secure them.

Figure 1: Expedition™ 570 Deployed

Figure 2. Solar Panel Sub-Assembly

Expedition™ 570 Operations Manual

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.

It is used as a measure of how much energy from the sun is striking a location on the earth’s surface over

a given time and, hence, available for harvesting. It is typically denoted as watts per hour per square

meter. 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, and geographic location. Solar irradiance is a measure of how much

solar power is available at a specific location and time. On a clear day with the sun’s rays directly

perpendicular to a surface the solar irradiance is about 1,000 watts per square meter (W/m2), which is

also known as one 1.0 sun. Terrestrial solar panel power ratings reference standard test conditions (STC)

of 1,000 W/m2, 25C and air mass spectrum 1.5 (AM1.5).

PV modules harvest solar radiation and produce direct current (DC) electricity. PV 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

Figure 3: Five Expedition™ 570 Stacked on a Standard Commercial Pallet

Expedition™ 570 Operations Manual

Diffuse and Direct Solar Radiation

As sunlight passes through the atmosphere, some of it is absorbed, scattered, and reflected by:

The result is diffuse solar radiation, which contains less concentrated solar energy. The solar radiation that

reaches the Earth's surface without being diffused is called direct beam solar radiation. The sum of the

diffuse and direct solar radiation is called global solar radiation. Atmospheric conditions can reduce direct

beam radiation by 10% on clear, dry days and by 100% during heavily clouded days.

Solar Panel Azimuth and Tilt Angle

Solar Declination Angle (), or Declination, is the angle between the equator and a line drawn from the

center of the Earth to the center of the sun. Declination varies based on the time of year due to earth’s

tilt, oscillating between 23.45north of the equator on June 21st and 23.45south of the equator on

December 21st (Figure 4). Azimuth is the angle along the horizon with zero degrees corresponding to

North and increasing in a clockwise fashion (when viewed from above) such that 90is East, 180is South,

and 270is West. Solar Azimuth Angle is the sun’s azimuth (Figure 5).

•

Air molecules

•Water vapor

•Clouds

•

Dust

•Pollutants

•

Forest fires

•Volcanoes

[Source: PVEducation.org]

Figure 4. Solar Declination Angle Annual Variation



Expedition™ 570 Operations Manual

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. Since most

Northern Hemisphere latitudes are north and most Southern Hemisphere latitudes are south of the sun’s

Declination for most of the year, a rule of thumb can be used for optimal fixed solar panel azimuth. That

is, in most locations at most times of the year solar panels and arrays should be emplaced facing true (not

magnetic) South in the northern hemisphere and true North in the southern hemisphere.

When using portable solar systems, it is possible to make fine adjustments to more closely track the sun

based on location, time of year, and even time of day. It may also be helpful to compensate for local

environmental effects. For example, in a valley with mountains to the west, facing solar panels slightly

east of true South to collect extra power during the morning can compensate for losing power in the

afternoon from the mountain shading.

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 at any given time. Once

a panel is aligned to the proper azimuth, the tilt angle is determined. Optimum tilt angle is determined by

latitude, solar declination angle (i.e. time of year) and time of day.

For a fixed solar panel system, 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. Figure 6

depicts this rule of thumb.

[Source: PVEducation.org]

Figure 5. Solar Azimuth Angle

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

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. Figure 7

shows linked solar panels in a solar array.

Most solar panels produce a relatively low amount of

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 to match load requirements.

Solar Array Location

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 care.

WARNING

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

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.

Figure 6. Tilt Angle Determination

Figure 7. Four-panel Solar Array

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

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.

1b. Unlatch the Case Assembly side latches by turning the butterfly handle of each latch

counterclockwise until tension is released then folding the handle flush and rotating the latch and hand

downward until flush with the Case Bottom.

CAUTION

Latch butterfly handles should remain flush with the latch and case except when being turned to

open or secure the case. Failing to maintain the latch handles flush during use and movement

may result in damage to the latch.

