Solar Stik 11-1000020 Installation instructions

|1July 2021 |Solar Stik®Inc.

OPERATOR AND MAINTENANCE

MANUAL

FOR THE

SOLAR EXPEDITION 450W

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

Updated:2021714

P/N: 11-1000020

Solar Expedition 450W Solar Array

July 2021 |Solar Stik®Inc.2 |

Contents

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Product Safety Information and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations on Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Recommended Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electric Shock Hazard Related to Solar Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Environmental and Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPERATOR INSTRUCTIONS

What’s Included in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Expedition Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1. Positioning and Orientation of System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2. Assemble the Expedition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3. Connect the four (4) PV Panels of the Expedition in Series . . . . . . . . . . . . . . . . . . . . . . . . . 12

4. Connect Expedition to Solar Input Port of HyPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5. Position the Expedition for Optimal Orientation and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6. Secure the Expedition to the Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Measuring Maximum Power and Open Circuit Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Procedure to Measure Voc of a Expedition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Procedure to Measure Voc of a Single Expedition Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Disassembling and Repacking the Expedition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

TROUBLESHOOTING PROCEDURES

HyPR User Interface Reports No Voltage from Array. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

HyPR User Interface Reports Low Voltage from Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Expedition Bypass Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SUPPORTING INFORMATION

Expedition Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Expedition Temperature Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ABOUT SOLAR STIK, INC.

Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

|3July 2021 |Solar Stik®Inc.

Solar Expedition 450W Solar Array

List of Figures

Figure 1. Expeditions, Power Hub, and Expander Paks supporting a sensor ................................................................. 4

Figure 2. Expedition components in transport case (top) and unpacked (bottom).......................................................... 9

Figure 3. Sandbag (left) and tent stakes (right)................................................................................................................. 9

Figure 4. Working-space radius for the Expeditions and associated equipment........................................................... 10

Figure 5. Setting up the Expedition ................................................................................................................................ 10

Figure 6. Unrolling and standing up panel support rack ................................................................................................ 11

Figure 7. Unfolding and attaching PV panels ................................................................................................................. 11

Figure 8. Seating PV panels from the top down ............................................................................................................ 11

Figure 10. Connect negative and positive ends of cables as shown ............................................................................. 12

Figure 9. Connecting H4 PV solar panel leads............................................................................................................... 12

Figure 11. Loose solar panel lead wires (A) versus tucked away, protected wires and H4 PV connectors (B).............. 12

Figure 12. Expedition connected to HyPR SOLAR INPUT port .................................................................................... 13

Figure 13. Lever for adjusting angle of PV panels ......................................................................................................... 14

Figure 14. Securing the Expedition with sandbags........................................................................................................ 16

Figure 15. Impenetrable surface—twelve (12) 50 lb sandbags in total .......................................................................... 16

Figure 16. Securing PV arrays with tent stakes.............................................................................................................. 16

Figure 17. Expedition deployed without ground securing: no stakes and no sandbags ............................................... 17

Figure 18. Bent or broken catches and latches along side of the PV panel .................................................................. 17

Figure 19. Improvised repair: panel secured to stand with bolt ..................................................................................... 17

Figure 20. Bent and creased PV panel ........................................................................................................................... 17

Figure 21. Disconnecting cables and unlocking panels from rack................................................................................. 19

Figure 22. Proper folding of Expeditions and routing/stowing of cables ....................................................................... 19

Figure 23. Rolling the Expedition and securing with Velcro straps ................................................................................ 19

Figure 24. Bypass diode reverse-biased measurement................................................................................................. 22

Figure 25. Bypass diode forward-biased measurement ................................................................................................ 22

Figure 26. HC-4 connectors from a Expedition panel .................................................................................................... 22

List of Tables

Table 1. Terrain Type and Ground Securing Method ...................................................................................................... 16

Table 2. Product Weight and Dimensions....................................................................................................................... 23

Table 3. Operating Temperature Range.......................................................................................................................... 23

Section Page(s) Description Date

Published 07 July 2021

Revision History

Solar Expedition 450W Solar Array

July 2021 |Solar Stik®Inc.4 |

Introduction

Thank you for choosing the Solar Stik® Expedition 450W Photovoltaic (PV) Array. The Expedition

provides more power per pound than most any other photovoltaic (PV) panel on the market. It is

lightweight, rugged, and easily transported and deployed on almost any terrain. Each Expedition

is capable of converting sunlight into 450 watts of continuous power—energy that can be used to

charge batteries (Power Paks and Expander Paks), to power a DC load directly or an AC load using

a HyPR. The Expedition, as indicated by the name, is modular, like all Solar Stik Systems, allowing

users to size a system to meet the demands of any application.

Before setting up, please take the time to thoroughly study this manual. It will make operation easier,

safe, and more productive!

This document is subject to frequent revisions based on user feedback and program ofce

requirements, so please check the revision date to make sure you are using the latest information

available.

Figure 1. Expeditions, Power Hub, and Expander Paks supporting a sensor

GENERAL INFORMATION, EQUIPMENT DESCRIPTION,

AND THEORY OF OPERATION

|5July 2021 |Solar Stik®Inc.

Solar Expedition 450W Solar Array

Limitations on Liability

Since the use of this manual and the conditions or methods of operation, use, and maintenance of

this product are beyond the control of Solar Stik, this company does not assume responsibility and

expressly disclaims liability for loss, damage, or expense—whether direct, indirect, consequential, or

incidental—arising out of or anyway connected with such operation, use, or maintenance.

