PowerRouter application guideline

Technical information about a self-use installation

1
Contents

Introduction...................................................................................................................... 3
Step 1. Assembly.............................................................................................................. 4
Step 2. PowerRouter AC connection................................................................................ 5
External relay for the backup power supply..................................................................... 8
External relay for load management................................................................................. 9
Step 3: Connecting the sensor....................................................................................... 11
Step 4: Connecting the solar strings.............................................................................. 14
Step 5: Connecting the batteries.................................................................................... 17
Step 6: Connecting the internet connection................................................................... 23
Step 7: Initialising the PowerRouter................................................................................ 25
Three-phase self-use system......................................................................................... 27
Glossary......................................................................................................................... 28

2
Introduction
This document explains, step-by-step, how to install a PowerRouter with batteries (PowerRouter Solar Battery
– PRxxSB-BS) to create a self-use system. It also describes important aspects that must be considered during
installation.

The steps in this document are based on the standard procedure for connecting the system. Detailed
information about the installation can be found in the installation manual that comes with the PowerRouter. That
manual can be downloaded from www.PowerRouter.com. Nedap recommends you read this manual thoroughly
before beginning the installation.

If you have any questions during configuration and installation, please get in touch with your local PowerRouter
Business Partner.

The PowerRouter is intended for use in a single-family household with a maximum service entrance rating of
13.8 kVA. The PowerRouter is the core element of the self-use system, as shown in the following section.

LOCAL OUT

0 1 7 7 6 3

0 1 7 7 6 3

Figure 1: Schematic depiction of a self-use system with PowerRouter

3
Step 1. Assembly
Important considerations
> 
The ingress protection rating of the PowerRouter is IP20 (protected against objects >12.5 mm; not protected
against water)
> 
The PowerRouter must be installed in a well-ventilated room in which the temperature is maintained between
-10 and 40 °C.
> 
Maintain a gap of 30 cm above and below the PowerRouter to allow sufficient ventilation.
> 
Maintain a gap of 80 cm above and below the PowerRouter when two systems are mounted one above the
other.

First attach the supplied mounting bracket to the wall. A drill template is provided to help you determine where
the holes are to be drilled for the mounting bracket. Use mounting hardware suitable for the wall to which the
PowerRouter is being attached.

Attach the PowerRouter to the bracket, as shown below.

Drill template the PowerRouter

2x

4x
Figure 2: Attaching the PowerRouter to the mounting bracket

4
Step 2. PowerRouter AC connection
The PowerRouter is a 1-phase inverter that is connected to the utility grid via the ‘AC grid’ connection. Figure
3 is a simplified technical diagram of a self-use system based on the PowerRouter. Although not shown in this
drawing, circuit breakers and a master switch must be installed.

AC GRID CAN

300A

25A

0 1 7 7 6 3

16A

Sensor

0 1 7 7 6 3

Figure 3: Technical diagram of a self-use system

The PV counter, designed as an optional extra for the PowerRouter, registers the amount of energy derived from
the PowerRouter. The amount of energy fed into the grid and the amount used from the grid are measured using
the bi-directional (generation/consumption) meter. These three values enable you to calculate the percentage of
self-use.

5
Optional backup power supply
The PowerRouter provides users with a self-use system with backup power supply which intervenes in the
event of a power outage. The PowerRouter has two AC connections: an AC GRID and an active AC LOCAL
OUT. In the event of a grid failure, the PowerRouter will switch selected loads over to AC LOCAL OUT via an
external 230V relay*, providing them with power.

*Recommended external relay UK: chint – NCI – 9508 – 230 VAC or an equivalent type
Recommended external relay rest of Europe: PRA1RLY available from your local PowerRouter distributor

AC
AC LOCAL
GRID OUT CAN

300A

25A 25A

0 1 7 7 6 3

230 Vac
95A

16A

Sensor
0 1 7 7 6 3

Figure 4: Connection diagram for a 1-phase self-use system with backup power supply

The mains power supplied to the PowerRouter is connected to the AC GRID terminal (see figure 4) and must be
between 180 and 264 VAC at a frequency of 45 to 55 Hz. Backup power is provided from the AC LOCAL OUT
connection, and the attached electrical load must be one or more 1-phase devices.

6
Earthing and current system
The PowerRouter is compliant with the following
N L N L
earthing systems: TN-S, TN-C, TNC-S or TT.

AC fuse
Nedap recommends that you add a 16 A circuit breaker
with B or (preferably) C characteristics to the AC GRID
line connection between the PowerRouter and the
electric utility meter. We also recommend installing the
same type of 16 A circuit breaker in the AC LOCAL OUT
line connection. It must be possible for the installation
engineer to switch off the circuit breakers to de-
NO NC NO NC

energise the PowerRouter so work on the system can AC GRID AC LOCAL OUT

be performed safely.

RCD rating PowerRouter type

16 A PR30S Figure 5: AC connection terminals on the PowerRouter

PR30SB-BS
PR37S
PR37SB-BS
25 A PR50S
PR50SB-BS

Cable cross section

Nedap recommends you to connect the PowerRouter in the vicinity of the grid connection and use copper
cables with a minimum cross section of 4 mm2. This eliminates unnecessary losses in the internal system and
also prevents voltage disconnects caused by high grid impedance when supplying a high output current.

