Solar Power Optimiser

Electrical Specifications

1. Battery Input: Nominal battery voltage 24, 36, 48 or 60V DC

2. Solar panel output: 200V DC absolute maximum

3. Switch Capacity: 240V AC, 30A

Steps for Installing the Solar Power Optimiser Device

Pack Contents:

• Solar Power Optimiser device
• 5-meter long 1mm² black (or blue) flexible wire
• 5-meter long 1mm² red (or brown) flexible wire
• 100mm length DIN rail plate
• 2 sets of 8mm Fischer pegs and screws
• User manual

A. Installing the Solar Power Optimiser Main Unit:

The Solar Power Optimiser is designed to complement an existing solar inverter setup with MPPT, solar panels, and storage batteries. Access to the battery bank terminals and the solar panel output (usually the MPPT input) is required.

1. Determine Location: Select a suitable location near the existing solar equipment where the live (L) utility power to the inverter can be interrupted and connected to the 2-pole AC SWITCH connector on the optimiser. Ensure the location allows for the 5m wires to connect the optimiser to both the battery terminals and the solar panels output (MPPT input).
2. Install DIN Rail:
   • Place the DIN rail horizontally at the selected location.
   • Mark two holes for mounting and drill the wall with an 8mm drill bit to a depth of 30mm.
   • Secure the DIN rail using the provided Fischer pegs and screws.

B. Pre-Calibration:

1. Mount the Optimiser:
   • Attach the optimiser unit to the DIN rail by hooking the upper part first, then applying light pressure to secure the lower part.
2. Open the Optimiser:
   • Use a narrow-tipped flathead screwdriver to separate the two parts of the optimiser box. Remove the cover to access the internal electronics.
3. Battery Voltage Selection:
   • Set the switch on the 4-way DIP switch located at the lower left side of the optimiser according to the nominal voltage of the battery bank. Voltage options (from left to right) are 60V DC, 48V DC, 36V DC, and 24V DC.
4. Solar Panel Voltage Selection:
   • If the solar panel's output voltage is known, or measured using a digital voltmeter in full sunlight, set the next higher voltage on the 4-way DIP switch (lower right of the optimiser). For example, if the output voltage is 80V-90V, select 100V.
   • If the output voltage exceeds 190V DC, do not use this optimiser and contact support for an upgraded model.

Note: Do not replace the optimiser cover yet, as final calibration is required after connecting both battery and solar panel voltages.

C. Connecting the Optimiser to the Battery Bank:

1. Prepare Wiring: Plan the wiring route for the connections between the optimiser, battery, and solar panel to ensure the provided 5m 1mm² black and red wires can reach both points.
2. Negative Pole Connection:
   • Do not remove the 2-pole terminal plug from the BATTERY socket (lower left of the optimiser).
   • Strip 5mm from the black wire, loosen the negative pole of the BATTERY connector (left pole), and secure the wire.
   • Connect the other end of the black wire to the negative terminal of the battery bank.
3. Positive Pole Connection:
   • Pull out the BATTERY plug from the optimiser before connecting the positive wire.
   • Strip 5mm from the red wire, loosen the positive pole of the BATTERY connector (right pole), and secure the wire.
   • Connect the other end of the red wire to the positive terminal of the battery bank.
4. Test the Voltage:
   • Use a voltmeter to check for battery voltage at the unplugged BATTERY plug.
   • Once verified, plug the connector into the BATTERY socket. The optimiser’s BATTERY LEVEL LEDs will light up according to the battery charge level.

D. Connecting the Optimiser to the Solar Panel DC Output:

1. Prepare Wiring: Ensure the 5m 1mm² red wire can reach both the solar panel's output and the MPPT input.
2. Negative Pole Connection:
   • Do not remove the 2-pole terminal plug from the PANELS socket (lower right of the optimiser).
   • Strip 5mm from the black wire, loosen the negative pole of the PANELS connector (right pole), and secure the wire.
   • Connect the other end of the wire to the negative terminal of the MPPT’s solar panel input.
3. Positive Pole Connection:
   • Strip 5mm from the red wire, loosen the positive pole of the PANELS connector (right pole), and secure the wire.
   • Connect the other end of the wire to the positive terminal of the MPPT’s solar panel input.
4. Test the Voltage:
   • Use a voltmeter to verify solar panel voltage at the unplugged PANELS plug.
   • Once verified, plug the connector into the PANELS socket. The optimiser’s OPTIMISATION LEDs will light up based on the current optimisation cycle.

E. Final Calibration:

1. Adjust Preset Resistor:
   • Using a terminal screwdriver, turn the preset resistor marked R23 (top right of the optimiser) fully to the left.
   • In bright sunlight, push the slider switch to "CAL."
   • Measure the DC voltage between the 0V2 and 10V terminals and slowly turn R23 until the meter reads 10V. If 10V cannot be achieved, select a lower voltage on the DIP switch.
2. Switch to RUN:
   • Once 10V is achieved, return the slider switch to "RUN."

F. Commissioning:

1. Mains Connection:
   • Isolate the mains power to the inverter before proceeding.
   • Cut the live (L) wire of the mains connection and attach each end to the AC SWITCH terminals on the optimiser.
2. Verify System Status:
   • Use a voltmeter to check battery and solar panel voltages.
   • Check the optimiser’s LEDs to confirm operation:
     • The BATTERY LEVEL LEDs will indicate charge status.
     • The OPTIMISATION LEDs will confirm whether solar power is fully optimised.
3. Final Test:
   • Turn on the mains power to the inverter. The optimiser will either switch to 100% solar power (MODE LED lit) or allow mains power to the inverter (MODE LED off), depending on the solar optimisation status.

This completes the installation process.