SwitchDoc Labs SolarMax Lead Acid Assembly And Testing Manual Download

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SolarMax Lead Acid Assembly and Testing Guide

December 2019

Version 1.4

For powering solar systems such as systems based on the

Raspberry Pi, Arduino and ESP32/ESP8266

and the SwitchDoc Labs System

Version 1.4 December 2019

Summary of Contents for SolarMax Lead Acid

Page 1: ...ead Acid Assembly and Testing Guide December 2019 Version 1 4 For powering solar systems such as systems based on the Raspberry Pi Arduino and ESP32 ESP8266 and the SwitchDoc Labs System Version 1 4 December 2019 ...

Page 2: ...e SolarMax Lead Acid 13 Solar Panel Wiring 13 Grove Wiring Table 16 Jumper Wiring 21 USB Cable Wiring 23 Lead Acid Battery Wiring 24 Connect your 12 V Lead Acid Battery 27 Finally 29 Testing Your SolarMAX Lead Acid System 30 Testing With SkyWeather 30 Testing with a Raspberry Pi without SkyWeather 31 Installing Your SolarMAX Lead Acid System 32 The Science and Education Goals Behind SolarMax 33 Su...

Page 3: ...POBATIN to 5V Added Grove cable from Arduino Mini Pro LP to USB PowerCentral Enable Control port to implement hysteresis during low power conditions See article on www switchdoc com Version 1 4 Removed step W8 Not needed Page 1 Version 1 4 December 2019 ...

Page 4: ...esigned to collect and return data about the solar panel system to the powered or other computer via a LoRa link SolarMAX collects and transmits the following data every 30 seconds Battery Voltage Battery Current Solar Panel Voltage Solar Panel Current Load Voltage Load Current It also supplies the following about inside the SolarMAX box Inbox Temperature Inbox Humidity Page 2 Version 1 4 December...

Page 5: ...3 Version 1 4 December 2019 Table 1 1 Solar Max LeadAcid Solar Max LeadAcid Minimum Nominal Maximum Solar Panel Voltage 15V 18V 18V Solar Panel Voltage Solar Panel VOC 25V Solar Panel VOC 5V Load Current 5A 5V Load Current Solar Charging Current 4A Solar Charging Current Battery Type 12V Lead Acid Battery Type Size of Battery Large Size of Battery Cost of Battery Low Cost of Battery Available Outp...

Page 6: ...arMax Lead Acid Kit 12 V Lead Acid battery We recommend 20000mAh https amzn to 2qGCVd8 This battery fits PERFECTLY in the Bud Enclosure below M2 Nylon Hex Thread Assortment https shop switchdoc com products 140pcs box m2 nylon hex thread assortment kit Solid Core Hookup Wire 22 Gauge https amzn to 3202Ppa Bud Enclosure NBB 22241 Style B 6 25 32 x 10 23 32 x 6 25 32 https amzn to 2zk8B8R Spade Quic...

Page 7: ...nal https amzn to 2U6IN9J Tools Soldering Iron Straight blade Small Screwdriver Crosspoint Small Screwdriver Super Glue Silicon Caulking Wire cutter Wire stripper Pliers Drill Drill Bits for 1 holes 2 3 holes Page 5 Version 1 4 December 2019 ...

Page 8: ...Weatherproof Plug Part G Short USB Cable Type A Type A Part H Identical LoRa 433MHz Radio one for SolarMax Part H Identical LoRa 433MHz Radio one for receiving Computer Part I 16MHz Mini Pro LP Part J HDC1080 Temp Hum Part K 6 Port I2C Hub Part L Dual WatchDog Timer Cables 20cm Grove Cables 6 Cables Grove Connector to Female Pin Headers 1 Cable Single Wire Female to Female Jumper 2 Wires Page 6 Ve...

Page 9: ...Page 7 Version 1 4 December 2019 ...

Page 10: ...he upper left side of the lower part of the Bud Box See Part A and Part B location on pictures above Step 2 Drill 3 1 holes in the front of the lower part of the box Separate the holes by at least 2 inches center to center Two vent holes and one hole for the Part F USB Weatherproof Plug Page 8 Version 1 4 December 2019 ...