Due to continuous improvements and product updates, the images shown in this manual may not

exactly match the unit purchased.

This equipment CAN BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER

MEDICAL EQUIPMENT or devices; however, without limiting the generality of the foregoing, Solar

Stik , Inc. makes no representations or warranties regarding the use of the system in connection with

life support systems or other medical equipment devices.

Your safety and the safety of others is very important.

We have provided many important safety messages in this Manual and on your system. Always read

and obey all safety messages.

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill you or

hurt you and others. All safety messages will follow the safety alert symbol and the word

“DANGER”, “WARNING”, or “CAUTION”. These words are dened as:

DANGER Indicates a hazardous situation which, if not avoided, will result in death or

serious injury.

WARNING Indicates a hazardous situation which, if not avoided, could result in death or

serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or

moderate injury.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of

injury, and tell you what can happen if the instructions are not followed.

Product Safety Information and Instructions

This manual contains important safety instructions that must be followed during the installation and

operation of this product. Read all instructions and safety information contained in this manual.

Exercise caution when handling or operating equipment. Live power may be present.

Safety Information Labels

Solar Expedition 450W Solar Array

July 2021 |Solar Stik®Inc.6 |

Fire Hazard

Fire Types

Class A ﬁre - Fires in ordinary combustibles such as wood, paper, cloth, trash, and plastics.

Class B ﬁre - Fires in ammable liquids such as gasoline, petroleum, oil, and paint.

Class C ﬁre - Fires involving energized electrical equipment such as motors, transformers, and

appliances. Remove the power source and the class C re becomes a class A or B re.

Recommended Fire Extinguisher

NSN 4210-00-288-7219 Fire Extinguisher, Carbon Dioxide, 10 lb

Carbon dioxide is a liqueed gas, which is highly effective ghting class B and C res. These

extinguishers are ideal for areas where contamination and/or cleanup are a concern, such as data

processing centers, labs, and telecommunication rooms.

Use Sweeping Motion

WARNING

Only CO2(carbon dioxide) re extinguishers should

be used with Solar Stik equipment.

Using the Fire Extinguisher

When using the extinguisher on a re, remember PASS:

Pull the pin.

Aim the nozzle or hose at the base of the re from a safe distance.

Squeeze the operating lever to discharge the re extinguishing agent.

Sweep the nozzle or hose from side to side until the re is out. Move forward or around the re as

the re diminishes.

Watch the area for reignition until the cause has been xed.

|7July 2021 |Solar Stik®Inc.

Solar Expedition 450W Solar Array

Electric Shock Hazard Related to Solar Panels

WARNING

Standing water around the electrical equipment and/or intrusion of water into the System

components can increase the risk of electrical shock.

DON’T LET THIS BE YOU!

HIGH VOLTAGE: Solar arrays, and generators produce potentially lethal line voltages. When servicing

equipment, extreme care should be taken to protect against electrocution. Always work with another

person in case an emergency occurs. Disconnect power before checking controllers or performing

maintenance. Be sure the generator is properly grounded. Wear safety glasses whenever working on

any part of the System that requires exposure to mechanical or direct electrical contacts.

• PV panels produce electricity when exposed to light.

• Live power may be present at multiple points.

• Never route the cables through standing water.

• All cables and connections should remain dry.

Solar Expedition 450W Solar Array

July 2021 |Solar Stik®Inc.8 |

Environmental and Handling Precautions

All Solar Stik components are ruggedized, yet there are a few things the operator can do to prevent

failures and prolong the operational life of the product.

Water

• Do not operate equipment in or around standing water.

• Do not place cables that conduct electricity in or near

standing water.

Impact

The Solar Panels should be protected from being struck

by hard objects.

Dust

• All Solar Stik equipment is designed for operation in

climates where high levels of dust or other particulates

may exist.

• Clean the surface of the solar panels regularly to

maintain maximum output. Dirty panels produce less

power.

Heat

• Heat and solar loading reduce efciency and life

expectancy. Shade products (except solar panels) to

prevent the negative effects of heat.

• Solar Panels should be placed so that they are

exposed to adequate airow.

Wind

It is imperative that the solar panels are properly secured

to the ground so that they do not become dangerous

projectiles in high winds.

|9July 2021 |Solar Stik®Inc.

Solar Expedition 450W Solar Array

What’s Included in the System

Expedition 450 W Array Kit

1(4 ea) 112 W Trifold Photovoltaic (PV)

Solar Panel

2 Transport Case

3 Rollable Stand

4(12 ea) Sandbags and (10 ea) Tent

Stakes (inside sandbag)

5 30’ Solar Leash (sold separately)

Figure 2. Expedition components in transport case

(top) and unpacked (bottom) Figure 3. Sandbag (left) and tent stakes (right)

OPERATOR INSTRUCTIONS

Solar Expedition 450W Solar Array

July 2021 |Solar Stik®Inc.10 |

1. Positioning and Orientation of System Components

Identify the best location for each component of the System, keeping in mind the length of all cables

that will be used to connect all of the components. The Solar Leash provided is 30 ft long. These

lengths may vary if using cables other than the ones supplied by Solar Stik:

Figure 4. Working-space radius for the Expeditions and associated equipment

Expedition Setup Guide

30’

Expedition

Power

Management/

Energy Storage

Components

The Expedition can be deployed within a 30’ radius (the length of the Solar Leash) of the HyPR. If the

Expedition must be deployed more than 30’ from the HyPR, extensions are available.

Figure 5. Setting up the Expedition

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