© PowerOptimal (Pty) Ltd 2017. 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 and User Manual
Version number: 1.19
Enquiries: info@poweroptimal.com
Address: PO Box 39521
Capricorn Square
7948
Cape Town
© PowerOptimal (Pty) Ltd 2017. 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.
• Solar PV modules exposed to the sun are live (i.e. will produce electricity)
and can give an electric shock. Special care should be taken and only
trained solar PV installers should install the modules.
• Do not attempt to alter or service the electrical installation, or open the
Elon 100 unit or controller for any purpose.
• Use the Elon 100 only for its intended purpose.
• Always make sure that every wiring connection is properly tightened.
• Do not earth either of the solar module wires (but do earth the frames).
• All installation wiring should be at least 2.5mm².
• Avoid coiling, since DC switching can create damaging spikes.
• Keep all wires as short as possible.
© PowerOptimal (Pty) Ltd 2017. 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.
Refer to our online instruction video for
easy to understand instructions on how to
use the PowerOptimal Elon
TM
100:
www.poweroptimal.com/elon100
PowerOptimal ElonTM 100 Installation & User Manual
DATE: 18/09/2017
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Version: 1.19
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property and/or information contained herein remain vested in PowerOptimal, except if otherwise agreed in
writing.
Table of Contents
Table of Contents .................................................................................................................................... 4
1. Introduction ........................................................................................................................................ 5
1.1 System overview ........................................................................................................................... 5
1.2 Main system components ............................................................................................................. 6
1.3 Deciding on size of Elon system (basic guide) ............................................................................... 6
1.4 Deciding on size of solar array (expert guide) .............................................................................. 6
1.5 PV array and geyser (water heater) element matching (expert guide) ...................................... 11
2. Installation ........................................................................................................................................ 12
2.1 Required tools ............................................................................................................................. 12
2.2 Basic wiring diagram ................................................................................................................... 13
2.3 Solar PV array installation ........................................................................................................... 14
2.4 Elon 100 installation .................................................................................................................... 16
2.5 Element installation (retrofit) ..................................................................................................... 16
3. Operation .......................................................................................................................................... 17
3.1 Elon 100 Controller ..................................................................................................................... 17
3.2 Mains / solar indicator lights ...................................................................................................... 17
3.3 Efficiency dial .............................................................................................................................. 17
3.4 Override button .......................................................................................................................... 18
3.5 How to maximise your savings .................................................................................................... 18
4. Maintenance ..................................................................................................................................... 20
4.1 Solar PV module maintenance .................................................................................................... 20
5. Basic troubleshooting ....................................................................................................................... 21
Appendix A. Solar yield ......................................................................................................................... 23
A1. Solar irradiance levels ................................................................................................................. 23
A2. Geographic features ................................................................................................................... 24
A3. Azimuth / horizontal angle ......................................................................................................... 24
A4. Inclination or tilt angle ................................................................................................................ 24
A5. Shading ....................................................................................................................................... 24
A6. Ambient temperature ................................................................................................................. 25
Appendix B. Technical Specification: Elon 100 ..................................................................................... 26
Appendix C. IEC/SANS Test Certificate: Elon 100 .................................................................................. 27
Appendix D. Warranty .......................................................................................................................... 28
Appendix E. Terminology ...................................................................................................................... 29
Notes ..................................................................................................................................................... 31
PowerOptimal ElonTM 100 Installation & User Manual
DATE: 18/09/2017
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Version: 1.19
© PowerOptimal (Pty) Ltd 2017. 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.
1. Introduction
Thank you for buying the PowerOptimal ElonTM 100 solar PV water heating unit! You can look forward
to many years of savings and free energy from the sun.
1.1 System overview
The PowerOptimal Elon 100 operates on a very simple principle: it enables direct current (DC)
electricity produced by solar PV modules to be used directly for water heating using a standard geyser
with alternating current (AC) heating element and AC thermostat.
You can connect the system completely off-grid, or integrate with your existing grid AC power supply.
Connecting the system to the existing grid supply allows for grid power backup in case of cloudy /
overcast days, or where your hot water use exceeds the generation capacity of your solar PV array.
Note: the system is designed in such a way that there is no possibility of solar array-produced
electricity feeding back into the grid.
Below is a simplified layout of the main components of the water heating system.
An array of solar modules (a string of 3 to 6 solar modules connected in series, or two parallel strings
of 4, 5 or 6 solar modules each) is connected to the Elon 100. Grid electricity is also connected to the
Elon 100.
The Elon 100 is connected to the geyser element and thermostat.
When the solar modules are producing electricity, the Elon 100 feeds this into the geyser element to
heat water, until the water reaches the temperature setting on the thermostat.