Page 11: ...Step 3 Insert Part F USB Weatherproof Plug into the BUD Box with the cap on the outside in the rightmost 1 hole Screw down Page 9 Version 1 4 December 2019 ...

Page 12: ... the back of Part D the Solar Controller Place the smaller heat sink on the top of Part D the Solar Controller If the heat sinks don t want to stay on us a small amount of superglue under the heat sinks Page 10 Version 1 4 December 2019 ...

Page 13: ... K and L Note Part E USB PowerCentral will hang off the Solar Control by itself without supports Feel free to add them if you wish Note that the Solar Charger has screws and headers included in the package with the heatsink Step 7 Glue an additional nylon spacer on Part J HDC1080 Temp Humidity Sensor and two on Part C INA3221 the same height of the spacers from Step 5 to provide a stable base Step...

Page 14: ...into the Solar Charger Board Part D Note you won t have the battery in the box yet But it s OK if you do Step 11 Label all parts optional but you will be happy you did Step 12 Using some Silicon Caulking attach some door screen over the center and left 1 hole to keep the bugs out of the box Now we move on to the wiring of the SolarMAX Lead Acid Page 12 Version 1 4 December 2019 ...

Page 15: ...f doing that https www switchdoc com 2015 07 handy tip building braided cables for projects NOTE We have now determined that if you are using 22 AWG wire you do not need to to double the wires One wire is sufficient for all the currents used inside the box Now insert one end of the braided wire with then ends stripped of the insulation into the pin the male pin has the larger hole in the end and c...

Page 16: ...Step 2 Place the other end of the black wire into the terminal of the Solar Charger SOLAR IN terminal Page 14 Version 1 4 December 2019 ...

Page 17: ... them together strip crimp then and assemble the female MC4 and install it in the Plus Hole in the box Run the end of this wire to the 3 Channel INA3221 ADC Part C and secure them in the IN2 screw terminal Page 15 Version 1 4 December 2019 ...

Page 18: ...in the SOLAR IN block This completes the Solar Panel Wiring CHECK YOUR WORK You will destroy the electronics if you mess up with this wiring Now we move on the Grove Wiring table Grove Wiring Table Note again make sure you are connecting things to the right places It all matters Optional We find the plastic clips on the Grove cable plugs annoying and often cut them off with wire clippers Page 16 V...

Page 19: ...ed I2C on USB PowerCentral Part E Any Port on the 6 Port I2C Hub Part K Step W3 20cm Grove Grove Connector on HDC1080 Temp Humidity Part J Any Port on the 6 Port I2C Hub Part K Step W4 20cm Grove Grove Connector Marked Grove I2C on Mini Pro LP Part I Any Port on the 6 Port I2C Hub Part K Step W5 20cm Grove Grove Connector Marked D6 D7 on Mini Pro LP Part I Grove Connector on LoRa TX Part H SolarMA...

Page 20: ...ader Black Wire to GND1 black header LABLED ON1 See picture below on Solar Charger Part D Clip the Yellow and White wires near the Grove Plug Step W8 Removed Step W9 20cm Grove Grove Connector Marked D3 D4 on Mini Pro LP Part I USB PowerCent ral Control Enable Grove Connector SolarMAX Lead Acid Grove Wiring Table Cable Type From To Notes SolarMAX Lead Acid Grove Wiring Table Step Page 18 Version 1...

Page 21: ...The below picture shows the results of Step W7 from above Don t get this wrong Check it again Page 19 Version 1 4 December 2019 ...

Page 22: ...This completes the Grove Wiring for SolarMAX Lead Acid Next is the jumper wiring Page 20 Version 1 4 December 2019 ...

Page 23: ...Jumper Wiring Step 1 REMOVED Page 21 Version 1 4 December 2019 ...

Page 24: ...w of the male pins on the Mini Pro LP Arduino board Part I See the picture below to get it right This is the wire that is connected to the WatchDog timer board If the WatchDog timer is not patted by the Arduino periodically then the WatchDog reboots the Arduino Mini Pro LP This makes sure the computer doesn t get lost and powers up correctly regardless of the funky way the power comes on from the ...

