MK III 12VDC 10Amp Single Axis Solar Panel Sun Tracker Controller Board for DIY projects

1. MK III Controllers Arrived

Single Axis MK III Design Features

New Features

1. Auto West to East Sensor at Night, Return automatically to east after the sunset

2. West to East trigger point adjustment

3. Set controller installation to be more natural orientation

4. Add over voltage TVS protection

5. Add anti flickering suppressor 

Common Features

1. Reverse Voltage Protection

2. LED indicators for each direction

3. Taller Water Clear 5mm LEDs

4. 12V 20 Amp Relay

5. No Need for heat sink, simplify the assembly and design

6. Thicken the main leads to be at least 1mm up to 3mm, better durability to high current

7. Smaller form factor to fit to a smaller dome case

*Note: Please see FAQ paragraph # 10 for common questions and answers

Mark II Sun Tracking Controllers arrived. These controllers are the best analog controllers until now with new innovative features. Better protection with over current and reverse voltage. Improved energy harvesting efficiency, now with built-in auto west to east sensor at night. Multiple flavors, e.g. Dual Axis, Single Axis, 12VDC3A, 12VDC10A, 24VDC10A etc... All in a compact form factor can be fitted into a Jar, Dome, or Small Enclosure for weather protection. In my eBay Store you can also find a variety of accessories that are added to existing systems, like Relay Modules, Wireless Controllers, Sensors etc...

Solar Panel Sunlight Tracker Controller advance technology, SMD low profile components, compact size, 10Amp 12VDC Relay. Required for hobbies, DIY projects, sunlight tracking, high quality etc... I'm using one from my own design at my garden, see pictures and movie clip.

I designed and fabricated this controller as a lesson learnt from my Solar Panel DIY project. I used controller for dual axis that I purchased on line, two of them actually stopped operating after several months mainly due to overheating causing the leads to "melt". In my design I added thick traces for the power lines. I also selected a comparator chip for extended temperature and made the PCB covered with white solder mask that should reduce a little bit the internal heat due to direct sunlight. I'm offering the controller with relatively comfortable price to the benefit of DIY hobbyists like me.

The design has two flavors, single axis or dual axis, i.e. one board with single sun tracking to control East/West or North/South and one with double axes to control West/East and North/South.

The sun tracker controller is supporting the most common application of 12VDC +/-20% from a battery, or any other power supply source. If you need 24VDC please see other listing in my eBay store.

The controller uses 20A/12V relay H-Bridge that drives the motor in either direction, i.e. clockwise/anticlockwise, left/right or up/down according to the sun location.  The controller do reposition for the morning sunshine automatically at night, it uses a dedicated west to east sensor on board. The design can work with only one LED, I put two LEDs for each compass direction to allow more flexible field of view since these LEDs have narrow angle field of view for better precision. Using the LEDs one can catch more field of view mainly due to clouds or other reasons that my block the sun, i.e. skew lightly the LEDs such that each LED will cover more angle, this will ensure smoother operation.

Please visit my Youtube Channel to see it working, URL: https://youtu.be/f_Z05bQw1kI?list=PL9n6C-MsF_W1AVWEN5f6w1MnkDQShryZh

You may like my other listing:

DIY Proto Breadboard PCB White or Yellow: https://www.ebay.com/itm/333234608146 

DIY Proto Breadboard PCB with Proto Build of H-Bridge Project: https://www.youtube.com/watch?v=YdZrKbVN09c&feature=youtu.be

Visit my eBay Store HobbizElectronics http://www.ebaystores.com/hobbizelectronics

DIY Sensors Board Module: https://www.ebay.com/itm/333405257471

DIY Single High Current Module: https://www.ebay.com/itm/333396177143

DIY Heat Temp Module: https://www.ebay.com/itm/333409364670

DIY Dark Light Module: https://www.ebay.com/itm/333409321972

DIY Auto West East  Sensor: https://www.ebay.com/itm/333728647371

DIY Dual High Current Module:: https://www.ebay.com/itm/333554217949

2. Parameter

3. Application

The applications for the controller are a matter of how wild or creative you are J

4. Instructions

The sensitivity of the sun tracker controller is set based on the LEDs (Green Water Clear) used to detect the sun and track it. The potentiometers on board are used to set the tipping point, should not touch them.