Depending on the Elon 100 efficiency setting (see Section 3.3) or when the user presses the override
button, the Elon 100 will boost the water heating with grid electricity.
PowerOptimal ElonTM 100 Installation & User Manual
DATE: 18/09/2017
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writing.
1.2 Main system components
The main components of the system are as follows:
• Solar modules with struts, brackets and cabling
• PowerOptimal Elon unit with controller
• Existing or new water heater or geyser (hot water tank with AC heating element and AC
thermostat)
• Isolators for grid and solar connections
1.3 Deciding on size of Elon system (basic guide)
The table below provides a basic guide to selecting the size of your Elon system based on number of
people in the household and/or hot water use. Refer to Sections 1.4 and 1.5 for a detailed guide (for
solar PV experts).
Elon kit
Showers
per day*
No. of people
50%+ of hot
water use
No. of
people
off-grid
Solar PV
array size
kW
p
Geyser
element
kW
Geyser (water
tank) size
litres
Kit 1 – Solar Boost
3 – 4
2-3
1-2
1.5 – 1.7
2
100 – 150
Kit 2 – Solar Living
5 – 6
3-4
2-3
2.4 – 2.7
4
150 – 200
Kit 3 – Solar Pro
7 – 8
4-5
3-4
3 – 3.5
4
200 +
* 6-minute showers at 40 ºC with 8 litre/min (low-flow) showerheads
1.4 Deciding on size of solar array (expert guide)
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 on your rooftop is referred to as a solar PV array1.
1
Image source: http://ohioline.osu.edu/factsheet/AEX-652-11.
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DATE: 18/09/2017
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writing.
TABLE 1. 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. Water heated
per day will be significantly lower in winter and significantly higher in summer. These numbers indicate
heating capacity – i.e. if no hot water is used on a given day, there will be less water heated on that
day. This is only an approximate guide.)
Solar + Elon
Annual average litres of water heated per day for X kWp installed solar capacity
Location
kWh/kWp/yr
0.8 kWp
1 kWp
1.2 kWp
1.4 kWp
1.6 kWp
1.8 kWp
2 kWp
2.5 kWp
3 kWp
3.5 kWp
Bloemfontein
1894
80
99
119
139
159
179
199
249
298
348
Cape Town
1624
68
85
102
119
136
154
171
213
256
299
Durban
1447
61
76
91
106
122
137
152
190
228
266
Jhb/Pretoria
1724
72
91
109
127
145
163
181
226
272
317
Mbombela
1627
68
85
103
120
137
154
171
214
256
299
Port Elizabeth
1565
66
82
99
115
132
148
164
205
247
288
Upington
1912
80
100
121
141
161
181
201
251
301
352
Saldanha
1623
68
85
102
119
136
153
170
213
256
298
Example:
For a solar array of 1.2 kWp, an installation in Johannesburg would yield about 1724 kWh/kWp/yr, or
1724 x 1.2 kWp = 2069 kWh/yr. This would be sufficient to heat on average 109 litres of water per
day. For a family of 2 each using 80 litres of hot water per day, this would provide about 109 ÷ (80 x 2)
or 68% of the annual hot water requirement.
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DATE: 18/09/2017
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TABLE 2. 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. Water heated per day will be
significantly lower in winter and significantly higher in summer. These numbers indicate heating
capacity – i.e. if no hot water is used on a given day, there will be less water heated on that day. This
is only an approximate guide.)
Solar + Elon
Number of showers per day (based on annual average) for X kWp installed solar capacity
Location
kWh/kWp/yr
0.8 kWp
1 kWp
1.2 kWp
1.4 kWp
1.6 kWp
1.8 kWp
2 kWp
2.5 kWp
3 kWp
3.5 kWp
Bloemfontein
1894
2.4
3.0
3.6
4.2
4.8
5.4
6.0
7.5
9.0
10.4
Cape Town
1624
2.0
2.6
3.1
3.6
4.1
4.6
5.1
6.4
7.7
9.0
Durban
1447
1.8
2.3
2.7
3.2
3.6
4.1
4.6
5.7
6.8
8.0
Jhb/Pretoria
1724
2.2
2.7
3.3
3.8
4.3
4.9
5.4
6.8
8.2
9.5
Mbombela
1627
2.1
2.6
3.1
3.6
4.1
4.6
5.1
6.4
7.7
9.0
Port Elizabeth
1565
2.0
2.5
3.0
3.5
3.9
4.4
4.9
6.2
7.4
8.6
Upington
1912
2.4
3.0
3.6
4.2
4.8
5.4
6.0
7.5
9.0
10.5
Saldanha
1623
2.0
2.6
3.1
3.6
4.1
4.6
5.1
6.4
7.7
9.0
The table is based on 6-minute showers at 40 °C and 8 litres/min low flow showerheads. Old
showerheads can use up to 15 litres/min and would substantially reduce the number of showers.
