SwitchDoc Labs SolarMax Lead Acid Assembly And Testing Manual

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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

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Page 1 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...
Page 2: Table Of Contents
What is SolarMAX Lead Acid? ..................SolarMAX Specifications ....................What is in the SolarMax Lead Acid Kit? ................. What Else is Required for the SolarMax Lead Acid Kit? ..........SolarMax Lead Part Identification ................. Step by Step Assembly ....................Wiring the SolarMax Lead Acid ..................
Page 3: Errata
Errata Version 1.3 - Removed single jumper pin from LIPOBATIN 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: What Is Solarmax Lead Acid
What is SolarMAX Lead Acid? SolarMAX Lead Acid is a SwitchDoc Labs designed system to charge Lead Acid batteries from 18V Solar panels in order to provide more power to small computer systems. SolarMAX is designed to collect and return data about the solar panel system to the powered (or other) computer via a LoRa link.
Page 5: Solarmax Specifications
SolarMAX uses a 433MHz LoRa module which can transmit up to 2 kilometers or further with larger antennas and uses very little power. This is a perfect system for powering SkyWeather and other small computer systems. SolarMAX Speciﬁcations Table 1-1 Solar Max Solar Max LeadAcid...
Page 6: What Is In The Solarmax Lead Acid Kit
Spade Quick Connect Crimp Cold-Pressed Terminals (for 12V Battery) - https://amzn.to/2OgxqLm You can buy all the above from SwitchDoc Labs as the SolarMAX Weather Proofing Kit. 100W 12V Solar Panel with MC4 Connectors - https://amzn.to/2rjjmYi (VOC 21.6V Max Power 17.4V)
Page 7 Solar Panel Crimping tools for MC4 (optional) - 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: Solarmax Lead Part Identification
SolarMax Lead Part Identiﬁcation • Part A - MC4 Minus Male (and Pin) • Part B -MC4 Plus Female (and Pin) • Part C -High Current INA3221 with Terminals • Part D -Solar Charger for 12V Lead Acid Batteries • Part E - USB PowerCentral •...
Page 9 Page 7 Version 1.4 December 2019...
Page 10: Step By Step Assembly
Note: Part C (High Current INA3221) will look like the picture below: Step by Step Assembly Step 1) Drill two 2/3” holes in the 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”...
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 Step 4) Place the large heat sink on 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 13 Step 5) Set the slide switch on the Solar Charger (Part D) to MPPT for the most efficient charging. Then set the Battery Gauge slide switch to Off also on the Solar Charger (Part D). Step 6) Attach Nylon Headers (with screws or nuts) to all the boards (Parts C, D, H, I, J, K and L). Note: Part E (USB PowerCentral) will hang off the Solar Control by itself without supports.
Page 14 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: Wiring The Solarmax Lead Acid
Wiring the SolarMax Lead Acid As you wire this unit, remember you are dealing with lots of current and voltages. Triple check your wiring! Wiring things backwards or incorrectly can result in destruction of the electronics and possible over heating.
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 Step 3) Using red 10cm long wires, braid 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 18: Grove Wiring Table
Step 4) Using Red 38cm long wires (We used White in the pictures above), braid them together and strip the ends. Run this wire from the 3 Channel INA3221 ADC (Part C) IN2- screw terminal to the “+ terminal on the Solar Charger (Part D) in the SOLAR IN block.
Page 19 Select the proper grove cables and connect them as shown in the table. SolarMAX Lead Acid Grove Wiring Table SolarMAX Lead Acid Grove Wiring Table Step # Step # Cable Type From Notes Step W1 20cm Grove Grove Any Port...
Page 20 SolarMAX Lead Acid Grove Wiring Table SolarMAX Lead Acid Grove Wiring Table Step # Cable Type From Notes Step W6 20cm Grove Grove Grove Connector Connector Marked D8/D9 on Mini Pro LP WatchDog (Part I) Timer (Part L) Step W7...
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
Jumper Wiring Step 1) REMOVED Page 21 Version 1.4 December 2019...
Page 24 Step 2) Take a Female to Female single wire jumper and connect it to the Arduino Reset on plug JP4 on the WatchDog Timer board (see picture). Step 3) Then connect the other end of the wire in Step 2) it to the 3rd to the left most pin on the second row of the male pins on the Mini Pro LP Arduino board (Part I).
Page 25: Usb Cable Wiring
If your jumper wires are loose, then put a drop of super glue at the place where the jumper meets the header. This will secure them. CHECK YOUR WORK! Things will not work if you don’t get the jumper wires correct! This finishes the Jumper Wiring.
Page 26: Lead Acid Battery Wiring
Lead Acid Battery Wiring This is the last of our wiring for SolarMax Lead Acid. Step 1) Cut two 38cm Yellow wires, braid them and strip both ends. Connect one 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.
Page 27 Step 3) Take the Red Cold Press Crimp spade connector 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 Step 4) Take the Yellow Cold Press Crimp spade connector 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: Connect Your 12 V Lead Acid Battery
Connect your 12 V Lead Acid Battery Step 1) If you have selected the recommended 12 V Lead Acid battery ( https://amzn.to/2qGCVd8 ), then place it into the Bud Box as shown. Positive terminal up. Use Velcro to hold the heavy battery in place. It fits snug into place.
Page 30 NOTE: The Solar Charger Board (Part D) has protection for reversing the 12V battery and the solar panels. If you reverse them, the appropriate LED will light up an there will be no damage. But, nothing will work either. :) 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.
Page 31: Finally
Finally Clean up your wiring by using some wire ties to make it neat! Page 29 Version 1.4 December 2019...
Page 32: Testing Your Solarmax Lead Acid System
Testing Your SolarMAX Lead Acid System If you are using a SkyWeather system, SkyWeather comes with support for SolarMAX. If you don’t have a SkyWeather system, jump down to “Testing your SolarMAX with a Raspberry Pi”. If you see the yellow light on the Mini Pro LP board (Part D) flicker about every 30 seconds then you are transmitting data.
Page 33: Testing With A Raspberry Pi (Without Skyweather)
After a while you will see something like this and then your SolarMax is working! You will see protocol 10, as this is a SolarMAX Lead Acid system. Otherwise you will see Protocol 8 (SolarMAX LiPo) or protocol 3, if you have a WXLink system.
Page 34: Installing Your Solarmax Lead Acid System
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 provides 5V through the USB cable.
Page 35: The Science And Education Goals Behind Solarmax
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.switchdoc.com If you have issues that can be solved by our fabulous customer service department, please go to www.switchdoc.com...
Page 36: Disclaimer
Disclaimer SwitchDoc Labs, LLC takes no responsibility for any physical injuries and possession loss caused by those reasons which are not related to product quality, such as operating without following the operating manual and cautions, natural disasters or force majeure.