v2 Meshtastic 3W Solar Enclosure Base Station LoRa Node for 3 Watt Solar Panel

This is a water resistant outdoor enclosure designed around a 3 watt solar panel. It was designed with Meshtastic in mind but it can be used for any solar project.

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Buy it fully assembled and ready to extend your mesh network:
https://www.etsy.com/listing/1312727008/meshtastic-solar-base-station-off-grid

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V2 Update

This update uses most of the same components and installation instructions as V1. Here are the differences:

• Supports the Multi-Chemistry Solar Battery Charger and Sensing Voltage Regulator (MCSBC-SVR-v1.1). A new solar charger that offers more efficient energy harvesting and support for LTO, LFP and Li-Ion batteries. Available on Etsy here.
• Supports 2 lithium titanate oxide (LTO) batteries. It still supports the dual 18650 battery holder listed below (use the v2-Battery-Sled). If you plan to use the RAK19004 Green Power module please let me know and I'll design a mount for it.
• Supports a round switch (comes with a water-resistant cover).
• Supports previous rectangle switch.
  • If using the MCSBV-SVR-v1.1 you can use an SPST switch of the same size since you only need to switch power from the charger to the RAK (use the same silicone cover linked below). The DPST switch linked below will still work, you'll just use one leg instead of both.
• Supports a hydrophobic vent (M12) to help equalize air pressure and reduce interior moisture.
• Supports the same cable gland and antenna pigtails as V1.
• The carrier plate from V1 was removed in favor of mounting the RAK base board and other components directly to the bottom of the enclosure. This helps to reduce print time/material and allows for a slightly shorter enclosure.
• The lid is taller which provides more strength. This helps to apply even pressure to the gasket and create a tighter seal.
• Increased the number of threaded inserts to 16 because the enclosure is a little larger and the screws would have been too far apart (I'm not aware of any issues with the V1 gasket/seal). You will need (16) M3x10 screws and inserts (use the link below for screws).
• Now supports two versions of heated inserts: Amazon (same as V1) or AliExpress (M3x5.0x6.0). Requires (16) total. 
• Requires (10) M2.5x4 screws
• Requires (4) M2.5x8 to mount the MCSBC-SVR-v1.1.
• V2 gasket is 132mm x 125mm. See below for instructions on cutting the gasket out of silicone using a Cricut. If you want to try printing a TPU gasket reach out and I'll provide the STL. It is not included here because it's not recommended. Most 3D printed TPU is too hard to provide a good enough seal to keep water and moisture from getting into the enclosure.

Print List for V2

• (1) Enclosure of your choice (there are 4 variant options for with/without the vent and for round/rectangle switch)
• (1) Lid
• (1) Hinge (same as V1)
• (2) Nut Carriage (same as V1)
• Battery options:
  • Li-Ion 2P 18650 Holder (linked below)
    • (1) Battery Sled
  • HTC2265 LTO (coming soon to Etsy)
    • (1) HTC2265 Holder Back
    • (1) HTC2265 Holder Front
    • (1) HTC2265 Holder Bar

Print settings are the same as described below. Installation instructions should be mostly the same as below. Reach out if you need more instructions.

V1.X

The enclosure is mounted directly to the solar panel. The interior space available for components is 100mm x 100mm x 28mm. The integrated bracket allows for setting a precise solar panel angle to take advantage of the sun in your area. It can be set at any angle from 0° to 90°.

The carrier mounts to the bottom of the enclosure using (5) M2.5x4 screws. If you need a special configuration for your components all you need to do is modify this one part.

The gasket is cut from 1/25" silicone rubber sheet using a Cricut machine (or any similar tool). Use the included SVG file and set the width and height to 4.921". You'll need to use the Deep Point Blade with "more" pressure. I was able to cut the gasket with one pass by using the Magnetic Sheet 0.5mm preset.

The RAK Wireless RAK19004 is the "Green Power" module. It has an input rating of 2v to 36v with an output of 5v. It has a buck/boost topology so even when the supply voltage from the solar panel is below 5v it will boost it. Normal regulators like this are not ideal for solar implementations. I now recommend an MPPT solar charger.

Print List - Solar Panel

• (1) Enclosure
• (1) Carrier
• (1) Lid
• (1) Hinge
• (2) Nut Carriage

Print List - No Solar Panel

• (1) Enclosure No Solar
• (1) Carrier
• (1) Lid

The “No Solar” version has mounting holes so it can be attached to a wall. Those holes are placed so you can use (2) U-Bolt clamps and attach this vertically to an antenna mast or pole. This version does not attach to a solar panel. If you want to use a solar panel you will need to arrange a bracket to hold it. Consider using this solar panel bracket for the popular 6 watt Soshine solar panel.