The diagram below shows that the PowerRouter must increase the AC voltage in order to feed the generated
electricity into the grid. This is because the impedance of the cable to the on-street transformer plays an
important role in this. However, the home installation is connected to the PowerRouter, so the voltage should
never be too high. The PowerRouter software will decrease the output current when this nears the maximum
permissible voltage (cut-off limit). This functionality is added to avoid any unnecessary cut-off in the event of an
ineffective AC grid.

250 V
20V
230 V
1Ω

20A Grid impedance

Street transformer
Figure 6: Influence of grid impedance on AC voltage

7
External relay for the backup power supply
Connecting an external relay N L NO NC N L

Through use of an external relay, some of the single AC grid AC local out

phase loads can be connected to the AC LOCAL OUT

connection on the PowerRouter, which provides backup
power during a power outage. This creates a backup
0 1 7 7 6 3

A1 A2

5 6
system with a switch-over time of ≥ 1 second providing
R7 R8
L
the connected loads with an backup with a stable 230 3 4

VAC/50 Hz output. The power provided during a power R1 R2

N

outage comes simultaneously from the solar energy

that is being generated at that moment and from the N
L1
batteries. It is important to note, however, that only L2
L3

a portion of the loads can be supplied with backup 0 1 7 7 6 3

power, because the reserve capacity of a self-use

system is limited by the available solar energy and the
size of the battery bank. N L1 L2 L3

Figure 7: Connecting an external relay for backup power

A beneficial aspect of this switching configuration is
that loads draw power from the grid whenever the
PowerRouter is restarted or in standby.

The PowerRouter has two sets of configurable potential-free contacts. When a grid outage occurs, loads are
switched to backup power via an external relay. An advantage to this system is that there is no current flowing
through the relay coil during normal use. In addition, the PowerRouter controls the exact moment of switch-
over, which enables it to bring the current provided at AC LOCAL OUT into synch with the mains current as
the grid power is restored. Another advantage is that delay times can be configured, using the PowerRouter
Software Installation Tool*. This makes it possible to prevent the backup power provision from responding to
brief power interruptions (brown-outs).

*For more information about the settings, please consult the PowerRouter application guideline - Software Installation Tool, which you can
download from our website.

Technical data - external relay

The external relay can be any standard, commercially available relay with the technical specifications shown
below.

Europe except UK UK
> Coil voltage: 230 VAC > Coil voltage: 230 VAC
> Contact ratings: 40 A for both N/O and N/C contacts > Contact ratings: 95 A for both N/O and N/C contacts
> Contact configuration: 2 contacts, or 2 N/Os and 2 N/Cs > Contact configuration: 2 contacts, or 2 N/Os and 2 N/Cs
> Contact gap: ≥ 3.2 mm > Contact gap: ≥ 3.2 mm

As indicated in the picture above, only single-phase consumers can be connected to AC LOCAL OUT. When
producing backup power, the PowerRouter generates its own AC output which cannot be synchronised with the
other two phases.

8
External relay for load management
Connecting the external relay N L NO NC

To increase self-use it is possible to have the PowerRouter AC grid

automatically connect larger loads when excess solar

energy is available. Below is a circuit diagram which 0 1 7 7 6 3

shows how the external relay (p/n PRA1RLY) is controlled A1 A2

R7 R8

by one set of potential-free contacts. 5 6

L
R1 R2

Activating load management

3 4
N

Load management is activated using the Software

Installation Tool. This is done by configuring the N
L1
L2
parameters as shown below. These values are based L3

on the capacity being fed into the grid, which means 0 1 7 7 6 3

that this is power above and beyond what is being used

to charge the battery.
N L1 L2 L3

A: The capacity of the consumer to be connected when Figure 8: Connecting an external relay for load management
extra solar energy is available that is not being used
to charge the battery.
B: The percentage of value A that must be available
before the load will be connected. In this example
the extra load will be connected once at least 100%
of 500 W is being fed back into the grid.
C: The percentage of value A at which the load will
be disconnected (can be set at 20-200%). In this
example, the extra load will be disconnected once
the excess power falls below 20% of 500 W.
D: Delay in seconds before the load is switched on,
once the activation conditions have been met (0-100
seconds).
E: Delay in seconds before the load is switched off,
once the deactivation conditions have been met (0-
100 seconds).
F: The maximum time the load will remain connected,
regardless of the available solar power.
G: The minimum time the load will remain connected,
regardless of the available solar power. Figure 9: Activate load management

9
Connecting alarm to potential-free contact
Once the alarm settings have been configured, the
alarm must be assigned to a set of potential-free
contacts. The terminals for these contacts are labelled
K201 (relay 1) and K202 (relay 2) and are located to the
right of the AC LOCAL OUT connection.

The potential-free contact can be activated in two ways:

1. 
Normal: The contact closes when the alarm is
activated and opens when the alarm is deactivated.
2. 
Pulse: The contact opens and closes at the selected Figure 10: Relay 1 of 2

frequency for the configured length of time when the

alarm is activated and does so again when the alarm
is deactivated.

