SolarEdge Optimizer Replacement SOP

Purpose: This SOP explains how field technicians should replace a SolarEdge power optimizer and update the system so the inverter, SolarEdge Monitoring Platform, and customer-facing app reflect the new optimizer correctly.

Simple rule: Replacing an optimizer is not just a hardware job. The system must be physically corrected, paired again, and updated in the SolarEdge monitoring layout with the new optimizer serial number.

Who should use this SOP

• Sunollo field technicians
• Solar service partners
• Project managers checking whether the job can be closed
• Customer care teams explaining why monitoring may not update immediately

Safety first

• Only trained and authorized solar technicians should perform this work.
• Follow local electrical safety rules and Sunollo site safety requirements.
• Do not touch DC or AC wiring until the system has been safely shut down.
• Always confirm the inverter and DC system are safe before touching optimizer wiring.

Before going to site

1. Confirm the site name, inverter model, number of panels, and expected number of optimizers.
2. Confirm which panel or optimizer is faulty from SolarEdge Monitoring.
3. Bring a compatible replacement optimizer. Do not assume any optimizer model will work.
4. Make sure the technician has installer access to SolarEdge SetApp and SolarEdge Monitoring Platform.
5. Prepare a phone camera to record the old and new optimizer serial numbers.

Tools required

• Replacement SolarEdge optimizer of the correct compatible model
• SolarEdge SetApp / installer app access
• SolarEdge Monitoring Platform access
• Phone camera for serial number photos
• Basic electrical testing tools as required by the technician
• PPE and roof safety equipment

Step-by-step field process

Step 1 — Shut down the system safely

1. Turn OFF the inverter ON/OFF/P switch.
2. Wait until the system indicates safe DC voltage, or wait at least the required safety period before continuing.
3. Turn OFF the AC supply to the inverter at the circuit breaker or distribution panel.
4. Turn OFF the DC safety unit or DC isolator, where applicable.

Expected result: The system is safe for the trained technician to work on.

Do not skip: This is a safety-critical step.

Step 2 — Replace the optimizer hardware

1. Locate the faulty optimizer physically on the roof.
2. Take a clear photo of the old optimizer serial number, if accessible.
3. Disconnect the old optimizer as per safe work procedures.
4. Install the new compatible optimizer.
5. Connect the module leads to the optimizer input connectors.
6. Connect the optimizer output connectors back into the string.
7. Ensure all MC4 or compatible connectors are fully seated and locked.
8. Ensure unused inputs on dual-input optimizers are sealed if applicable.
9. Take a clear photo of the new optimizer serial number.

Expected result: The new optimizer is physically installed and wired correctly.

Step 3 — Check the string basics before restart

1. Check connectors are tight and not under strain.
2. Check correct polarity.
3. Check the optimizer is securely mounted.
4. Check the physical panel location matches the replacement record.

Expected result: No obvious wiring, polarity, or connector issues remain before pairing.

Step 4 — Power up the system

1. Turn ON the DC isolator or DC safety unit, where applicable.
2. Turn ON the AC circuit breaker.
3. Turn ON the inverter.
4. Wait for the inverter to initialize.

Expected result: The inverter is ready for SetApp commissioning checks.

Step 5 — Run optimizer pairing in SolarEdge SetApp

1. Open SolarEdge SetApp / installer app.
2. Connect to the inverter.
3. Go to Pairing.
4. Tap Start Pairing.
5. If SetApp asks for optimizer count, enter the expected number of optimizers.
6. Wait for pairing to complete.

Important: Perform pairing when the modules have sunlight. If there is no sunlight or very low irradiance, optimizers may not wake up or report correctly.

Expected result: The inverter detects the new optimizer and the total optimizer count matches the site design.

Step 6 — Verify optimizer count

1. Compare detected optimizer count against the number of panels / optimizers installed.
2. If expected count is 20, detected count must be 20.
3. If the count does not match, do not close the job.

If count is wrong: Re-check wiring, connector seating, polarity, optimizer compatibility, and sunlight conditions. Then re-run pairing.

Step 7 — Update SolarEdge Monitoring Platform layout

1. Log in to the SolarEdge Monitoring Platform.
2. Open the correct customer site.
3. Go to site administration / layout area.
4. Find the old optimizer serial number or the affected panel in the layout.
5. Use the replace function in the logical layout, where available, to replace the removed optimizer serial number with the newly installed optimizer serial number.
6. If using the physical layout editor, assign the new optimizer serial number to the correct panel position.
7. Save the layout changes.

Expected result: The monitoring platform is no longer pointing to the old optimizer serial number.

Step 8 — Confirm panel mapping

1. Check that the new optimizer is assigned to the correct physical panel location.
2. Do not randomly assign the optimizer to a different panel just to make the app look normal.
3. Wrong mapping causes wrong troubleshooting later.

Expected result: The monitoring layout matches the real roof layout.

Step 9 — Wait for data sync

1. Allow time for SolarEdge Monitoring to sync.
2. Data may take time to appear after pairing and layout update.
3. Check again after sufficient sunlight and communication time.

Expected result: The replaced panel begins reporting normally in the monitoring platform and app.

Step 10 — Final verification before leaving site

• Pairing completed successfully.
• Detected optimizer count equals expected optimizer count.
• New optimizer serial number recorded.
• Monitoring layout updated with new serial number.
• New optimizer assigned to correct physical panel position.
• Photos uploaded to CRM or project record.
• Customer care notified if data will take time to refresh.

Common problems and fixes

Problem: App still shows the old panel missing

Likely cause: Pairing was done but the monitoring layout still has the old optimizer serial number.

Fix: Update the Monitoring Platform layout and replace the old serial number with the new serial number.

Problem: New optimizer is not detected during pairing

Likely causes: Loose connector, wrong polarity, wrong optimizer model, low sunlight, or optimizer not connected into the string.

Fix: Check physical wiring first. Then re-run pairing in sunlight.

Problem: Optimizer count is lower than expected

Likely causes: One optimizer is not connected, one module is not connected to its optimizer, or there is a string issue.

Fix: Do not close the job. Check all connectors and string continuity.

Problem: Data appears under the wrong panel

Likely cause: The serial number was added but mapped to the wrong physical panel location.

Fix: Correct the physical layout mapping.

Problem: Customer app has no obvious update option

Reason: Optimizer replacement is normally handled through installer-level pairing and monitoring platform layout updates, not by a simple customer app refresh button.

Minimum CRM record required

• Customer name
• Site address
• Date of optimizer replacement
• Old optimizer serial number, if available
• New optimizer serial number
• Panel position / roof section
• Technician name
• Photo of new optimizer serial number
• Confirmation that SetApp pairing was completed
• Confirmation that optimizer count matched expected count
• Confirmation that monitoring layout was updated
• Final status: reporting / waiting for sync / issue remains

Job closure rule

Do not close the service job until all three are true:

1. The hardware replacement is complete.
2. SetApp pairing has been completed and optimizer count is correct.
3. SolarEdge Monitoring layout has been updated with the new optimizer serial number.

Field team one-line memory

Replace hardware, run pairing, replace the serial in Monitoring, then verify the panel mapping.

Official source notes

• SolarEdge installation guidance says that after adding, removing, or replacing power optimizers, technicians should perform pairing and then replace the removed optimizer serial number with the newly installed optimizer serial number in the monitoring platform logical layout.
• SolarEdge guidance also explains that physical layout mapping is required to show the actual location of power optimizers and modules in monitoring.
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