1c. Separate the Case Top from the Case Bottom by grasping the Case Top lip and lifting it free, and

then rotating to place on the ground next to the Case Bottom with the stowed solar payload facing

upward. The lower solar panel hinges that connect each set of joined Solar Panel Sub-Assemblies to the

Case should be placed toward the intended solar panel azimuth. (Figure 9)

Figure 9. Unlatch, lay out and orient the Expedition™ 570 Case Top and Bottom

Storage Strap

“E”Hooks

Case front

toward

recommended

solar azimuth

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. Pivot the bracket to the case rear, placing the bracket

base against the back wall of the case. Repeat this step for the other Case half. (Figure 10)

2b. Starting with either the Case Top or Bottom, rotate the upper Solar Panel Assembly to a position

in plane with the lower Solar Panel Assembly. Repeat for the other Case half. (Figure 11)

Figure 10. Un-stow Solar Panel Assemblies and lock the Solar Panel Support Tubes in

place

Storage Straps

Disconnected

Figure 11. Rotate the solar panels into position.

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)

WARNING

Failure to secure solar panel Support Straps could result in damage, death, or injury.

3b. Secure each Expedition™ 570 Case Assembly with (16) 50 lb. sandbags using (8) sandbags per

case half, as shown in Figure 13.

WARNING

Failure to properly secure solar array to surface with sandbags could result in damage, death, or

injury in high winds.

Figure 13. Sandbag the Case Top and Bottom

Figure 12. Secure the Solar Panel Assembly Support Straps

Expedition™ 570 Operations Manual

4. Electrically Connecting the Expedition™ 570 Solar Array

4a. Prior to connecting any solar panels to power electronics or a load, electrically connect the four

solar panels as required to remain within power electronics voltage limits. The standard system

configuration is a four-panel string in series (4s) connection. An alternate configuration that connects the

Solar Panel Sub-assemblies into series pair (2s) strings within each Solar Panel Assembly and then connects

these two strings/Solar Panel Assemblies in parallel (2p) is also possible. The 2s/2p configuration requires

a cable or controller with diode protection between parallel circuits to prevent electrical current feeding

from one 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.

•4 Series (4s) Connection (Figure 14). At STC, the 4s connection provides a typical voltage of 79.7VOC

(open circuit) when not under load and 65.2V under load. In this configuration, the average current

delivered by the array under load is 8.72A.

•2 Series/2 Parallel (2s/2p) Connection (Figure 15). At STC, the 2s/2p connection provides a typical

voltage of 39.8V (open circuit) when not under load and 32.6V under load. In this configuration, the

average current delivered by the array under load is 17.4A.

4b. As required for the desired configuration, connect the positive (male) and negative (female) H4

connectors between solar panels by joining the male and female ends until they click together securely.

(Figure 16).

4c. Once the panel string is connected in series, connect the free positive and negative H4 connectors

to the opposing male or female H4 connection of the Wire Harness Collector Cable.

Figure 14. Four Series (4s) Electrical Configuration (Standard)

Expedition™ 570 Operations Manual

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. Solar array inputs that exceed controller

power ratings may result in damage to the controller electronics.

CAUTION

The 2s/2p configuration requires adequately rated blocking diode protection between parallel

solar panel circuits (strings). Connecting the array in a 2s/2p configuration without this protection

creates a risk of panel damage and failure.

WARNING

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

Negative (Female) H4 Connector

Figure 16. Making Electrical Connections

Positive (Male) H4 Connector

Figure 15. Two Series / Two Parallel (2s/2p) Electrical Configuration

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.

5b. Connect the Wire Harness Collector Cable ‘Y’ end female and male H4 connectors to the male

and female H4 connectors from the solar array. Figure 17 shows the Wire Harness connectors.

5c. Connect the Wire Harness to the solar controller. The standard Wire Harness terminates with an

ITT Cannon 2 Contact Bayonet female connector (P/N CA3106F20-23SB) that is intended to mate with a

male connector (CA3106E20-23SB) on the controller. The plug type can be modified at the factory or by

qualified personnel in the field to adapt to other solar and hybrid controllers. To connect the standard

harness, align the nubs on the Harness connector coupling nut with the slotted threads on the controller’s

solar input connector and twist clockwise until the connectors fully seat and lock together with a click.

5d. Connect additional Expedition™ 570 arrays in the same manner, as desired and as the controller

permits. Figure 18 shows an example configuration with four Expedition™ 570 inputs.

Figure 17. Wire Harness Collector Cable Ends

‘Y’end

connectors

Cannon

connector

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