Health is wealth, and that goes for solar systems too!
Always consult the experts and ensure your system is fit and robust!I
CASE STUDY ILLUSTRATING THE CORRECTIVE WORK WE DO
In the rapidly evolving world of solar technology, the difference between a substandard installation and a professionally executed one can dramatically impact performance, longevity, and overall satisfaction.
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BEFORE
AFTER
HIGH LEVEL SUMMARY
Recognizing the pivotal role of expertise in solar installations, our solar specialist is an established go-to expert for corrective work on poorly executed projects in the industry.​
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In the BEFORE pic (left above), this poor solar system was coughing and spluttering its way through every sunny day. The patient received the urgent care it needed in the AFTER pic! Here's what our solar doctor diagnosed as the key mistakes:​
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BATTERY
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1) There was a miscommunication going on between the average storage grade quality battery, typically found in South Africa. The batteries are missing in the pic as they were constantly being "fixed" in the workshop.
2) The dangerous 1:1 ratio of inverter and battery capacity.- Overdraw during load shedding risking BMS burnout.
3) NO Busbar for even power distribution.
4) Misleading SOC indicator lights!​
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EARTHING & WIRING
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1) Risky combination of DC connected to AC earth—hello, fire hazard!
2) DC and AC cables wrongly housed together; a no-go by SANS101.2.
3) Mysterious third DB box - what's it even for?​
POWER DISTRIBUTION PITFALLS
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1) The imbalance of a 3-phase home matched with a single-phase inverter. Only one phase reaping the solar benefits, while others hit those high Eskom tariffs.​
2) Certification Concerns:- Gauteng, we need tighter regulations! A SAPVIA greencard isn't always enough.​​
DETAILED REPORT
INVERTER ISSUES:
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• The inverter is a 10kw and the batteries are 10.2kw; rule of thumb is to avoid a 1:1 ratio. The inverter can achieve almost 360 Amps when it's pulling (during load shedding), which is double what the batteries can handle, hence why the BMS's were recently burnt.
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• In hybrid mode (when the Eskom grid is connected), a set and allowed draw is controlled. It doesn't allow the system to draw more than it can handle.
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• In invert mode (load shedding), using a heavy drawing appliance or appliances together (kettle and toaster for example), the draw runs back on the thermware of the machine and it attempts to meet the draw, if it cannot meet it, the bms gets burnt.
BATTERY TROUBLES:
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• Battery performance was highly irregular in the BEFORE pic installation, batteries could very well be flat (with flicking lights on/off), however inverter is reading that the batteries are full. There is no communication between the storage grade batteries.
• Both built in bms's (battery management systems) have been set with the same IP address, which means they clash and cannot "speak/communicate" to the lithium cells - hence why the indicator lights are blinking, as they transmit and attempt to communicate with the system.
• Battery pack should have been designed with a minimum capacity of 20 kwh, especially with 24 solar panels.
•Storage solar grade batteries in the South African market have a 0.5C rating. Repurposed EV (electric vehicle) batteries are built to withstand high draws (to get vehicles moving forward). They are the best value batteries in the market, repurposed as storage batteries. They are designed to withstand bumpy roads, cold/hot temperatures, and high spikes.
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•REVOV Batteries C rating is listed at 1C on their R9 batteries, (but can possibly achieve 2C). A new lithium cell loses 5% capacity in the first 3 years, This means that a 100Ah storage grade average storage grade battery's performance reduces rapidly. A repurposed battery has already lost the rapid loss, and therefore the tested cells have a longer life, as these EV batteries have 16 cells too, whereas storage grade batteries have 15 cells.
• REVOV warranties are 10 years or 3500 cycles, which ever comes first. A cycle is a full charge and discharge of the battery. Most of the REVOV batteries will last 15 years if cared for and worked or installed properly.
• SOC of the batteries should be obvious to every client at a glance. but the SOC indicator lights (line of lights on the battery above the "arrow head" type marking); are just blinking endlessly showing you nothing currently. It should show you if battery is empty (one light) or full (all lights).
MAIN DB and CRITICAL LOAD SPLIT INCORRECT:
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• The best approach for a 3 phase home is to match it to a 3 phase inverter. This splits the power in a balanced way. The original db configuration seen in photo below, the client was only receiving a saving on one phase.
•The solar panels are only supplying one phase, which are plugs that don't necessarily draw a lot of power and for recharging your batteries, leaving other phases to creep over the 500 unit limit, where Eskom charges you a higher tariff.
•We split the balance over all 3 phases, keeping all 3 phases below the higher tariff mark and economising the client's electricity bill. 1 phase is nice for load shedding backup only. There are 24 solar panels, the client needs to maximise on those with electricity savings.
•The wiring in this db very untidy, we make db's pretty.