PowerOptimal Elon® 100 Installation Manual Version number: 2.20 Version date: 2022/05/23 Enquiries: info@poweroptimal.com Address: PO Box 5 Kleinmond 7195 Patented: GB2583814, ZA2019/02129. Patents pending: PCT/IB2021/050542, GB2206504.9 © PowerOptimal (Pty) Ltd 2022. The content of this document is confidential and all rights to the intellectual property and/or information contained herein remain vested in PowerOptimal, except if otherwise agreed in writing.
SAFETY WARNING • Installation of the Elon® 100 should ONLY be performed by an electrical contractor registered with the Department of Labour (the so-called “wireman’s licence”) and strictly according to the installation instructions in this manual. The electrician should provide you with a Certificate of Compliance (CoC) once installation is completed. • We strongly recommend that you use a reputable and experienced solar photovoltaic (PV) system installer to install your solar PV modules.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 3 of 37 Version number: 2.20 Table of Contents Table of Contents .................................................................................................................................... 3 1. Required tools ..................................................................................................................................... 4 2. Basic wiring diagram ...........................................................
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 4 of 37 Version number: 2.20 1. Required tools The following tools are required for the installation. Use insulated tools wherever applicable.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 5 of 37 Version number: 2.20 2. Basic wiring diagram Note 1: Both AC & DC circuit breakers or isolators must be installed within 1.5m of the geyser (water heater), line of sight. Note 2: Surge Protection Device (SPD) only required in higher lightning strike density areas (such as parts of Gauteng and Mpumalanga), or where the DC cables are long. See Appendix F. © PowerOptimal (Pty) Ltd 2022.
Page 6 of 37 Version number: 2.20 Wiring detail: Elon 100 with wiring kit (see Figure 4.1) PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Note: Surge Protection Device (SPD) only required in higher lightning strike density areas (such as parts of Gauteng and Mpumalanga), or where the DC cables are long. See Appendix F. © PowerOptimal (Pty) Ltd 2022.
Page 7 of 37 Version number: 2.20 Wiring detail: Elon 100 with element adapter (see Figure 4.2) PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Note: Surge Protection Device (SPD) only required in higher lightning strike density areas (such as parts of Gauteng and Mpumalanga), or where the DC cables are long. See Appendix F. © PowerOptimal (Pty) Ltd 2022.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 8 of 37 Version number: 2.20 3. Solar PV array installation Modules should only be installed by a trained solar PV installation technician. Array position and orientation have a major impact on power production (see Appendix B). Review the instructions from your solar PV module supplier / manufacturer on installation.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 9 of 37 Version number: 2.20 7. Install the wiring from the solar PV array to the Elon® 100 unit in the ceiling space. Ensure circuit breakers / isolators are in the “Open” position. Installation of a Surge Protective Device (SPD) between the solar PV array and the Elon® 100 is required in high lightning strike areas, such as parts of Gauteng and Mpumalanga. See Appendix F for more information. 8.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 10 of 37 Version number: 2.20 4. Elon® 100 installation 1. Isolate the geyser – switch off the geyser circuit breaker at the main electrical distribution board (DB) AND switch off the geyser isolator at the geyser. 2. Confirm with a multimeter that there is no voltage across the wires. 3. Install circuit breaker (or isolator and fuse) for solar PV (DC) supply. Also install AC supply isolator / circuit breaker if there is none.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 11 of 37 Version number: 2.20 9A WIRING KIT INSTRUCTIONS (follow these if you have the wiring kit as per Figure 4.1) Note: As per the wiring diagram, the thermostat and element should be connected to the Elon® SEPARATELY (independently). d.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 12 of 37 Version number: 2.20 9B ELEMENT ADAPTER INSTRUCTIONS (follow these if you have the element adapter as per Figure 4.2) d. Plug the thermostat into the element adapter as per Figure 4.7, ensuring a snug fit. Check that spade terminals enter female terminals correctly. Figure 4.7 Thermostat plugged into element adapter Figure 4.8 Thermostat & element adapter plugged into element e.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 13 of 37 Version number: 2.20 a. Confirm solar PV array supply voltage and DC power to geyser when thermostat is closed. The Elon® 100 will switch DC power to the geyser approximately 10 to 15 seconds after DC power to the Elon® has been switched on (if there is enough sunlight). (If thermostat is not closed, open hot water tap in house until thermostat closes.) b. Test mains power supply by turning the dial to "MAINS ONLY".
