icon Solar Battery Charge Controller for Home UPS

icon Solar Battery Charge Controller for Home UPS

1. Introduction icon is an intelligent solar charge controller that is capable of converting the existing home battery backup systems like inverters and UPS to a solar powered system, with minimum investment. icon with its patented technology to inhibit battery charging from utility grid, controls the charging of the battery from the solar and from the utility grid in such a way that it maximizes the solar utilization and minimizes the utility grid consumption. icon does battery equalization in regular intervals which helps in maintaining the battery health. Customers can see their real time solar savings and most importantly the environment savings anytime through our web portal. 2. General Information 2.1. About the User Manual The manual covers all necessary information including procedure to install, configure, use and troubleshoot icon solar battery charger for home UPS. The device is compatible with almost all photovoltaic modules (PV), batteries and inverters of various brands. Refer the instruction manual of each manufacture for confirming compatibility with icon. 2.2. Important Safety Information The installation of icon should be done strictly adhering to the safety instruction given in the manual. It is always better to depend on qualified personnel for installation and commissioning. 2.3. Symbols used in this manual Fatal injury to the operator if the instruction marked with this symbol is not taken care Material risk and/or suspension of warranty if the instruction marked in this symbol is not taken care 2.4. Warranty Preserve the last page of the manual to claim warranty. 2.5. Limitation of Liability All damage caused due to an installation that does not comply to instruction, operating the device in faulty condition and inadequate maintenance cannot be claimed under warranty. The use of icon is purely the responsibility of the customer.

icon is not designed for vital medical care equipment nor any critical equipments that cause potential risk to human and environment. Any attempt to copy/reproduce the technology could be subjected to legal consequences. NyQuest Innovation Labs reserves all rights to make any modification to the product without prior notification. NyQuest Innovation Labs is not responsible for any incidental, direct or indirect damages of any kind caused due to defective equipment. 3. Installation 3.1. Unpacking Check the device is intact and free of any physical damage during transportation and that all accessories listed below are present. Any fault must be immediately brought under the attention of the distributor or the contact mentioned at the end of the manual. icon with female part of the MOLEX Battery wires- black and red wire with ring type tag on one side and pin type tag on other side Three core wire 3.2. Where to install icon is designed to be installed on a flat wall vertically. Leave sufficient space around the unit for air circulation. Install icon in an area which is Not accessible by children and unauthorized person Protected from direct sunlight or heated objects. This may cause the internal components to heat up and affect the working of icon. 4. Connecting icon Special care has to be taken to connect high voltage systems, Battery terminal. Always rely on professionals for installation Take care not to connect the panels to the battery input or the batteries to the PV input Phase in and Phase out are very close in the device. Take care to avoid any external short. Similarly be careful regarding phase to neutral short in AC connection icon is intended to be connected exclusively to photovoltaic source. It is suitable for charging any type of lead-acid battery

Fig 2 Removing top plate The PCB lugs where the battery, inverter and solar terminals need to be connected, could be accessed by removing the top plate of the casing. Cable entry is made through the holes present in the side casing and tightened from the top. Ensure that the cables are sufficiently tightened and the connection are correct. The AC connections could be given from outside using the MOLEX. 4.1. Installation/Operation points in the device S/No Description Comment 1 Terminal to connect inverter + Ensure proper cable size is taken 2 Terminal to connect battery + Both the ends of the connecting wire should be crimped and connected 3 Terminal to connect solar + with appropriate wire tag Ensure that the wires are not 4 Terminal to connect solar - connected interchanged or reversed 5 Terminal to connect battery - 6 Terminal to connect inverter - 7 AC neutral out Phase and neutral wire from the AC wall socket is connected to the AC 8 AC neutral in phase in and AC neutral in AC phase out and AC neutral out 9 AC phase in goes to the phase and neutral in of the 10 AC phase out inverter The four pins of the molex are very close. Ensure proper crimping Ensure that phase and neutral wires are not connected in reverse 11 Earth wire Earth wire from the AC wall socket has to be externally shorted with the earth wire that goes into the inverter 12 Push switch and USB port Push switch used for configuration

Push switch used for delaying force trip by 30 minutes Note: USB port in the product is only meant for factory and service purpose. The port should not be used for any normal USB operations like mobile charging, plugging mass storage etc.

