ACRouter — Open Source Solar Router Controller

Intelligent AC Power Router for Solar Energy Management <a href="#features">Features</a> • <a href="#hardware">Hardware</a> • <a href="#quick-start">Quick Start</a> • <a href="#operating-modes">Modes</a> • <a href="#documentation">Docs</a> • <a href="#contributing">Contributing</a> <img src="https://img.shields.io/badge/Platform-ESP32-blue?style=flat-square" alt="Platform"> <img src="https://img.shields.io/badge/Framework-ESP--IDF%205.5-green?style=flat-square" alt="Framework"> <img src="https://img.shields.io/badge/License-Open%20Source-orange?style=flat-square" alt="License"> <img src="https://img.shields.io/badge/Status-Active%20Development-brightgreen?style=flat-square" alt="Status">

What is ACRouter?

ACRouter is an open-source controller that automatically redirects excess solar energy to resistive loads (like water heaters) instead of exporting it to the grid. It helps you maximize self-consumption of your solar power and reduce electricity costs.

Why ACRouter?

| Problem | Solution | |---------|----------| | Excess solar energy exported to grid at low rates | Route it to heat water or other loads | | Expensive battery storage systems | Use thermal storage (water heater) instead | | Complex commercial solutions | Simple, open-source, DIY-friendly | | Fixed on/off control wastes energy | Smooth phase-angle dimming for precise control |

Typical daily behavior of a grid-connected PV system with a water heater load.

| Parameter | Without ACRouter | With ACRouter | |---------|------------------|---------------| | Daytime solar export | High | Low | | Self-consumption ratio | ~40–50% | ~70–85% | | Water heating source | Grid (evening/night) | Solar surplus (daytime) | | Evening grid import | High | Reduced | | Battery required | Yes (for storage) | No | | Energy wasted/exported | Significant | Minimal | | Grid interaction | Uncontrolled export | Controlled, grid-friendly | | Overall energy cost | Higher | Lower - reduce 30% |

Features

⚡ Real-Time Power Monitoring

AC voltage measurement (ZMPT107 sensor)
Multi-channel current monitoring (up to 3× SCT-013/ACS-712 sensors)
12-bit ADC with DMA for high accuracy
200ms update cycle (5 updates/second)

🎛️ Intelligent Load Control

Phase-angle AC dimming (0-100% smooth control)
TRIAC-based, zero-cross synchronized
Multiple operating modes for different scenarios
Anti-flicker algorithms

📱 Easy Configuration

Built-in WiFi Access Point for setup
Modern web dashboard (Material UI)
REST API for integration
Serial console for advanced users
All settings stored in non-volatile memory

🔗 MQTT & Home Assistant (v1.2.0+)

Full MQTT client with auto-reconnect and LWT
Home Assistant Auto-Discovery
Real-time metrics publishing
Remote control via MQTT commands
Web UI for MQTT configuration

🔌 Flexible Hardware

Configurable GPIO pins via web interface
Support for various sensor types
Multiple dimmer channels
Relay outputs for on/off loads

Web Dashboard

The web interface provides:

Real-time metrics — Voltage, current, power for all channels
Mode selection — One-click switching between modes
Manual control — Slider for direct dimmer control
WiFi settings — Network scanning and connection
Hardware config — GPIO pin assignment without reflashing

Serial console for advanced users

Real-time metrics display
Command line for hardware and device parameter configuration
Operating mode selection

<img width="1582" height="722" alt="image" src="https://github.com/user-attachments/assets/5b7454cb-5034-4c70-b23f-9d14c9c04934" /> See [🗺️ Commands](docs/07_COMMANDS.md) Complete guide for ACRouter serial terminal and REST API commands. ---

Hardware

Controller Board

ACRouter runs on ESP32-based development boards designed for AC power control.