In the event that presetting was moved and a new calibration is needed, verify the following

Motor Connector Status for Single Axis

Note:

1.    J2_2 Square Shape Pad

2.    The above table is true when a light source (e.g. High-Power flashlight) is directed to the relevant LEDs

3.    In a dark room or no specific light source the output voltage on all connectors is Zero.

In a dark room or no specific light source directed to the PhotoLEDs, the output voltage on all connectors should be zero. If not, turn the potentiometer clockwise till it stops rotating the blue LED will turn ON. Verify no light source directed to the sensor LEDs and turn it anticlockwise slowly until the voltage on the relevant connector is zero or that the blue LED turn OFF, if needed turn to add extra notch to guarantee zero so it will not be too sensitive. Using a flashlight as source for light, test the correctness of the above table status, i.e. aim the flashlight beam to selected PhotoLEDs pair from close proximity and check the voltage on the relevant connector per above table the blue LED will turn ON.

The sensor (a.k.a Sun Tracker Controller Board) must be aligned with the axis, e.g. east to west, the controller has to be in parallel to the axis you would like to control. The sensor must seat on the axis moving with it, in parallel to the axis such that when the sun move from east to west the controller detect the movement and drive the motor to move the axis to the optimal point where the sun is.

For optimal performance of tracking the sun, the tracking sensor must not be hidden from the sun, i.e. be in the shad or be obstructed by nearby buildings, trees etc. In some cases such as clouds, fog, blur sky, dust the tracking after the sun might not be optimal.

For safety purposes you should use limit switches for your motor to prevent full circle but also end of move automatic stop such that the motor is not stressed unnecessary causing it to heat up and waste energy darning your battery or even be damaged. In most linear motors the limits switches are built in, this is not the case for axial motors.

5. Power Source

The Sun Tracking Controller is powered by using DC 12V +/-20%. The voltage source can be for example a car battery, Power Supply, an array of batteries etc. A good practice is to add a fuse in series to the power line of a 10Amp in order to protect the controller board from over current.

6. What in the Box

1.  1x Controller Board per order

2.   The box don't include a Dome or Jar Enclosure

I made special design to miniaturize the PCB form factor so it can fit a off the shelf 150mil Jar with 81mm/3.2in inner diameter, you can use your own DIY Jar. 

Please visit my store for Jar PET Kit, a bundle with installation hardware, make it easy for your project. 

Now my Dual and Single Axis Controller boards enhanced++ design can be installed in a 150mil Jar.

Jar Dome Sealed Enclosure Single Axis Solar Sun 12VDC Tracking Controller Board

http://www.ebay.com/itm/Jar-Dome-Sealed-Enclosure-Single-Axis-Solar-Sun-12VDC-Tracking-Controller-Board-/333533559105?hash=item4da8263941

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10. FAQ

1. I have just installed the sensors, full of sun but they are doing mostly nothing.

Check the wiring relative to the motor physical location and follow the sanity testing paragraph #3.

2. How to calibrate the potentiometers?

2.1. What is the best orientation of the photosensors?

2.2. Cannot adjust it accurately and it does not find the sun as it should?

2.2.1. Calibrating the LED East West Angle

Skew (left/right) lightly the LEDs such that each LED will cover more angle, this will ensure smoother operation.

It's an iterative process, where you adjust the LED angel slightly each time until you are satisfied with the results

2.2.2. Calibrating the LED North South Angle

Skew (up/down) lightly the LEDs such that each LED will cover more angle, this will ensure smoother operation.