Fig 3 Connecting diagram

Push button: The push button when pressed during normal operation of icon, would delay the force trip by 30 minutes. This feature is used in order to help the customer run high loads in the inverter circuit when the utility power is available. Note: Availing this feature frequently will adversely affect the savings that is expected from icon. It is always better to connect heavy loads to non inverter circuit. 4.2. Solar PV connections Any panel string voltage between 0 V to 60 V is acceptable for icon. Considering the efficient utilization of the connected solar panel, it is advised to connect the solar panel with Voc less than 25 V for 12 V battery system and solar panel with Voc less than 40 V for 24 V system. Battery voltage (V) Ideal Solar panel 150 W Panel 250 W Panel Voc (V) Vmp (V) Voc (V) Vmp (V) 12 22 19 NA NA 24 NA NA 36 32 Table 2 Ideal Voc for 12 V and 24 V system Depending upon the load requirement, the panel has to be parallel so that the overall power of the solar installation doubles keeping the Voc unchanged. The maximum power rating for solar installation is limited to 450 W for 12 V system and 750 W for 24 V system, considering efficient solar utilization. The solar positive and negative wires are connected tightly, to the corresponding terminals of the device. Note: The solar panels made by the same manufacturer and with the same rating should be used for paralleling. 4.3. Battery and inverter connection icon connects the PV to the existing inverter. Battery and the mains has to be disconnected from the the inverter. Battery positive and negative wires are connected to the corresponding battery connecting terminals of the icon. The inverter wire which is supposed to be connected to the battery, need to be connected to the positive and negative inverter connecting terminals of icon. Usually the battery wires of the inverter comes with ring type tag at the end, which has to be cut and the end of the wire should be crimped for connecting it to inverter terminals of the icon. The phase and neutral wires from the AC plug has to be connected to the AC phase in (9) and AC neutral in (8) pins of the 4 pin MOLEX connector of icon. The AC phase out (10) and AC neutral out (7) pins of 4 pin MOLEX connector of icon has to be connected to the inverter s

mains in. Loads are supplied from mains out of the inverter just as in the normal inverter connection. Connect the phase in, phase out and neutrals as specified in the manual. Swapping may lead to short circuit. The MOLEX pins are very close and hence solder the AC wire tips so as to prevent short circuit due to stray strands. The battery and inverter wires should be crimped and wire tags should be placed on either side of wire. Pin type wire tag on icon side and ring/pin type wire tag on the other side depending upon the requirement of the inverter/battery. 5. LED and Buzzer Indication The icon s present mode/state of operation and errors are indicated using LED. Device startup: The LED blinks RED BLUE GREEN with the music Device State (Blinks in every 5 seconds) LED Colours YELLOW GREEN MAGENTA CYAN BLUE RED Error / States Waiting for full charge detection Solar charging - Mains Inhibition Mains Inhibition** Battery force trip** Solar assisted force trip Normal Inverter mode Solar assisted power failure OFF Device OFF Table 3. Device state LED indications **Force trip: The utility power is disconnected from the load. This is usually done when the solar is available and considering the battery voltage. This feature maximizes the solar utilization. **Mains inhibition: The utility is prevented from charging the battery. This feature increases the overall savings when compared to all other charge controllers. The LED indication along with the error description is mentioned in table 4. Contact the service men to get it rectified.

Errors RED (Steady) LED Colour RED (Blinks in every 1 second) Error / States Cannot detect the memory Not Calibrated MAGENTA (Blinks in every 1 second) Not Configured YELLOW (Blinks in every 1 second) RTC not set Table 4. Error indication 6. Initial power up and configuring icon Battery power ups the icon and hence it is always better to keep any of the battery terminal open until all the other connection is done. PV+ and PV- : Connect the PV+ and PV- to the corresponding terminal in the icon tightly. It is safe to keep the MCB (not mandatory for small power solar installation) for solar, as it become easy to isolate the PV when required. Check the voltage across the solar+ and solarterminal in icon, so that Voc will be shown (in the presence of sunlight). Inverter+ and Inverter- : The red (+) and black (-) wires of the inverter that are usually connected to battery+ and battery- in normal inverter connection need to crimped properly and tightened to inverter+ and inverter- terminals of the icon. AC Mains connection : Three core wire with three pin plug on one side, is used to bring phase in and neutral wire from the wall socket to the corresponding pins of the four pin MOLEX. Three core cable is used to connect the phase out and neutral from the corresponding pins of the four pin MOLEX to the mains in of the inverter. The earth wire should be shorted externally. Do not turn on the AC mains before icon gets powered from the battery. Battery+ and Battery- : The battery connection can be closed once all other connections are done. The battery wire which are crimped on either sides with appropriate wire tags are connected to the battery+ and battery- terminal of the icon. Connect the final battery connection using resistor to prevent sparking. icon gets powered and the LED blinks RED BLUE GREEN with the music. Turn on AC mains only icon is powered from battery. icon has to be configured in order for the device to start running its advanced algorithm. If not configured, magenta LED blinks in every 1 sec showing the error. Configuration has to be done by the installation engineer using his laptop/pc with the icon configuration utility V2.0 installed in it. The icon configuration utility tool screen will look like Figure 3.

Fig 3. icon configuration utility screen Step wise procedure to configure icon is as below Step 1: Configuring inverter system specification

Step 2: Configuring network credentials Step 3: Syncing time

Step 4: Testing connectivity with AP and server 7. Specification icon- 12/24 V Battery system voltage 12 V 24 V Power rating of the recommended solar panel (W) Max continuous output current (A) 150/300/450 450/600/750 100 100 PV open circuit voltage (V) < 25 < 40 MPP voltage range (V) < 20 < 34 Input current from PV (A) 30 Ambient temperature range ( ) -10 to 60 Advanced Features Force tripping to enhance the solar utilization Intelligent and adaptive algorithm that studies load pattern and solar availability from the previous data to optimize solar utilization Utility charge inhibition to prevent the unnecessary charging of the battery from the utility grid

Peak time battery charge inhibition for reducing the stress on utility grid Web and mobile based UI for viewing user data Ports Solar -, Solar +, Inverter-, Inverter+, Battery+, Battery- Four pin MOLEX for phase in, phase out, neutral Product weight (gms) 610 8. Product dimension