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FUGU-ARDUINO-MPPT-HARDWARE-KICAD

An open source Arduino ESP32 MPPT Solar Charge Controller firmware equipped with charging algorithms, WiFi, LCD menus & more! Stay tuned for the design release and video tutorial.

Orginal Firmware project found here https://github.com/AngeloCasi/FUGU-ARDUINO-MPPT-FIRMWARE
Oringal Hardware project found here https://drive.google.com/drive/folders/1Sd2jWAb-F8NAXlJ6PLdhcnPDQV0alD15?usp=sharing

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charge_controller's Issues

Status of this project?

Did you get this PCB made? Do you need any more eyes lookin over it?

I'm trying to get one of these installed in my truck :)

Add input surge suppression

@krzysztof9nowak commented

  • Input fuse F1 might be unnecessary. MPPT current of a solar panel is about 90% of short circuit current, so it's impossible to select a fuse, which would fail on short circuit. However, I would consider adding some over-voltage protection in form of either Zener diodes or varistors, which could protect from voltage spikes induced by lightning strikes.

What do you think about this TVS? https://jlcpcb.com/partdetail/Brightking_Elec_taiwan-50SMDJ120CA/C729864 I see it's 26A peak amps. I'm not finding much for a better option at JLCPCB. I'd like more like 50A peak, so it has a chance of blowing the fuse if there is a surge event.

Design review

Hi, I am no electronics guru, but here are my suggestions.

Schematic:

  • Move C7 as shown on the screenshot. When buck converter operates, the current flowing between C7 and Q2 is a square wave. If this square wave current passes through ACS712 it introduces unnecessary noise to input current readings and increases losses on Q1 (according to P=I^2*R).
    image
  • Input fuse F1 might be unnecessary. MPPT current of a solar panel is about 90% of short circuit current, so it's impossible to select a fuse, which would fail on short circuit. However, I would consider adding some over-voltage protection in form of either Zener diodes or varistors, which could protect from voltage spikes induced by lightning strikes.
  • Isolated converter U2 can be replaced by a simple bootstrap circuit made from two transistors.
  • What core are you using for L1? 6 turns seems to be low for 64uH.

Layout:

  • The current loops of the converter seem excessively large. Have a look at this guide
  • Transistor Q3 will make poor contact with the heatsink and limit it's airflow.
  • The radiator seems a bit small, do you have any thermal specs or calculations for it?

Wrong resistor values in 3.3v regulator

Hi, thanks for making this available!

Just wanted to point out that the resistor values for the 3.3v regulator (R17/18/19) are wrong, this will fry your ESP32. In Angelo's original design they are 33k/33k/10k.

Change location of C7 to other side of current sensor

@krzysztof9nowak commented

  • Move C7 as shown on the screenshot. When buck converter operates, the current flowing between C7 and Q2 is a square wave. If this square wave current passes through ACS712 it introduces unnecessary noise to input current readings and increases losses on Q1 (according to P=I^2*R).
    image

C7 has been moved. As well C8 has been changed from Axial to Radial cap.

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