SOLAR SERVER HOW-TO

STEPS

1. Order components
2. Make the USB-to-RS245 cable
3. Program the Battery Disconnect  
4. Wire up the Solar Server Box
5. Wire up the PV module
6. Modify the Enclosure
7. Connect it all together
8. Some mounting options (wall-mounted, ballasted, pole-mounted, etc.)

STEP 1 - Order components!

See the Bill Of Materials for a list of components, materials and tools needed.

STEP 2 - Make the USB to RS245 Cable

1. Cut one end off an ethernet cable. Identify the solid blue and solid green wires and feel free to trim off all the others as well as the insulation.

[ALT - An ethernet cable with one end cut off and blue and green wires exposed]

2. Strip carefully the blue and green wires so that about 1/4 inch is exposed.

[Exposed blue and green wires ]

3. Inspect the USB to RS245 dongle and unscrew the two screw terminals.

[USB adapter with screw terminal]

4. Flip the adapter over and check the markings.

        [USB adapter flipped over on the side with markings A, B, D+ and D-]

5. Screw the blue wire into terminal B and the green wire into terminal A

        Blue → B / D-

        Green → A / D+

        [USB adapter and ethernet cable connected]

6. Secure the USB adapter using electrical tape. And voila’! Your USB to Ethernet RS245 adapter cable is done!

        [USB and ethernet cable secured together by electrical tape]

STEP 3 - Program the Battery Disconnect

1. Inspect the blue object and familiarize yourself with its inputs & outputs.

2. Unplug the remote green plug before programming the battery disconnect.

3. Disconnect anything that might be connected to the battery disconnect out.
4. ➽ To program the unit: attach the ground wire from the battery AND the ground wire coming out of the battery disconnect AND one more piece of wire together.  
5. Connect the terminal marked as IN to the positive + end of the battery.
6. With the disconnect powered on, make a connection with the loose ground wire to the PROG screw terminal pin until the 7-segment display displays the number 8. If unsure or if you made a mistake, you can reprogram it anytime by reconnecting a wire and touching the PROG pin until the desired state is displayed.

STEP 4 - Wire up the Solar Server Box

1. Layout all of the components.
2. Prepare the wire for the positive + terminal of the battery by cutting about 1-2 ft of red wire, and using scissors or wire strippers remove a ¼ inch of the rubber coating from all the ends. Screw-in the 20Amp in-line circuit breaker. Crimp the other end with a suitable connector for your battery terminals.

3. Prepare the wire for the negative terminal - of the battery by cutting ~1-2 feet of black wire, stripping one end and finishing the other end with the suitable terminal connector.

4. Prepare the wire you will use to connect the positive + terminal from the charge controller output (marked with the lightbulb icon) to the IN of the battery disconnect with the 10Amp inline circuit breaker.

5. Crimp the end with the right ring connector & connect to the IN side of the battery disconnect.  
6. Prepare the wire for the ground of the output from charge controller.
7. Connect the + wire of the USB voltage regulator/adapter to the OUT of the battery disconnect.
8. Connect the - wire of the USB voltage adapter to the other 2 black wire/grounds with a screw nut or just by stripping them and twisting them together securing them with electrical tape.  
9. Plug in the ethernet to USB adapter into the ethernet plug on the charge controller and the other end in one of the USB ports of the Raspberry pi.
10. Plug the USB to USB-C cable to connect the RaspberryPi.
11. Connect the battery and you should see the charge controller come to life.

STEP 5 - Wire up the PV module

1. Unbox your 50W solar panel and connect the 15Amp in-line fuse to the + connector in the back of the solar panel.

[In-line fuse on the positive end of the PV panel]

2. Connect one PV cable to the 15Amp fuse connector on the positive + side. Connect the other PV cable to the - connector and set aside.

 STEP 6 - Modify the enclosure

1. Using a step drill bit, or ~⅕ in drill bit, drill two adjacent holes for the two PV cable. Then screw in the smaller glands.

2. Drill one 1 in to 1¼ in hole, where you might want to connect the Server Box to an Ethernet connection, and screw in the Ethernet gland.

3. Drill a 0.69inch vent hole on the side of the enclosure, closer to the bottom. Screw in the vent.  

4. Using ¼ inch masonite, perf-board, MDF or plywood cut a piece YxZ size to mount all the elements inside and secure components with zip ties or screws components in place.

 STEP 7 - Connect it all together

1. ⚠ ALWAYS connect the battery first! ⚠ Most solar charge controllers on the market currently need a battery to operate and require to be plugged into the battery first in order to give the energy coming from the PV somewhere to go! To disconnect make sure to follow the reverse order: Disconnect the PV panel first >> then the battery 

2. Press the rightmost button on the charge controller to toggle between allowing energy to flow to the output or not. Shut it off before wiring up the USB voltage adapter to the output.

3. Lastly wire the + and - from the PV panel into the charge controller, by running the cables through the glands.

4. Check that the battery disconnect 7-segment display has a dot in the corner that blinks, this means that the disconnect is working.

5. If you are planning to connect the server box to your network through a wired Ethernet connection, connect a short ethernet cable from the ethernet port on the Pi to the ethernet gland.

 STEP 8 - Some mounting options

1. Depending on your specific location, there are different options for installing the system.  Ultimately the PV panel needs to be placed in direct sunlight, at an approximate 40° angle (based on your latitude) and facing towards the equator (if you are located in the Northern Hemisphere you are going to want to aim towards SE/W, if in the Southern Hemisphere towards NE/W).

2. There are multiple bracket options for installing the 50W PV:

1. Pole mounting                      b. Wall mounting                                 c. Tilt mounting

Tilt mounting brackets and hardware can easily be screwed onto a frame made of wood 2”x4” and weighted down with sandbags, cinder blocks, bricks or other weights.

Wiring Diagram