Description
Micron Solar Tracker Controller – Single Axis Automatic Solar Tracking & Intelligent Charging Controller
The Micron Solar Tracker Controller is an advanced control unit designed for single-axis solar tracking systems, enabling solar panels to automatically follow the sun’s apparent movement throughout the day. The controller uses astronomical solar positioning calculations, real-time clock (RTC) information, and an inbuilt inclinometer for actual panel-angle feedback to position the solar panel at its required target angle.
Unlike simple timer-based tracking systems that operate an actuator for a predetermined duration, the Micron Solar Tracker Controller uses a closed-loop angle-control approach. It calculates the required target angle and operates the actuator until the panel reaches the desired position. This approach helps compensate for deviations caused by manual intervention, mechanical disturbances, or changes in the panel position.
The controller is designed for 12 V DC systems and provides a 12 V actuator output capable of handling loads up to 20 A. Its compact 170 mm × 120 mm enclosure is constructed from IP65-rated ABS material, making it suitable for outdoor solar installations where protection against dust and water ingress is important.
An integrated 16 × 2 LCD display provides useful operating information, including time, date, present panel angle, sunrise and sunset information, target angle, target time, load current, and system status. Four front-panel keys allow the user to access manual, programming, and installation/calibration functions.
The controller also incorporates an intelligent three-stage battery charging system, providing boost, equalization, and trickle charging for a 12 V, 7.5 Ah sealed lead-acid battery. This integrated charging arrangement helps maintain battery charge while protecting the battery against inappropriate charging conditions.
Astronomical Single-Axis Solar Tracking
The primary function of the Micron Solar Tracker Controller is to control the azimuth angle of a single-axis solar panel according to astronomical sun positioning.
The controller uses the current date and time obtained from its built-in RTC to dynamically calculate relevant solar positioning information, including sunrise and sunset timing. Based on this information, it calculates the appropriate target position for the panel.
The actuator is then operated to move the panel toward the calculated target angle.
The tracking process is repeated at a programmed interval during daylight hours.
This method provides a more intelligent approach than basic fixed-time actuator operation.
Closed-Loop Angle Feedback
A major feature of the controller is its automatic closed-loop control using an inbuilt inclinometer.
The inclinometer provides feedback regarding the actual panel angle. The controller compares this actual position with the calculated target position and operates the actuator accordingly.
This means the controller does not simply assume that the panel moved by a certain number of degrees because the actuator was energized for a certain period.
Instead, the objective is to achieve the required physical panel angle.
This provides an important advantage if the panel position changes because of:
- Manual intervention
- Mechanical movement
- Installation adjustments
- External disturbances
- Temporary actuator operation
- Maintenance activities
During the next tracking cycle, the controller can identify the difference between the actual and required angle and attempt to restore the panel to the appropriate position.
Adjustable Tracking Interval
The controller allows the user to configure the tracking interval.
The programmable interval can be selected from:
15 minutes to 90 minutes
in 5-minute increments.
At each programmed interval during daytime operation, the controller recalculates the next required target angle and target time and operates the actuator when required.
This provides flexibility for different solar-tracking applications and mechanical configurations.
12V Actuator Control
The Micron Solar Tracker Controller provides a:
12 V DC actuator output up to 20 A load
This allows it to operate suitable 12 V DC actuators used for single-axis solar tracking mechanisms.
The controller manages the actuator movement according to the calculated target angle and actual angle feedback.
The current monitoring and protection features help protect the actuator and controller from excessive load conditions.
The connected actuator must be selected according to the controller’s specified voltage and current capacity.
Wide Axis Angle Adjustment
The tracker axis angle is settable up to:
±60°
This allows the mechanical tracking arrangement to be configured according to the installation requirements.
An installation/calibration mode is provided for defining the start angle and end angle of the panel.
These limits help ensure that the actuator does not unnecessarily drive the panel beyond its configured mechanical operating range.
Automatic Mechanical Failure Protection
The controller incorporates an important actuator protection feature.
The actuator ON time is internally limited to approximately:
2.5 minutes
If the actuator operates for this maximum period but the panel does not reach the required target position, the controller assumes that a mechanical movement problem may have occurred.
The actuator output is then switched OFF to help prevent unnecessary battery drain and prolonged actuator operation.
The LCD displays:
“Mech Failure”
for approximately 3 seconds before the controller skips to the next target angle.