10
Step 3: Connecting the sensor
The 1-phase sensor (p/n PRA1SENSE) or the 3-phase sensor (p/n PRA3SENSE) measures the flow of current
to and from the public electricity grid. This enables the PowerRouter to measure the demand from the loads
and detect the amount of power being supplied to the grid. When the battery is not fully charged, priority is
first given to charging the battery. During the evening and night, when no solar power is being generated, the
power needed for the loads in the home is drawn from the battery. The grid and the loads are connected to the
PowerRouter’s AC GRID connection via a parallel switch.

1-phase sensor for consumption monitoring

AC Grid
N L

0 1 7 7 6 3

L
Sensor

0 1 7 7 6 3

N L

Figure 11: Position of the 1-phase sensor in the self-use system

It is possible to connect a 1-phase sensor to the PowerRouter Solar Inverter (PRxxS) to measure single-phase
consumption. It is also possible to connect a 3-phase sensor to the PowerRouter Solar Inverter.

The 1-phase sensor must be connected to the external line (L) conductor at a point where it is possible to
measure the electricity flowing towards the utility grid. The sensor will only work correctly if the arrow on the
sensor is pointing towards the utility grid.

11
Figure 12: 1-phase sensor Figure 13: Connecting the 1-phase sensor

The cable on the sensor is terminated with an RJ45 plug, which must be inserted into the PowerRouter’s CAN
terminal. The sensor must be connected to the lower RJ45 socket, which is covered by a blind hole cover (see
Figure 13). Remove the blind hole cover and insert the RJ45 plug in the socket. The standard cable length is 1
metre, but it can be extended with a CAT-5e cable having a maximum length of 10 metres by means of a CAT-
5e cable coupling.

Figure 14: CAT-5e coupling Figure 15: CAT-5e cable

Important information about the 3-phase grid connection

When a 3-phase grid connection is available the sensor must be connected to the same external conductor to
which the PowerRouter is connected. During initialisation of the system, sensor operation is tested to ensure
that the system is connected correctly. If the current sensor is not connected correctly, code P105H will appear
on the display.

12
3-phase sensor
With a 3-phase sensor, load demand can be measured for all three phases at the same time. When used
with a generation/consumption meter that is capable of two-way communication, this makes it possible to
compensate for consumption on one phase by feeding power into the grid on the other two phases.

With this two-way communication, all power flows can be added together, so the meter indicates the total
positive or negative balance. In the example below, there is 2.5 kW of consumption and 2 kW of generation,
so the meter indicates 0.5 kW of consumption from the grid. The 2 kW of available generated power is fed into
the grid on phase 1 to compensate for the consumption drawn from phases 2 and 3. This method enables the
1-phase PowerRouter to work as a 3-phase system.

2 kW 1,5 kW 1 kW 4 kW 1,5 kW 1 kW

Import Import
0.0 kWh 1.5 kWh
Export Export
0.5 kWh 0 kWh

Figure 16 : How a meter with two-way communication works

The 3-phase sensor must be connected to the home wiring connected directly to the generation/consumption
meter, before any branches to consumers in the house. The PowerRouter uses the sensor to measures the
amount of energy being consumed at any moment on any phase.

The PowerRouter only works with this type of 3-phase sensor (p/n PRA3SENSE), and a 3-phase sensor can
only be connected to one PowerRouter.

fuse
fuse 315 mA
315 mA
to to
thethe
grid grid
11 N
1 L1 Fuse
315 mA

4 L2
7 L3

11 1 4 7 0 1 7 7 6 3

L3 L2 L1 N

SeNSor
L3 L2 L1
3 6 9

to the installation
to the installation
9 L3
0 1 7 7 6 3

6 L2
3 L1

41 Green/white wire 42 Green wire 43 Orange/white wire

Figure 17: Connecting a 3-phase sensor

Note: For a more detailed explanation of how to connect the 3-phase sensor, please refer to the manual
included with the 3-phase sensor.

13
Step 4: Connecting the solar strings
Because the PowerRouter’s photovoltaic connections are electrically isolated from the AC section, the
PowerRouter can be used with all kinds of solar modules and a wide range of input voltages.

Modules that can be connected to the PowerRouter:

> Monocrystalline modules
> Polycrystalline modules
> Thin-layered or amorphous modules

The 3.7 and 5 kW versions of the PowerRouter have two isolated photovoltaic connections. The 3kW version
only has one photovoltaic connection. MC4 connectors are used for the photovoltaic connections on the
PowerRouter. Each photovoltaic connection has its own MPP tracker in order to maximise the output from the
modules.

Figure 18: Photovoltaic connections on the PowerRouter

Each input has a wide open-circuit voltage (VOC) range of 150-600 VDC and is designed for a maximum input
current of 15 A. Warning: The 600 VDC threshold must never be exceeded. If the 15 A is exceeded, the solar
input will limit the current.

In the morning, the PowerRouter switches on at around 150 VDC with a power of 40 W based on 2 solar inputs.
After switching on, the MPP tracker seeks to provide the best possible power output level; it does so at a
voltage level of 100- 480 VDC.

The optium MMP-voltage for each string input of the PowerRouter at 25°C ambient temperature is 330Vmmp.