Example:
For a solar PV array of 2.5 kWp, an installation in Johannesburg would yield about 1724 kWh/kWp/yr,
or 1724 x 2.5 kWp = 4 310 kWh/yr. This would be sufficient for about 6 to 7 showers per day.
PowerOptimal ElonTM 100 Installation & User Manual
DATE: 18/09/2017
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TABLE 3. 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. Water heated
per day will be significantly lower in winter and significantly higher in summer. These numbers indicate
heating capacity – i.e. if no hot water is used on a given day, there will be less water heated on that
day. This is only an approximate guide.)
Solar + Elon
Annual average % of hot water requirement supplied for 2 people each using 80 litres of hot
water per day for X kWp installed solar capacity
Location
kWh/kWp/yr
0.8 kWp
1 kWp
1.2 kWp
1.4 kWp
1.6 kWp
1.8 kWp
2 kWp
2.5 kW
p
3 kW
p
3.5 kW
p
Bloemfontein
1894
50%
62%
75%
87%
99%
112%
124%
155%
187%
218%
Cape Town
1624
43%
53%
64%
75%
85%
96%
107%
133%
160%
187%
Durban
1447
38%
47%
57%
66%
76%
85%
95%
119%
142%
166%
Jhb/Pretoria
1724
45%
57%
68%
79%
91%
102%
113%
142%
170%
198%
Nelspruit
1627
43%
53%
64%
75%
85%
96%
107%
134%
160%
187%
Port Elizabeth
1565
41%
51%
62%
72%
82%
92%
103%
128%
154%
180%
Upington
1912
50%
63%
75%
88%
100%
113%
126%
157%
188%
220%
Saldanha
1623
43%
53%
64%
75%
85%
96%
107%
133%
160%
186%
Examples:
An array of 1.2 kWp will provide approximately 64% of the annual hot water requirement for a family
of two people in Cape Town.
An array of 2 kWp will provide approximately 124% x (4 / 2) = 62% of the annual hot water requirement
for a family of four people in Bloemfontein.
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DATE: 18/09/2017
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TABLE 4. 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.
No. of cells
per module
Module STC
power rating (Wp)
Total peak power at STC in kWp for an array of X modules
3 modules
4 modules
5 modules
6 modules
2 x 4 (8)
modules
2 x 5 (10)
modules
2 x 6 (12)
modules
60
250
0.75
1.00
1.25
1.50
2.00
2.50
3.00
60
255
0.77
1.02
1.28
1.53
2.04
2.55
3.06
60
260
0.78
1.04
1.30
1.56
2.08
2.60
3.12
60
265
0.80
1.06
1.33
1.59
2.12
2.65
3.18
60
270
0.81
1.08
1.35
1.62
2.16
2.70
3.24
60
275
0.825
1.10
1.375
1.65
2.20
2.75
3.30
60
280
0.84
1.12
1.40
1.68
2.24
2.80
3.36
60
285
0.855
1.14
1.425
1.71
2.28
2.85
3.42
60
290
0.87
1.16
1.45
1.74
2.32
2.90
3.48
72
295
0.885
1.18
1.475
1.77
2.36
2.95
3.54
72
300
0.90
1.20
1.50
1.80
2.40
3.00
3.60
72
305
0.915
1.22
1.525
1.83
2.44
3.05
3.66
72
310
0.93
1.24
1.55
1.86
2.48
3.10
3.72
72
315
0.945
1.26
1.575
1.89
2.52
3.15
3.78
72
320
0.96
1.28
1.60
1.92
2.56
3.20
3.84
72
325
0.975
1.30
1.625
1.95
2.60
3.25
3.90
72
330
0.99
1.32
1.65
1.98
2.64
3.30
3.96
72
335
1.005
1.34
1.675
2.01
2.68
3.35
4.02
72
340
1.02
1.36
1.70
2.04
2.72
3.40
4.08
Examples:
An array of 4 x 300 Wp modules in series will have a total peak power (at STC) of 1.2 kWp.
An array of 2 parallel strings of 5 modules of 280 Wp each (10 modules of 280 Wp in total) will have a
total peak power (at STC) of 2.8 kWp.
NOT ALLOWED
(exceeds maximum rated Elon
100 voltage)
NOT ALLOWED
(exceeds maximum rated Elon
100 voltage)
NOT RECOMMENDED
(poor matching efficiency
with heating element
)
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