MK III 12VDC 3Amp Single Axis Solar Panel Sun Tracker Controller Board or DIY projects Including Jar Dome Enclosure made from PET

1. MK III Controllers Arrived

Single or Dual Axis MK III Design Features

New Features

1. Resetting Self-Recover Fuse for electrical short/over current protection 

2. Auto West to East Sensor and Night, Return automatically to east after the sunset

3. West to East trigger point adjustment

4. Set controller installation to be more natural orientation

5. Add over voltage TVS protection

Common Features

1. Reverse Voltage Protection

2. LED indicators for each direction

3. Taller Water Clear 5mm LEDs

4. Improve efficiency using complementary N and P MOSFET channels to eliminate self heat dissipation under load

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

6. Thicken the main leads to be at least 1mm up to 2mm, better durability to high current

7. Smallest Controller Board form factor to fit to a smaller dome case or Jar 150mil - 250mil (Inner diameter 81mm/3.19in)

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

Many of my dear hobbyist friends asked me time after time for a solution, an enclosure for my Solar Panel Sunlight Tracker Controller. The solution I provide is an affordable Transparent Jar Sealed Enclosure made from PET.

I customized the Jar and added an installation kit. The Jar Sealed Enclosure support Single Axis Controller Board and also my Enhanced Plus Dual Controller Board.

Jar Dome Enclosure Features

1. Waterproof Cable Gland PG9

2. Waterproof Cable Gland IP68

3. Transparent Jar (Made from PET) Sealed Enclosure

4. Dust and Water Proofed (must tight strongly the Metal Lid to the Jar for best sealing performance)

5. All metal parts are anti corrosion treated 

6. Includes the Jar Transparent Dome and HW Installation Kit

7. Support the Enhanced Plus Dual Axis Sun Tracking Controller Board

8. The controller Board is included

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, small size, solid state high power MOSFETs. Required for hobbies, DIY projects, sunlight tracking, high quality etc... Im 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 support dual axis, i.e. the board with dual sun tracking control East/West and North/South for the southern and northern hemisphere.

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 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 Dual Axis

Notes:

1.    J2_1 Square Shape Pad, J3_1 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 3Amp in order to protect the controller board from over current. MK III controllers has on board 3Amp electronic fuse.

1. Single Channel High Current Module with on board replaceable 1808F 10Amp fuse

2. Dual Channels High Current Module with on board replaceable 1808F 10Amp fuse

3. 10Amp 12VDC Single Axis Solar Panel Sun Tracking Electronic Linear Control Board

For more details Please visit my Store: http://www.ebaystores.com/hobbizelectronics

* 2x Screws (D 4mm) (0.157in)

* 1x Plastic washers

* 2x Nuts

* 1x Plastic Spacer (H 9mm) (0.35in)

* 1x 100mm metal bar

* 1x Cable Gland PG9

8. Payment

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11. 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.

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. 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

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 +/-.

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.

4.4. Where to find an enclosure?

4.4.1.  DIY using a honey 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

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

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…