It's an iterative process, where you adjust the LED angel slightly each time until you are satisfied with the results

2.2.3.  Calibrating the Potentiometer

In a dark room (natural light) or no specific light source directed to the Photo LED sensors (clear 5mm LED), the output voltage on the motor connector should be zero and all the SMD (Blue can be other color) LEDs are OFF. If not, turn the potentiometer clockwise till the potentiometer stops rotating, the relevant SMD LED will turn ON. Verify no light source directed to the Photo LED sensor and now start to turn the potentiometer anticlockwise very slowly until the relevant SMD LED turn OFF and the voltage on the relevant motor connector is zero. After this procedure use a flashlight to check again, it should work much better. You may need to do so several times until balance in the sensitivity is achieved.

3. How to verify the correctness of controller operation - Some Sanity Testing.

3.1. Use a flashlight to directly illuminate the clear 5mm photo LED sensors and see if it moving east and west and or north and south?

3.1.1. Illuminate West Photo LED, SMD (Blue) LED is ON, if you connected the linear motor, it will pull in or the PV move west

3.1.2. Illuminate East Photo LED, SMD (Blue) LED is ON, if you connected the linear motor, it will push out or the PV move east

3.1.3. Illuminate South Photo LED, SMD (Blue) LED is ON, if you connected the linear motor, it will pull in or the PV move south

3.1.4. Illuminate North Photo LED, SMD (Blue) LED is ON, if you connected the linear motor, it will push out or the PV move north

Calibrating the Controller: https://youtu.be/ggq5NX60bY8

Testing West to East Sensor: https://youtu.be/E2Q2Qx5fBH0

Testing the controller Functionality: https://youtu.be/kVAYwMuqoc0

3.2. Check the wiring connection. The +/- of the linear motor is set such that for

3.2.1.  East to West the actuator will pull-in. 

3.2.2.  In the morning, it will go West to East and it will push-out

3.2.3.  South to North the actuator will push-out. 

3.2.4.  In the morning, it will go North to South and it will pull-in

3.2.5.  Its common that the East to West actuator is installed in the right side when you look at the panel in front of you. In this case you should swap the motor +/-.

3.3. Check the DC power line and motor connectors wiring connection. 

3.3.1. 12VDC for 12V Controller

3.3.2. 24VDC for 24V Controller

3.3.3. The +/- of the DC power line is protected from reverse polarity

3.3.4. Verify the power line is connected to the DC connector only. Connecting the DC power line to the Motor Connector will damage the board beyond repair. In this case the warranty will be null and void.

3.3.5. The caption on the connectors is very clear and show what is the Motor connector and what is the DC power line connector. Furthermore, please consult with the technical information attached in the list or contact us for support.

3.3.6. The +/- of the motor connector will not harm the controller, yet polarity/direction of the motor will be swapped, e.g. instead of pull, it will push or rotate anticlockwise instead of clockwise.

4. Sensor installation

4.1. Where to install the Sensors Board?

The sensors board must be installed on the moving PV Panel

4.2. What is the orientation?

The sensors board should be installed horizontally to the panel and perpendicular to the compass directions and above the PV panels such that it will see the sun without obstructions. Use the compass bearing caption on the board

4.3. How to protect the board from rain, dust?

Use a Dome, Jar any transparent sealed enclosure.

4.3.1. Transparent enclosure material 

4.3.1.1. Glass is the best, yet its fragile and heavy

4.3.1.2. Acrylic with UV resistance, super transparent

4.3.1.3. PET - Poly Ethylene Terephthalate, strong, fully recyclable and fair resistance to UV

4.3.1.4. ABS, Polycarbonate are OK as long as they are UV treated. If not, they will deteriorate and be milky/yellowish over time

4.4. Where to find an enclosure?

4.4.1.  DIY using a honey/jam Jar made from Glass, cosmetic Jar PET. The inner diameter of the Jar opening should be at least 81mm and with metal lid for grounding and longer life survival.