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 14 of 37 Version number: 2.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 15 of 37 Version number: 2.20 The control dial sets the mains & solar times as follows: Dial Setting Time on Mains* Time on Solar* MAINS ONLY 24 hr Never 1 12:00 to 08:00 08:00 to 12:00 2 14:30 to 05:30 05:30 to 14:30 3 17:00 to 03:00 03:00 to 17:00 SOLAR ONLY Never 24 hr 24-Hour Clock * Times are approximate – will vary slightly with season and location © PowerOptimal (Pty) Ltd 2022.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 16 of 37 Version number: 2.20 5. Element installation (retrofit) If you need to exchange the element on an existing geyser, please follow the instructions provided by the element supplier. There are two main types of geyser heating elements: screw-in and flange type. There are three main types of thermostats: VKF-11, TSE and Thermowatt (the TSE and Thermowatt thermostats are quite similar).
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Element type Compatible thermostat type Thermowatt (RTS) thermostat: Spiral element (flange type) with smaller TSE thermostat: diameter thermostat pocket: Page 17 of 37 Version number: 2.20 Comments The spiral element generally has a smaller thermostat pocket than the screw-in element. The TSE and Thermowatt (RTS) thermostats fit into this smaller pocket.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 18 of 37 Version number: 2.20 Appendix A. Basic Troubleshooting Guide for Electricians NOTE: This Troubleshooting Guide is intended for electricians and not general users. Users should please refer to the User Manual, which can be found at www.poweroptimal.com/manuals. Things to Remember • The red mains LED will only start functioning once stable mains voltage between 190 and 260 V AC is present for more than 4 minutes.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 19 of 37 Version number: 2.20 Appendix B. Solar yield Note: only basic information is provided here. Your solar PV installation design engineer or technician should advise on the best configuration for your specific location, roof structure, etc.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 20 of 37 Version number: 2.20 You can expect the following approximate energy generation from solar modules for various locations2: Location Bloemfontein Cape Town Durban Johannesburg / Pretoria Mbombela Port Elizabeth Upington Electricity generated kWh/kWp per year 2055 1762 1570 1871 1766 1698 2075 B2. Geographic features Major geographical features (such as hills or mountains) can reduce the total solar yield. B3.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 21 of 37 Version number: 2.20 B6. Ambient temperature Solar PV modules’ performance decreases with increasing temperature. Wind will reduce the temperature of the solar array and will thus improve performance. Thus, it is important to install rooftop solar modules with an air gap of at least 40 mm between the modules and roof3. B7.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 22 of 37 Version number: 2.20 Appendix C. Deciding on Size of Solar Array Terminology used Solar power is generated by solar cells, which are arranged in framed modules, typically of 60 or 72 cells each. The total set of solar PV modules installed is referred to as a solar PV array4. The table below provides a basic guide to selecting the size of the solar PV array based on number of people in the household and/or hot water use.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 23 of 37 Version number: 2.20 TABLE C1. ANNUAL AVERAGE LITRES OF WATER HEATED PER DAY The below example table indicates the average number of litres of water per day that the system will heat from 15 to 60 °C over a year period for different solar array peak power ratings. (The amount of water heated will vary with weather conditions, by geographic location and by season.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 24 of 37 Version number: 2.20 TABLE C2. ANNUAL AVERAGE NUMBER OF SHOWERS PER DAY The below table indicates the average number of showers per day for which the system will supply hot water over a year period for different solar array peak power ratings. (The amount of water heated will vary with weather conditions, by geographic location and by season.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 25 of 37 Version number: 2.20 TABLE C3. PERCENTAGE OF ANNUAL HOT WATER REQUIREMENT The below example table indicates what % of the annual hot water requirement will on average be supplied by the system for 2 people each using 80 litres of hot (60 °C) water per day. (The amount of water heated will vary with weather conditions, by geographic location and by season.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 26 of 37 Version number: 2.20 TABLE C4. PEAK POWER OUTPUT FOR VARIOUS SOLAR MODULES AND ARRAY SIZES The peak power production (Wp) of the modules at STC (Standard Test Conditions) and at NOCT (Nominal Operating Cell Temperature) are provided by the solar PV module manufacturer. The below table indicates the peak power at STC for a range of solar module power ratings and array sizes.