Page 25: ... t get the jumper wires correct This finishes the Jumper Wiring Now on to the USB wiring USB Cable Wiring Step 1 Take your short Type A to Type A USB Cable Part G and plug one end into the USB connector on USB PowerCentral Part E to the USB Connection on the USB Weatherproof Plug Part F This finishes the USB Wiring Now on to the Battery wiring Page 23 Version 1 4 December 2019 ...

Page 26: ...end to IN1 screw terminal and the other end to the Plus terminal on the 12 V BAT IN plug on the Solar Charger Part D BE CAREFUL TO DO THIS CORRECTLY CHECK IT AGAIN Step 2 Cut two 26cm Green wires braid them and strip both ends Connect on end of the Green wires to the 12V BATIN screw terminal as shown in the picture above Page 24 Version 1 4 December 2019 ...

Page 27: ...onnector and place the stripped Yellow Wires from the INA1 Screw down connector on the INA3221 ADC Part C into the spade connector and crimp the connector to hold them in place and make connection with the spade Page 25 Version 1 4 December 2019 ...

Page 28: ...nnector and place the Green Wires From the 12V BATIN Screw Connector on the Solar Controller Board Part D into the spade connector and crimp the connector to hold the wires in place and make connection with the spade Page 26 Version 1 4 December 2019 ...

Page 29: ...p 2 Slide the Yellow Spade connector connected to the Green wire which is connected to the terminal on the Solar Control Part D 12V BATIN screw down terminal on the Negative Spade on the 12 V Battery CHECK YOUR WORK Step 3 Slide the Red Spade connector connected to the Yellow Wire which is connected to the IN1 screw terminal on the IN3221A Part C board onto the Positive spade on the 12 V Battery M...

Page 30: ...r Reverse connection LED indicator when the battery is reverse connected at the BAT IN or SOLAR IN the corresponding orange LED REV BAT or REV SOLAR turns ON informing the user a reverse connection error If you have hooked up everything correctly you will see a number of LED lights on the WatchDog timer Part L the Mini Pro LP board Part I and the USB PowerCentral board Part E Page 28 Version 1 4 D...

Page 31: ...Finally Clean up your wiring by using some wire ties to make it neat Page 29 Version 1 4 December 2019 ...

Page 32: ... plug in the LoRa Radio Part H into the Serial Grove connector on the Raspberry Pi Pi2Grover board Next login into your Raspberry Pi in the SkyWeather kit and cd SDL_Pi_SkyWeather Note You can t be running SkyWeather in the background when you are running this test You must kill the process by doing something similar to this your process number will be different pi switchdoclabs SDL_Pi_SkyWeather ...

Page 33: ... LoRa Radio to the serial port on the Raspberry Pi This can be done most easily by using a Pi2Grover and plugging the Grove cable into the Grove Serial connector on the device Otherwise you will need to wire up the device to 3V Ground and then connect Rx GPIO 14 and Tx GPIO 15 Easier to use use a Pi2Grover https shop switchdoc com products pi2grover raspberry pi to grove connector interface board ...

Page 34: ... 16 SolarMax loadCurrent 170 90 SolarMax solarPanelVoltage 18 70 SolarMax solarPanelCurrent 412 00 SolarMax auxA 0 00 SolarMax Message ID 14675 It s working Installing Your SolarMAX Lead Acid System Plug your solar panel into the appropriate MC4 plugs on the outside of your box and your SolarMAX system is complete Take a TypeA USB to TypeA USB Cable and plug in your computer system SolarMAX provid...

Page 35: ...radio to gather and transmit data to a Raspberry Pi or Arduino Connecting up a radio to the Raspberry Pi Understand how your Solar Panel system is behaving by looking at the4 data Understand your solar environment and what affects it Learn about the new technology called the Internet of Things Support As with all SwitchDoc Labs products technical support is given through the forums on Forum switch...

Page 36: ...ed to product quality such as operating without following the operating manual and cautions natural disasters or force majeure SwitchDoc Labs LLC has compiled and published this manual which covers the latest product description and specification The contents of this manual are subject to change without notice Page 34 Version 1 4 December 2019 ...

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