The Photovoltaic Master
A RasPi2Pv Project
The Project    Installation    Configuration    Self Construction

  Top Schematic

  Mount LEDs

  Power supply

  Bottom Schematic

  Raspberry PI Zero W

  DIN Module Box

  Support the Project


  Data protection

The RasPi2Pv self construction guide


The build process of the RasPi2Pv DIN rail Hardwarebox is quite simple. There are no SMD devices to solder so with a bit experience this is a possible job for everybody. I will guide you with a lot of pictures so just take your time and follow the instructions.


On the left you see the Schematic (click to enlarge) of the upper PCB Module, you will need the following material to build the module:
  • 8 * LED 3mm 2mA red
  • 7 * LED 3mm 2mA green
  • 1 * LED 3mm 2mA yellow
  • 16 * resistor 1.50KOhm
  • 2 * ULN 2803A
  • 2 * Dual Body Pin Headers 8 pin
  • 3 * Dual Body Pin Headers 4 pin
For the optional power supply:
  • 2 * Diode STPS 2H100
  • 1 * Diode P6KE 36CA
  • 1 * Capacitor 220uF 35V
  • 1 * Capacitor 1000uF 16V
  • 1 * LM2576 T5.0
  • 1 * Coil 100uH


We start with the smallest parts. In our case the diodes. Doublecheck the direction of D1 and D2 (STPS 2H100) marked by a ring on the end. D3 (P6KE 36CA) do not have a polarity.


Next we solder the sockets for the driver ICs.


Now we can solder all the 1.50 KOhm resistors.


To get the LEDs soldered in a row with the same height prepare a small stripe of plastic or carton with 23mm of size. Start with two LEDs and put them over. Solder just one leg so you can adjust them in the next step.


Bring the helping stripe in right angle and solder the second leg of the LED. All anodes of the LEDs are in the middel row.


Now you can solder all the other LEDs in that row. Make sure the polarity is correct.


The second row of the LEDs can be prepared in the same way. Start with two LEDs, bring them in right angle and solder all the other parts.


Before we start with the power supply push the Relays and LED drivers in their socket.


If you plan to provide a 5V power supply to the RasPi2Pv Box just solder a piece of wire between the marked pads. You can skip the next step and proceed with the pin headers.


If you prefer, what is recommended, to power the device with a voltage between 12V and 24V you need to solder the Power supply parts as well.


The easiest way to solder the pin headers is to get the help of the main pcb. Put all pin headers to the holes of the bottom pcb and you will get the right adjustment. Now you can solder all teh parts on the upper pcb.


Well done and ready to stack.


On the left you see the Schematic (click to enlarge) of the main PCB Module, you will need the following material to build the module:
  • 1 * Raspberry PI Zero W
  • 1 * Female Header 2,54mm 2x40 pin
  • 1 * Female Header 2,54mm 2x4 pin
  • 2 * Female Header 2,54mm 1x8 pin
  • 1 * Female Header 2,54mm 1x4 pin
  • 1 * PCB Terminal Block 9 pin
  • 1 * PCB Terminal Block 4 pin
  • 1 * PCB Terminal Block 2 pin
  • 1 * USB-A Socket
  • 3 * resistor 470Ohm
  • 1 * 3 pin wired PCB Connector
  • 8 * miniature relais FRT5 DC 5V
  • 3 * optocoupler LTV817


The main pcb is soldered in the same way, we start with the smallest parts, here the 470 Ohm resistors.


We proceed with the LTV817 optocouplers.


Next we solder the 8 miniature FRT5 relays. Be aware of the polarity marked by the stripe on one side.


The Female Headers and the USB Socket is the next step.


Now we can solder the wired PCB Connector that is used for our Raspberry PI USB bridge.


The last step will be to solder all the Terminal Blocks.


The Raspberry PI USB connection need to be bridged to the main PCB. This is done with our PCB Connector. Keep the wires as short as possible, as you can see later on the connector is right beside the RasberryPI module.


The DIN Rail case that will hold all our modules need to be prepared as well. Maybe there will be a 3D Printer solution in the future here.


We need to cut of the tabs as otherwise those tabs well press on the SD Card and break it.


To prepare the holes for the LEDs you can use this template. Just scale it with the printer to the needed size and mark the center with a center punch. Now you can drill the holes with a 3mm drill. The holes for the screws of the Terminal Blocks are already preprepared. Note that on one side we do not break out 4 holes as the USB socket is underneath.


We are almost finished. Screw the main PCB in the DIN Rail bottom. As we want the USB socket on the upper side, screw the pcb in the shown direction. USB opposite of the black lock.


Now we can stack the Raspberry PI Module on the main PCB and connect the USB bridge with our PCB Connector.


The upper PCB is just stacked above the other modules.


Before we can close our DIN Rail case make sure the SD Card is inserted to the Raspberry PI SD Card holder!


In the final step we close the cover of the box. Well done! How to connect the Box to the outher world is described in the installation guide.


Support the RasPi2Pv Project


If you like to support the project, what is very welcome, you can help with a donation (just use the Donate with PayPal button on the left side) or help with translation or other work that is helpful. If you like to work on the project or add your extra features just contact me!