3 modules 72 or 144 72 or 144 72 or 144 72 or 144 72 or 144 72 or 144 72 or 144 425 430 435 440 445 450 455 1.275 1.29 1.305 1.32 1.335 1.35 1.365 Total peak power at STC in kWp for an array of X modules 4 5 6 8 (2 x 4) 10 (2 x 5) modules modules modules modules modules 12 (2 x 6) modules NOT ALLOWED (exceeds maximum rated Elon® 100 voltage) Module STC power rating (Wp) 1.7 1.72 1.74 1.76 1.78 1.8 1.82 2.125 2.15 2.175 2.2 2.225 2.25 2.275 2.55 2.58 2.61 2.64 2.67 2.7 2.73 3.4 3.44 3.48 3.52 3.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 28 of 37 Version number: 2.20 Appendix D. PV array and geyser (water heater) element matching It is important to match PV array specifications and heating elements for maximum power transfer efficiency. See the below table for the recommended heating element power rating for different solar array sizes.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 29 of 37 Version number: 2.20 Appendix E. Technical Specification Summary: Elon® 100 Refer to the PowerOptimal website for the full Technical Specification www.poweroptimal.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 30 of 37 Version number: 2.20 Appendix F. Surge Protection Device (SPD) Recommendations This Appendix outlines under which circumstances a Surge Protection Device should be installed as part of a solar PV system installation such as the Elon® 100.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 City Upington Pietermaritzburg Greytown Polokwane Bloemfontein Queenstown Vryburg Mahikeng Mbombela (Nelspruit) Kimberley Pretoria Vereeniging Welkom Johannesburg Ermelo Newcastle Lightning strike density Ng (strikes/km²/yr) 6 to 15 15 to 21 15 to 21 15 to 21 15 to 21 15 to 21 15 to 21 15 to 21 15 to 21 21 to 27 21 to 27 21 to 27 21 to 27 27 to 33 33 to 42 33 to 42 Page 31 of 37 Version number: 2.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 32 of 37 Version number: 2.20 Appendix G. IEC/SANS and EMC Test Certificates: Elon® 100 © PowerOptimal (Pty) Ltd 2022. The content of this document is confidential and all rights to the intellectual property and/or information contained herein remain vested in PowerOptimal, except if otherwise agreed in writing.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 33 of 37 Version number: 2.20 © PowerOptimal (Pty) Ltd 2022. The content of this document is confidential and all rights to the intellectual property and/or information contained herein remain vested in PowerOptimal, except if otherwise agreed in writing.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 34 of 37 Version number: 2.20 © PowerOptimal (Pty) Ltd 2022. The content of this document is confidential and all rights to the intellectual property and/or information contained herein remain vested in PowerOptimal, except if otherwise agreed in writing.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 35 of 37 Version number: 2.20 Appendix H. Warranty If the PowerOptimal Elon® 100 (“the Product”) is found to be defective, you will be entitled to a repair or replacement within 2 (two) year of the date of delivery of the Product to you. Please keep your receipt as proof of purchase. If you are a consumer as defined in the Consumer Protection Act No.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 36 of 37 Version number: 2.20 Appendix I. Terminology AC Alternating Current – an electric current that reverses its direction many times a second at regular intervals, with voltage typically varying in the form of a sine wave. CoC Certificate of Compliance – to be issued by the electrician installing your Elon® 100 system CPA Consumer Protection Act No.
PowerOptimal Elon® 100 Installation Manual Version date: 2022/05/23 Page 37 of 37 Version number: 2.20 Notes © PowerOptimal (Pty) Ltd 2022. The content of this document is confidential and all rights to the intellectual property and/or information contained herein remain vested in PowerOptimal, except if otherwise agreed in writing.