The two solar inputs can be used non-symmetrically (e.g. input 1 at 2kWp, input 2 at 4 kWp), but the maximum
solar output fed to both inputs at any given moment is limited to 6 kW. If too much current is being supplied, the
MPP point will be adjusted to limit the solar power. In the event of gradual changes >6kW (cloud in front of the
sun), a power-overload message will appear on the display of the PowerRouter and via myPowerRouter.com.

14
Connecting the photovoltaic modules
To optimally configure the solar modules, take a look at our PV calculation tool (available online at
www.PowerRouter.com/calculator). You can choose the PowerRouter version and photovoltaic modules you are
using. The calculator tool then calculates the correct string configuration for this combination.

Solar cables
Photovoltaic modules often come with short cable connections (usually Ø 4 mm2) with MC4 connectors. If
the total length of the free running cable between the modules and the PowerRouter is less than 50 m, Nedap
recommends that you use a double-insulated solar cable with a diameter of 4 mm2. If the length exceeds 50 m,
we recommend you use 6 mm2 cables.

Warning: The plus and minus cables must not be run in the same conduit.

Earthing photovoltaic modules

Earthing varies according to the type of photovoltaic module in use and is different for the fixed frame and thin
film types.

The contact protection on the metal frame and the frame surrounding the photovoltaic module has a
considerable bearing on safety. Nedap therefore recommends that you connect the metal frame to earth.
The PowerRouter has an earthing bonding terminal to which an earth cable can also be connected. Since the
photovoltaic section of the PowerRouter is also electrically isolated from the AC part, ESD spikes do not affect
operation of the PowerRouter.

Thin film modules produced by various manufacturers are earthed in different ways; consult the manufacturer’s
specifications. For this type of module, one of the connections must be earthed. Depending on the brand/
manufacturer, it may be the frame or the ‘+’ or ‘-’ terminal that is to be earthed. These photovoltaic modules
will degrade more quickly if they are not connected to earth. The PowerRouter has been designed with this in
mind: it has an earth connection between the photovoltaic connections. Figure 19 provides an overview of the
possible earthing configurations.

In the case of negative earthing, only 1 ‘-’ input needs to be earthed, because the 2 ‘-’ inputs are connected
together inside the PowerRouter. In the case of positive earthing, the special adapted shown in the figure below
must be connected to the two inputs.

Figure 19: Ground connection possibilities for photovoltaic modules

15
DC disconnection switch
Since the voltage across the photovoltaic connections can be very high, it is important that the PowerRouter
can be disconnected from the photovoltaic modules for assembly or maintenance or in an emergency. A DC
switch is located on the back side of the PowerRouter. On PowerRouters with two photovoltaic inputs, this
switch disconnects both at the same time.

Figure 20: DC disconnection switch on the PowerRouter

16
Step 5: Connecting the batteries
The PowerRouter has an integrated intelligent 24 Vdc battery manager capable of temperature-compensated
charging based on current and voltage regulation, which extends the life of the batteries and improves the
charging process of the batteries. This way it also ensures the safety.

Suitable types of battery

Different types of battery can be connected to the PowerRouter.

Sealed lead-acid batteries

Sealed lead-acid batteries offer good value for the money. These batteries are available in a 2 V version as
well as versions that produce a higher voltage (e.g. 12 V), which are made up of multiple 2 V cells. There are
two versions of this battery type: gel-cell batteries (with a gel-like electrolyte) and AGM (Absorbent Glass Mat)
batteries. Both battery types have a sealed construction and are 100% maintenance-free.

Lead-acid wet battery

Lead-acid (wet) batteries are also suitable. However, they require more maintenance than the sealed type: for
instance, they need to be regularly replenished with distilled water. Charging also generates gas. This means
that these batteries must be installed in a well-ventilated room.

Determining the required battery capacity

The purpose of a self-use system is to enable the household to maximise its own use of the solar power it
generates. In other words, the batteries must be able to store enough energy to meet the power requirements
in the home during the evening and night. The average energy consumption during non-daylight hours can be
used to work out the required battery capacity.

The battery capacity can be compared using the calculation tool at www.PowerRouter.com. This tool enables
you to enter the annual consumption and the consumption profile. The energy that will be available with
different battery sizes is shown. The calculation is based on the rule of thumb that 1 kWh is stored for every 100
Ah (24 V) and that a fully-charged battery can be discharged to 50% DOD.

Nedap recommends that you connect a battery of at least 150 Ah at 24 V. The capacity value is specified in the
battery datasheet as a C10 value (the 10 here stands for the time to discharge).

For determining the (optimum) battery capacity it is important to keep three things in mind:

1. Annual household consumption (kWh)

2. Household consumption profile (at home or away during the day)
3. Size of PowerRouter system (kW)

Optimum battery capacity recommendations

5.0 kW PowerRouter Solar Battery Battery bank with a capacity of at least 200 Ah but not more than 600 Ah
3.7 kW PowerRouter Solar Battery Battery bank with a capacity of at least 200 Ah but not more than 500 Ah
3.0 kW PowerRouter Solar Battery Battery bank with a capacity of at least 200 Ah but not more than 400 Ah

17
Batteries from Nedap
Nedap supplies batteries manufactured by Hoppecke. Each battery bank comes complete with external
housing with two fuses and a set of cables. We also supply Enersys batteries which also include a set of cables
and a fuse.