This feature can help protect the system in situations such as:
- Actuator obstruction
- Mechanical linkage failure
- Excessive mechanical resistance
- Jammed panel mechanism
- Actuator malfunction
Intelligent Three-Stage Battery Charger
The Solar Tracker Controller includes an integrated charger based on a three-stage intelligent CV/CC charging profile.
The charging sequence consists of:
1. Boost Charging
The boost stage rapidly replenishes battery energy when the battery requires charging.
The specified boost voltage is:
14.4 V DC
with a boost current limit of:
1.0 A
2. Equalization Stage
After reaching the peak charging voltage, the system enters the equalization stage.
The specified equalization voltage is:
14.4 V DC
Charging continues until the current falls to the specified threshold of:
0.01C / approximately 0.07 A
for the specified 7.5 Ah battery.
3. Trickle Charging
Once the battery is sufficiently charged, the charger switches to trickle charging.
The specified trickle voltage is:
13.5 V DC
with a trickle current limit of:
0.4 A
This helps maintain the battery in a charged state while compensating for internal losses.
Low Battery Protection
Battery voltage is continuously monitored.
The specified low-battery threshold is:
10.8 V DC
If the battery falls below this threshold, the controller automatically disconnects the actuator load to prevent unnecessary battery depletion.
If sufficient photovoltaic voltage is available, the charging system can begin the appropriate charging stage to replenish the battery.
This feature is particularly important for solar tracking installations because the actuator can consume considerable energy during movement.
IP65 ABS Enclosure
The controller is housed in an IP65-rated ABS enclosure.
This provides protection suitable for outdoor and industrial installations where the controller may be exposed to dust and water.
The enclosure is specified as ABS grade, IP65, making it suitable for appropriately installed solar-tracking systems.
Two IP65-rated ABS cable glands are provided for cable termination.
Proper installation, cable routing, gland tightening, and enclosure sealing remain important for maintaining the intended environmental protection.
LCD Display and User Interface
The controller uses a:
16 × 2 character LCD display
The display provides important system information and operating status.
In Normal Mode, the display cycles through information such as:
- Current time
- Present panel angle
- Sunrise time
- Sunset time
- Next target angle
- Next target time
- Load current
- Current date
This provides the operator with a convenient overview of the solar tracker system.
Operating Modes
The Micron Solar Tracker Controller provides several operating modes.
Normal Mode
Normal Mode is the default operating mode.
The display cycles through important operating parameters, allowing the user to confirm system operation.
Manual Mode
Manual Mode allows the user to manually move the panel in the forward or reverse direction.
It is particularly useful during:
- Initial installation
- Mechanical alignment
- Maintenance
- Troubleshooting
The manual mode is intended primarily for installation and servicing and should be exited when normal automatic tracking is required.
Program Mode
Program Mode allows users to configure parameters such as:
- Date
- Time
- PV threshold
- Actuator current limit
- Tracking time interval
This allows the tracker to be adapted to different installation requirements.
Installation/Calibration Mode
The installation mode allows the user to establish the:
- Start angle
- End angle
These limits define the permitted mechanical tracking range and help prevent the actuator from being driven beyond the intended panel position.
Safety and Protection Features
The controller includes several safety features:
- Reverse polarity protection
- Over-current protection
- Voltage spike suppression
- Actuator mechanical-failure protection
- Low-battery load disconnection
- Actuator ON-time limitation
- Configurable current limit
- Configurable start/end mechanical angles
These features are intended to improve the reliability and protection of the solar-tracking control system.
Conclusion
The Micron Solar Tracker Controller is an intelligent single-axis solar tracking control solution designed to automatically position a solar panel according to the sun’s astronomical position. By combining RTC-based solar calculations, an inbuilt inclinometer, closed-loop actuator control, programmable tracking intervals, and configurable mechanical limits, the controller provides a more accurate and adaptable approach to solar panel positioning.
Its integrated three-stage battery charger, low-battery protection, actuator current monitoring, mechanical failure detection, and 2.5-minute actuator time limit add important protection and energy-management functions to the system.
The IP65 ABS enclosure, 12 V DC operation, 20 A actuator capability, 0.1° resolution, and large information-rich LCD make it suitable for appropriately designed outdoor solar tracking installations.
For solar-system manufacturers, solar-tracking integrators, renewable-energy engineers, OEMs, and specialized solar installations requiring automatic single-axis panel positioning and integrated battery management, the Micron Solar Tracker Controller provides a comprehensive control platform for accurate and protected solar tracking.
Japsin Instrumentation – Since 1974