ACRouter-modules-simple-1920x

| Component | Specification | |-----------|--------------| | MCU | ESP32-WROOM-32 / ESP32-WROVER | | CPU | Dual-core 240 MHz | | Flash | 4 MB minimum | | WiFi | 802.11 b/g/n |

Sensors

| Sensor | Purpose | Link | |--------|---------|------| | ZMPT107+ Zero-Cross Detector | AC Voltage Measurement & AC waveform synchronization | Guide | | SCT-013 | Current Transformer (current variation) | Guide | | ACS-712 | Current Transformer (current variation) | Guide |

Dimmers & Control

| Module | Purpose | Link | |--------|---------|------| | AC Dimmer Module | Phase-angle power control | Guide |

💡 Note: ACRouter is designed to work with hardware from rbdimmer.com and any opens source DIY modules

Operating Modes

ACRouter supports 6 operating modes to cover different use cases:

| Mode | Description | Best For | |------|-------------|----------| | OFF | System disabled, dimmer at 0% | Maintenance | | AUTO | Automatic grid balance (P_grid → 0) | ⭐ Standard solar routing | | ECO | Prevent export, allow import | No feed-in tariff | | OFFGRID | Use only solar excess | Off-grid systems | | MANUAL | Fixed dimmer level | Testing, night tariff | | BOOST | Maximum power (100%) | Fast heating |

AUTO and ECO modes are the primary solar routing modes used in grid-connected systems.

AUTO Mode — The Heart of Solar Routing

☀️ Solar: 3000W    🏠 House: 800W    ⚡ Grid: -2200W (export!)
                              ↓
                    ACRouter detects export
                              ↓
                    Increases dimmer → heats water
                              ↓
☀️ Solar: 3000W    🏠 House: 800W    🔥 Heater: 2200W    ⚡ Grid: 0W ✓

Quick Start

1. Flash the Firmware

Option A: Use Pre-built Binaries (Recommended for Quick Start)

No compilation required! Download the latest firmware and flash it directly:

Download the latest release from GitHub Releases
Extract the archive
Flash using the included script:
- Windows: flash.bat COM5
- Linux/Mac: ./flash.sh /dev/ttyUSB0

Option B: Build from Source

# Clone the repository
git clone https://github.com/robotdyn-dimmer/ACRouter.git
cd ACRouter

# Set up ESP-IDF environment
. $HOME/esp/esp-idf/export.sh

# Build and flash
idf.py set-target esp32
idf.py build
idf.py -p /dev/ttyUSB0 flash monitor

2. Connect to ACRouter

After flashing, the device creates a WiFi network:

| Setting | Value | |---------|-------| | SSID | ACRouter_XXXXXX | | IP Address | 192.168.4.1 |

3. Configure via Web Interface

Connect to the ACRouter WiFi network
Open browser: http://192.168.4.1
Configure hardware GPIO pins
Connect to your home WiFi
Select AUTO mode and start saving energy!

Documentation

| Document | Description | |----------|-------------| | 📖 Application Overview | Complete documentation | | 🔧 Hardware Reference | Pin assignments and specifications | | ⚙️ Compilation Guide | Build instructions and troubleshooting | | 📐 Architecture | Software modules and API | | 🎮 Operating Modes | Detailed mode descriptions | | 🔗 MQTT Guide | MQTT integration and topics | | 🏠 Home Assistant | Home Assistant integration | | 🗺️ Roadmap | Development plans |

REST API

ACRouter exposes a REST API for integration with home automation systems:

# Get current status
curl http://192.168.4.1/api/status

# Set mode to AUTO
curl -X POST http://192.168.4.1/api/mode -d '{"mode": 1}'

# Get power metrics
curl http://192.168.4.1/api/metrics

See API Documentation for full endpoint list.

What ACRouter Is Not

Not a battery inverter
Not a smart plug or relay controller
Not a certified grid protection device
Not suitable for inductive or electronic loads

Safety Notice

⚠️ WARNING: This project involves mains voltage (110V/230V AC)

Installation must be performed by a qualified electrician
Always use proper galvanic isolation
Install appropriate circuit breakers and RCD/GFCI protection
Only use with resistive loads (heating elements)
Not suitable for motors, LEDs, or electronic devices

Contributing

We welcome contributions! Here's how you can help:

🐛 Report bugs — Open an issue with details
💡 Suggest features — Share your ideas in discussions
📝 Improve docs — Fix typos, add examples
🔧 Submit code — Fork, develop, and create a pull request

Community

GitHub Issues — Bug reports and feature requests - (https://github.com/robotdyn-dimmer/ACRouter/issues)
Discussions — Questions and community support - (https://github.com/robotdyn-dimmer/ACRouter/graphs/community)

License

ACRouter is open-source software. See LICENSE for de

ACRouter

Install / Use

README