Figure 21: Enersys type SBS 190F Figure 22: Hoppecke type OPzV

Battery service life

A battery’s service life is usually expressed in terms of the number of charge/discharge cycles and the depth
of discharge (DOD) value. The number of charge/discharge cycles is high for self-consumption, since energy
is drawn from the battery every night. The number of achievable battery cycles drops the higher the depth
of discharge (see chart). For this reason, the PowerRouter is configured to limit discharge to 50% by default.
Determination of a battery’s service life should be based on the manufacturer’s specifications. A graph like the
one shown below (figure 23) is usually provided to indicate the service life (measured in accordance with IEC
standards).

Looking at the number of cycles, we can assure one cycle per day. This does not include days when the system
is in winter mode. Deducting two months of operation in winter mode, this amounts to 300 cycles per year. A
cycle is understood to be charging from 50% to 100% and discharging to 50% again.
12000 SBS 190F
11000 OPzV
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0 10 20 30 40 50 60 70 80 90 100

Figure 23: Number of cycles versus DOD value

The display and the graphs for the PowerRouter do not show the depth of discharge (DOD), but rather the
charging status. This is 100% when the battery is fully discharged and 0% when fully charged.

When used for backup power, the battery can discharge to a lower depth than for self-use. At that point more
energy is available from the battery. The DOD can be configured using the Software Installation Tool.

When using a 3-phase sensor, Nedap recommends limiting the level to which the battery can discharge. This is
to avoid discharging the battery too quickly so that the C10 value no longer applies.

18
Temperature effects
Ambient temperatures have a large influence on battery capacity. At low temperatures, the capacity drops
quickly. This is illustrated in figure 24 (capacity of a gel battery). The temperature of the room where the
batteries are installed must therefore be kept above 10 °C.

Maximising battery service life

Batteries must not be left in the discharged state for too long, because doing so reduces their service life. With
this in mind, various protection mechanisms have been built into the PowerRouter.

Maintenance charging
At regular intervals – once every 3 weeks – the battery
is forced to run through the 3-state charging cycle.
If maintenance charging coincides with a request for
self-generated power, charging will take priority. Once
the battery is fully charged and the SOC is 100%,
maintenance charging is complete and the battery
becomes available for self-use again.

Likewise, in the winter mode, this cycle of maintenance

continues. The battery module is activated and the
Figure 24: Temperature versus battery capacity
battery charged to 100%, after which the winter mode
is once again activated.

It is possible to start or stop the maintenance charging

manually in the PowerRouter’s display menu. However,
to achieve the maximum service life from the battery, 800 Wintermodus Solar
this is not recommended.
700

Winter mode 600

This mode is for using the batteries in the winter, when 500
there is less solar output and greater demand. This
400
annual cycle is shown in figure 25, as the blue line
which represents total household consumption. 300
Because solar output only now and again exceeds
200
consumption, full charging of the battery occurs less
frequently. Longer periods without full charging shorten 100

the service life of the battery. This is the reason for the 0
jan feb mar apr may jun jul aug sep okt nov dec
winter mode, as this protects the battery and ensures a
longer service life. Figure 25: Winter mode

The moment the system is switched to winter mode, maintenance charging begins, to fully charge the battery.
Once at maximum charge, the PowerRouter’s battery module is switched off. There is no more self-use from
the battery. The period during which the battery is in the winter mode can be programmed with the installation
tool. The standard period is from 1 December to 1 February. At the end of this period, the system completely
recharges the battery again and it can be used for self-use. It is important to choose this period carefully, taking
into account whether or not the system is equipped with a 3-phase sensor. If it is, consumption will be higher
than for a 1-phase measurement.

19
When in winter mode, maintenance charging continues to be performed as usual. If the PowerRouter is
configured to perform maintenance charging once every three weeks, the battery will be fully recharged at
this interval. Even in winter mode, the battery is always available to provide backup power. When needed, the
battery is reactivated and then used to provide the backup power.

Battery charging methods

The PowerRouter can be configured to use either of the two available battery charging methods: fixed float
voltage or 3-state adaptive charging. The 3-state adaptive charging method is best suited for rapid battery
charging. This is the best configuration for a self-use system.

3-state adaptive charging

In the first stage the battery is charged at a high current
until it reaches 70-80% of the battery’s charge capacity
(blue line). The battery voltage (green) rises to the bulk
voltage during this stage. In the second stage, the
voltage applied to the battery remains constant, while
the charging current gradually drops to a quarter of
the bulk current. This stage ends once the battery has
reached approximately 85-90% of its capacity. In stage
3 the charging voltage is reduced to the trickle-charge
voltage and the battery is gradually charged to 100%.
This final stage lasts the longest. Figure 26: 3-state adaptive charging

Battery discharge limiter

200A
To protect the battery against excessive discharge 100A
current, it is possible to limit the discharge power
during self-use. This limit value can be configured in
the Software Installation Tool. The value that should
be set depends on how the batteries are connected
12V 12V
(number of parallel branches). When using batteries 100A
for which the battery supplier specifies a maximum
discharge rate of 100 A, for example, the limit value for
four 12V batteries connected in two parallel strings of 12V 12V
two should be (2x100Ax24V=) 4800W, but for two 12V
batteries connected in a single string (in series) the
Figure 27: Battery discharge limiter
limit value should be just (100Ax24V=) 2400W. When
the system is providing backup power, however, it
temporarily disables the limiter.