4.4.2.  DIY using security camera box or a dummy camera box with the transparent dome. Two caveats, the dome should be UV resistance otherwise it will become opaque/milky over time. Use some silicon glue for sealing.

4.4.3.  There are multi links on eBay/AliExpress for UV resistance " 4 Inch Indoor / Outdoor CCTV Replacement Acrylic Clear Monitoring Camera Cover Dome Housing"

4.4.4.  You can find on my eBay Store a DIY Jar PET - Poly-Ethylene Terephthalate plus hardware installation kit 

4.5. I'd like to start with just one axis system and then add a second axis afterwards. Is this possible by just leaving the North / South clamps on your board empty?

4.5.1. Yes, each axis works in parallel and independently

4.5.2. Just connect the right axis to the right actuator and it will work fine 

4.6. Installing the controller board. What should I do with the plastic spacer and washer in the box

4.6.1. The spacer shall be installed under the board to isolate it and prevent potential electric short

4.6.2. The washer shall be installed between the PCB and the screw head or nut to prevent damage to the board traces when tightening it 

4.6.3. When handling the controller board please have ESD protection in place

5. Limit switches, why I need it? How I install them?

The limit switches prevent from the motor to exceed end of move for linear motors or prevent 360 rotation of axial motors, thus preventing damage, overheating and burning of the motor or the controller.

5.1. Most if not all linear motor actuator has a build in limit switches no precautions are needed. However axial motors usually do not have such and do need limit switches

5.2. Wiring diagram URL: https://i.ebayimg.com/images/g/sk8AAOSw5Mle87~3/s-l1600.jpg

6. Will this work for stepper motors, brushless, or actuators?

The sun tracking controller support DC voltage motors such as

6.1. Linear Motor or an Actuator that move In and Out

6.2. Axial Motor that rotate 360 clockwise or anticlockwise

6.2. The sun tracking controller does not support Stepper Motors that need pules to rotate clockwise or anticlockwise.

7. West to East Sensor

The controller support returning to east at the end of the day after the sunset automatically

7.1. It is highly recommended that the controller will not be installed under or near by a lantern / street light. This may prevent the sensor to work properly.

7.2. The default setup of the sensor is to deep night i.e., very low light. The LDR (Light Dependent Resistor) is calibrated using a 3.3MOhm. To trigger the move to East earlier, need to adjust the 3.3MOhm to lower value. The trade off is false alarm where it may trigger too early due momentarily conditions such as a dark cloud, shadow from nearby buildings, dark gray sky etc…

8. Tips to Improve Durability

Is there something in your design that would make it more durable? First, all new MK III have an Over Current, Over Voltage and Reverse Voltage Protection. With all the electronics baking under a glass enclosure midsummer, would your unit fail also due to too much heat in a short time. Any thoughts would be appreciated.

8.1. Would it help to just remove glass dome during our long dry season to get air flow on electronics? No, it will bring other issues like dust, dew, bird poop etc…

8.2. Adding a hole at the lid bottom side for ventilation can help, somewhat

8.3. Ultraviolet due to direct sun will cause over time degradation to components, and plastic parts like connectors, LEDs etc…

8.3.1. A good option is to use the Sensor Board Only, such that the controller can be placed away from the direct sun

8.3.2. Can put a cardboard that will cover/shadow the electronics from direct sun. This will prolong the life of the controller. Do not cover the Photo LEDs or the LDR

8.4. Another thing that you can do, is to flip and place the board upside-down such that the back side will face the sun (need to put the LDR and Photo LEDs at this side too) 

9. Where do I find Fuse for my controller or relay module?

9.1. I have checked the relay module and it appears the XX Amp fuse is blown. Is this item something I can find in the U.S.?

9.2. First check why the fuse was triggered, are the wiring correct? Is the load is too high? was there any electrical short?

9.3. You need to look for "1808 SMD Ceramic Fuse XXA" on eBay/AliExpress (I'm using slow blow from Littlefuse)