Instructions on this page are written for the Solar version. Use your judgement to determine what steps are appropriate for the No Solar version.

Print Settings

Print all parts at 0.2mm layer height, 6 perimeters, 5 layers top/bottom, and 50% infill. This needs to be strong. No supports needed. I printed this on a Prusa Mini+ using a heated enclosure.

Parts List

• 3 Watt solar panel
• RAK19007
• RAK4631 (Arduino variant)
• RAK19004
• 1/4" by 3" bolt
• 2x 1/4" washers
• 1/4" locking nut
• 6x M5x16 screws
• 6x M5 locking nuts
• 12 M5 washers (10mm diameter, no larger)
• 12x M3x10 screws
• 12x M3 brass threaded insert
• 5x M2.5x4 screws
• DPST Rocker Switch (4 pin)
• Rocker Switch Silicone Cover
• 1' 2p round cable 22 gauge
• JST-PH 2.0 male end with crimper tool (can solder an end on)
• 2x pair of JST-PH 2.0 male and female cables
• Various sizes adhesive shrink tubing
• U.FL/IPEX to N-Type female pigtail
• Silicone rubber gasket (custom)
• Full sheet of 220 grit sand paper
• Z-bracket
• U-bolt clamp
• PG7 cable gland
• Battery of your choice (the carrier also supports this 2P 18650 holder)
• Zip-ties (for battery)

Assembly Instructions:

1. Print all parts in ASA at 0.2mm layer height (ASA is waterproof, UV resistant and highly recommended). You could probably print this in PETG but it wouldn't hold hold out water as well.
2. Add the M3 threaded inserts to the enclosure using a soldering iron set to 270C (for ASA). Refer to this video (ignore the temp from the video): https://imgur.com/a/AIfxFGb
3. Put the sandpaper on a hard flat surface and sand the top of the enclosure evenly (where you just put the inserts). This will remove surface imperfections so the gasket creates a better seal. Refer to this video: https://imgur.com/a/WRl3HG4
4. Cut the barrel connector off the solar panel (cover the solar panel so it's not producing power). Cut one wire at a time to avoid a short.
5. Solder the 1' 2p cable to the solar panel. Use adhesive heat shrink for each leg and then a larger piece to cover all of it. Adhesive heat shrink will make this connection waterproof.
6. Solder or crimp a male JST-PH 2.0 connector onto the end of the 1' cable.
7. Prepare the two Nut Carriages by inserting the lock nuts and then the washers
8. Attach the enclosure to the solar panel.
   1. On a flat surface, lay the solar panel upside down so the wire is coming off the little box to the right (the solar panel label should be upside down).
   2. Slide the nut carriages under the holes in the solar panel.
   3. Set the enclosure on the solar panel so the holes align.
   4. Use two M5 screws with washers to screw the enclosure to the solar panel.
9. Solder the JST connectors to the switch according to the photo. The DPST switch can switch two independent lines. The switch should go between:
   1. The solar panel and the RAK19004
   2. The battery and the RAK19003/RAK19007
10. Attach the electronics and battery to the carrier. I used small zip-ties to secure the flat pack LiPo battery. You can choose to install a 2P 18650 holder instead. The carrier has holes for (4) M2.5x4 screws. Keep in mind this will be upside down. The battery needs to be secured so it won't move around.
11. Install the carrier into the enclosure with (5) M2.5x4 screws.
12. Install enclosure ports (cable gland, N-Type antenna pigtail and switch with cover)
13. Thread the solar panel cable into the cable gland and tighten the gland.
14. With the switch in the OFF position, connect everything to the switch. DO NOT turn it on without first attaching an antenna.
15. Lay the gasket over the enclosure so the holes align with the M3 inserts
16. Screw down the lid using (12) M3x10 screws
17. Use the U-bolt flat bracket (with holes in it) as a template against the z-bracket. Use a pencil to trace the holes from the flat bracket onto the z-bracket. Drill two holes at 5/16" (this should be on the side with one existing hole).
18. Attach the Z-bracket to the hinge using (4) M5 screws, (4) lock nuts and (8) washers.
19. Attach the hinge to the enclosure using the 3" bolt, washers and locking nut.

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Buy it fully assembled and ready to extend your mesh network:
https://www.etsy.com/listing/1312727008/meshtastic-solar-base-station-off-grid