20
Cross section of the battery cable
The cross section of the required battery cable depends on the resistance and the contact resistances in the
cable. To draw 5 kW from a 24 V battery, more than 200 amps of current flow through the cable. To keep losses
as low as possible, the cable must have a sufficient cross section.

Nedap recommends the following cable cross sections for the various PowerRouter versions:

5.0 kW system – Copper wire, 95 mm2

3.7 kW system – Copper wire, 70 - 95 mm2
3.0 kW system – Copper wire, 60 - 95 mm2

Place the battery as close as possible to the PowerRouter to keep the cable as short as possible (≤ 2.5 m).

Voltage sense
When using longer battery cables (> 2.5m), Nedap recommends connecting sensor wires for voltage
compensation. This enables the PowerRouter to measure the voltage across the poles of the battery before any
voltage losses through the cables and connections. Connect a red wire with a 1 A fuse between the ‘+’ pole of
the battery and the +BAT terminal on the PowerRouter. Connect a black wire between the ‘-’ pole of the battery
and the -BAT terminal on the PowerRouter. We recommend you use stranded wire (not included).

Figure 28: Voltage Sense

Temperature sensor
The temperature sensor measures the temperature of the battery during charging. When the temperature
increases too rapidly, the PowerRouter will lower the charging current to protect the battery during charging. For
precise measurement, the sensor should be stuck onto one of the batteries near the ‘+’ pole. The firmware has
been programmed to automatically perform temperature compensation of 50 mV/°C. If the battery temperature
rises above 50 °C, charging/discharging is stopped to protect the battery.

21
Fuse
A 300 A (slow-blow) fuse must be installed in the ‘+’
cable to ensure safe installation and use of a battery.
In the event of a short circuit on the PowerRouter side,
the fuse will interrupt the very high short-circuit current
and prevent a dangerous situation. The fuse, including
holder, is supplied by Nedap. The matching fuse holder
is manufactured by Pudenz and its part number is
Figure 29: Fuse with holder
177.5701.00.

Warning: Make sure the battery terminals are covered with insulating caps during installation. This prevents the
possibility of a dangerous short circuit if a conductive object falls across the terminals.

Connecting the battery measuring devices to the PowerRouter

The current shunt, voltage sense and temperature sensor are connected to the PowerRouter via the connecting
rail provided for this purpose (see figure 30).

+BAT

-BAT

TMPS

GND

SH+

SH-

(-) pole PowerRouter

Temperature
sensor
- Black
+Red

SH- wire
(grey) SH+ wire
(orange) (+) pole battery
Battery
sense

Figure 30: Connecting the battery measuring devices to the PowerRouter

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Step 6: Connecting the internet connection
Internet connection
The PowerRouter has two (RJ45) sockets, one of which has a blind hole cover (intended for the sensor). The
upper socket is used for connecting to the Internet. The PowerRouter uses this connection to send log data
to the Nedap server once per minute, which can then be read and monitored remotely. These log data are
available to customers, installation engineers and dealers at myPowerRouter.com. The information provided by
this webportal can be found in the myPowerRouter.com brochure. This functionality is provided free of charge.

Figure 31: RJ45 connection for the Internet connection

Communication
The PowerRouter communicates with the internet via port 80. This port must be available in the network. A
second condition is that the internet router in the network must provide dynamic IP addresses. Installation
engineers can use the display on the PowerRouter to check whether the PowerRouter has an active server
connection (via ‘Status internet connection’ in the control menu).

Figure 32: Internet setup

23
Monitoring – myPowerRouter.com
Installation engineers and dealers can use the monitoring function in the myPowerRouter.com web portal
to monitor the status of the PowerRouter remotely. When a customer phones with a question or to report
a problem, the installation engineer or dealer can check the system and possibly even correct the problem
without ever leaving the office. This function can also be used to perform updates on the PowerRouter.

The monitoring function is also what makes it possible to provide the widgets on the website. The widget shown
in figure 33, for example, displays the system’s percentage of self-use. Another widget, shown in figure 34,
shows the percentage of the solar energy which has been generated and used in the home.

Figure 33: Chart showing the self-use value (available on my.PowerRouter.com)

The self-use widget indicates the level of autonomy of the installation in relation to the power grid. In this
example, 27% of the energy required still has to be drawn from the grid.

Figure 34: Percentage of self-generated energy

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Step 7: Initialising the PowerRouter
Perform the following steps to put a PowerRouter in service:
1: Connect a charged battery to the PowerRouter
2: Switch on the connection to the solar strings with the switch on the base of the PowerRouter
3: Connect the PowerRouter to the grid power supply
4: Switch on the PowerRouter with the switch to the right of the display

The display now shows a message indicating that the PowerRouter can be configured in one of two ways.

