Harbor Freight Solar Panel Charge Controller

This is the charge controller included in the Harbor Freight 45W solar panel kit. The housing is a very nice aluminum extrusion which is also used as a heat sink for the electronics.

There are the following outputs on the unit:

- 5V USB

- Cigarette Lighter for the power inverter

- Cigarette lighter for 12 VDC

- 3.5mm jack for 3 VDC

- 3.5mm for 6 VDC

-  2x xxmm for 12 VDC

Model number of PCB: TPS-545-4A-02

Component List:

U1- ST LM393N - Dual voltage comparator
U2
U3 - not populated
U4
U5

Q1
Q2
Q3
Q4
Q5
Q6 - not populated

K1
K2
K3
9V - not populated
L-B-
3V
6V
USB
LED1
B-B+

C1
C2
C3 - not populated
C4 - not populated
C5 - not populated
C6

D1
D2
D3
D4
D5 - not populated
D6
D7
D8
D9
D10
D11
DZ - not populated

F1
F2 - to external ATO fuse

L1 - not populated
L2
L3 - shorted

R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21 - not populated
R22 - not populated
R23 - not populated
R24

EL 817 Optocoupler

Update (May 11th, 2015):
I've discovered another website with more information on the controller as well as schematic. Please see the links below.
http://www.kiblerelectronics.com/corner/ccii_29.html
http://www.kiblerelectronics.com/corner/HF_charger_sch.pdf

Snow Blower Light & Voltage Regulator Functional!

Revision 2.0 of the circuit board. The differences from version 1.0 are:

- PCB Mounted 15 Watt Heatsink (at 90% efficiency & 5A load, only 6-7 watt of dissipation needed)

- Mini ATO Automotive Type Fuse Holder (5A Fuse)

- New improved layout of components

- It actually works! Regulates voltage to ~12VDC.

Known problems with the circuit:
-TO-220 Package diode hole are obstructed by the headsink (as seen in the picture above)
-Tantalum capacitor still not in circuit (ran out of them from blowing them on the v1.0 pcb)

Hour meter at top of the picture reads 11.6 hours. I don't have that many hours on it. I've put about 2 hours on it since installing the meter on the blower. Below the hour meter is a DC lighted switch for the LED spot light.

LED light is mounted on the left side on the blower, but in retrospect the right side may have been better because of the location of the snow shout. It gives plenty of light for night work.