On the PowerRouter display

Press the ‘yes’ button for help when initialising the system for the first time. Follow the instructions on the
display, and use the keys adjacent to the display to control the system.

With the aid of the Software Installation Tool (USB)

Use the Software Installation Tool to put the PowerRouter in service. This tool not only allows you to initiate the
PowerRouter, but also to make extensive changes to the settings or, if necessary, to upgrade the PowerRouter’s
firmware.

To upgrade the firmware you need a USB cable and a laptop or PC with the Software Installation Tool. In
addition to an internet connection, there is also a USB connection with which the PowerRouter can be
connected to a computer.

Before the Software Installation Tool can be used, it must be installed on the laptop/computer. The software
installation tool can be downloaded from the following website: www.PowerRouter.com (you need to create
an account to access this website). The installation tool can be used to install a new firmware version on
the PowerRouter. This means that if an old firmware version has been installed on the PowerRouter, it can
be upgraded with a new version. The installation tool includes the latest firmware version so that no further
downloads are required.

To install, open the software installation tool with ‘setup_installtool.exe’ (which has been downloaded from the
PowerRouter website). Click the ‘Start installation’ icon to change the settings. This allows you to change the
language and date and time settings, for example.

Figure 35: USB connection Figure 36: Start screen software installation tool

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Battery parameters
For the PowerRouter Solar Battery, it is necessary to configure a number of battery parameters to achieve
optimal operation. These data can be entered using the Software Installation Tool or the installation help on the
display.

Capacity
Capacity of the connected 24 V batteries. Specified on the battery datasheet, with discharge time.
Example C10 200 Ah: This means that the battery capacity is 200 Ah if it is fully discharged within 10 hours
(around 1 night). If a C10 value is not specified, enter the closest C value. For the system to work well, the
capacity must be between 150 Ah and 1000 Ah. On a 5kW system, Nedap recommends a battery capacity of
350 - 450 Ah.

Charge current
Maximum battery charging current. Nedap recommends 1/4 or 1/5 of the capacity.

Type
Battery type: Lead acid, wet or gel

Charging method
3-state adaptive or fixed voltage

Vfloat
Fixed charging voltage. Specified on the battery datasheet. Warning: The voltage is often given PER CELL and
must be multiplied by the number of cells in the battery. Use the standard settings if the charging voltage is not
specified.

Vbulk
Bulk charge voltage, also called ‘boost’. Specified on the battery datasheet. Warning: The voltage is given PER
CELL. This must be multiplied by the number of cells of the battery. Use the standard settings if the bulk voltage
is not specified.

Software Installation Tool settings

These battery parameters can be changed via the
Software Installation Tool. In addition to these, there are
many other settings possible.

More information about the options for the settings

can be found in the Application guideline – Software
Installation Tool, which can be found on the website:
www.PowerRouter.com.

Figure 37: Software Installation Tool settings

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Three-phase self-use system
The PowerRouter is a 1-phase inverter. It can be used to supply the energy to a single external conductor. Three
PowerRouters and three battery banks allow you to set up a 15kW system which optimises self-use on three
phases.

PowerRouter in the three-phase system

The PowerRouter Solar Battery can be deployed in a three-phase self-use network. A PowerRouter with its
own, independent photovoltaic strings and independently connected batteries can be connected between
each external conductor and the Neutral conductor (it is not possible to use a common battery bank for all
three PowerRouters). The PowerRouter synchronises to the frequency of the power on the external AC mains
conductor when feeding back to the utility grid. This ensures that the 120° phase shift between the three
phases of a 3-phase system is maintained. Figure 38 shows how the PowerRouters should be connected in a
three-phase network.

PowerRouter 1 PowerRouter 2 PowerRouter 3

AC Grid AC Grid AC Grid
N L N L N L

0 1 7 7 6 3 0 1 7 7 6 3 0 1 7 7 6 3

L3

L2

L1

0 1 7 7 6 3

Sensor
N L1 L2 L3

Figure 38: The PowerRouter in a three-phase self-use system

A system with three PowerRouters, each with its own battery bank, cannot be used for three-phase backup
power. The PowerRouter is not capable of delivering three phases itself, it can only match the three phases of
the grid power. Single-phase backup power is possible, however.

If 1-phase sensors are used, the maximum length of an extension cable for the sensor is 10 metres. If this is still
too short, 3-phase sensors can be used, which should be configured as 1-phase sensors. In the manual for the
3-phase sensor, this configuration is designated ‘1p’.

More than one PowerRouter on single-phase

If the system is suitable for this purpose, it is possible to connect more than one PowerRouter Solar Inverter
(PRxxS) on single-phase. This is different however, when you use a PowerRouter Solar Battery (PRxxSB-BS).
Because this system uses a sensor to measure consumption levels, the readings are subject to interference
from other transformers which have a parallel connection on the phase. This results in incorrect readings on
a number of graphs on myPowerRouter.com (e.g. consumption). However, its actual functioning will not be
disrupted; the self-use system provides more solar output for charging the battery.

27
Glossary
1-phase sensor Sensor that is clamped around the phase conductor which
measures the direction and magnitude of the current into the
grid.

3-phase sensor This sensor senses the current flow on all three phases of the
grid connection at the same time.

3-stage charging Charging method in which a battery is charged in three

stages, each with different characteristics.

Autonomy time An indication of how long power can be provided to the
connected load in the event of a grid outage. This is
dependent on the load, the solar output and the capacity of
the connected batteries.

External relay An electromechanical switch used to control load

management or activate backup power.

120° phase shift Phase shift between L1-L2, L1-L3, L2-L3 to implement a
3-phase AC network.

+BAT/-BAT Connection for voltage measurement.

Absorbed Glass Mat (AGM) In a ‘normal’ AGM battery, the plates are placed next to each
other. Otherwise, they are similar to a spiral cell battery:
the electricity is stored in glass fibres. These batteries can
actually be deployed anywhere. The advantage lies in the
fact that it is possible to replace any of the batteries. You
can draw large currents without damaging the battery. The
specified service life is 5 to 10 years.

AC Local Out The PowerRouter has a unique function that provides an

uninterrupted power supply in applications with a grid
connection. The PowerRouter can provide a steady voltage of
230 VAC/50 Hz even if the public grid fails. The PowerRouter
switches from grid electricity to solar energy and battery
current within milliseconds, with no interruption to the power
supply. If the grid fails, the PowerRouter is automatically
disconnected from the grid and will reconnect once the
grid is stable again. This protects the connected loads from
power disruptions.

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Backup time Indicates how long the connected load can be supplied with
energy in the event of a grid failure. This depends on the
continuous load.

C10 value Capacity of the battery when discharged in 10 hours.

CAN terminal Controller Area Network (CAN), a standard for the serial
databus.

CAT-5e cable Identifies the quality of a UTP network cable.

Charge cycle A cycle is understood to be charging from 50% to 100% and

discharging to 50% again.

Contact numbering Connection contact numbers of a relay.

DC disconnection switch Switch used to disconnect the DC circuit between the

PowerRouter and solar strings.

DOD Depth of Discharge of the battery.

Drill template Paper template to help drill the holes for the PowerRouter
mounting bracket in exactly the right position.

Dynamic feed-in limiter This enables the PowerRouter to limit the amount of energy
fed into the grid. The sensor measures the power at the grid
connection point to ensure that the set limit is adhered to.

ESD ElectroStatic Discharge.

External conductor In the light network, the “external conductor” is the wire
which has an electrical coupling with the light network
voltage. Together with the Neutral conductor, the external
conductor guides the electrical current from and to the
connected devices. The external conductor is normally
identified with the designation L1, L2 or L3 in a circuit
diagram.

Float charging Charging the battery with a fixed voltage.

Grid impedance Impedance measured from the source to the load and from
the load back to the source.

Load management Connecting an additional consumer if extra solar energy is

available.

Maintenance charging Periodic charging cycle to fully charge the battery.

29
Monocrystalline solar modules Monocrystalline solar cells have an extremely regular crystal
structure which arises through the controlled cooling of
liquid, pure silicon. Monocrystalline cells are easily identified
by the separate disks and their black colour.

MPP tracker Maximum Power Point Tracker; allows the inverter to use the
largest possible output from the photovoltaic modules under
various conditions.

MPP voltage DC solar voltage (V) supplied at the maximum output.

Open circuit range Open terminal voltage of a solar module/solar string. The
voltage is measured across the photovoltaic connection,
which means there is no load across the solar modules.

Overcurrent fuse A protective device in the supply part of an electrical system.

The circuit breaker disconnects the electrical circuit when the
current entering the system becomes too high.

Photovoltaic connection Connection for the solar modules, generally via an MC4
connector.

Polycrystalline solar modules Polycrystalline solar cells (also known as multicrystalline).

Like monocrystalline cells, except that the effectiveness of
these cells is generally somewhat lower and they are dark
blue in colour.

Port 80 The port on an internet router which the PowerRouter uses to

communicate with the Nedap web server.

RJ45 connector Plastic connector with 8 contacts.

SOC State of Charge of the battery.

Software Installation Tool The Software Installation Tool not only enables you to initiate
the PowerRouter, but also to make extensive changes to the
settings or provide the PowerRouter with the latest firmware.

Temperature sensor Sensor which is installed on the battery. Measures the

battery temperature to protect the battery and optimise
charging.

Thin-layered or amorphous modules A layer of amorphous silicon is deposited over a . This is

known as the thin film method. Since relatively small amounts
of silicon are used, the effectiveness of this method is lower
than with crystalline modules, but it costs considerably less.

30
TN-S/TN-C/TNC-S/TT Earthing systems.
TN-S system: PE and N are separate conductors that are
connected together only near the power source.
TN-C system:a combined PEN conductor fulfills the functions
of both a PE and an N conductor.
TN-C-S system: part of the system uses a combined PEN
conductor, which is at some point split up into separate PE
and N lines.
TT system with neutral conductor: the protective earth
connection of the consumer is provided by a local connection
to earth, independent of any earth connection from the grid.
IT system with neutral conductor: the electrical distribution
system has no connection to earth at all.

Voltage measurement Voltage measurement directly across the battery terminals.

The voltage drop across the battery cables is compensated
for. See +Bat/-Bat.

Winter mode Period in which the batteries are protected against low
battery charging.

31