Progress Report: System Check & Load Testing
Overview
We've done a full diagnostic run on the electrical system, measuring load currents for every major component, troubleshooting power anomalies, and identifying key improvements.
Key Findings:
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General System Health:
- System functions as expected, but a few design oversights need correction.
- Power distribution is uneven, with some unexpected loads running off unintended circuits.
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Battery & Charging:
- MPPT Controller Reset Fixed Charging Issue
- Previously showed zero charging current, but now pulling a healthy 25A.
- Green LED confirms proper solar charging operation.
- Battery Load Benchmarking Completed
- Measured power draw for all major devices, giving us a clear power budget.
- MPPT Controller Reset Fixed Charging Issue
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Load Measurements (All Rounded to Nearest Decimal):
- Nook + Monitor + Speakers: 1.6A
- Fridges (Both Running): 4.4A
- All lights (except overhead workbench ones): 3.8A
- Water Pumps: Kitchen = 2.2A, Shower = 2.0A (shower pump likely underpowered)
- Television (Idle, No Signal): 8.6A
- Projector: 2.0A (estimated from spec sheet)
- Full System Running (Excluding Pumps): 16.5A
- Peak Draw (TV + Everything Else On): 22.1A
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Power Distribution & Wiring Issues:
- Overhead workbench lights mistakenly wired into the UPS.
- Fix: Separate UPS loads from general circuits (new dedicated switch panel needed).
- 13.8V DC-DC Converter Always On.
- Fix: Investigate why power is leaking past switch.
- UPS Power Isolation Issue.
- Fix: Install big-ass diode to prevent reverse current flow from UPS to main system.
- Overhead workbench lights mistakenly wired into the UPS.
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Solar Array Performance Test:
- Open Circuit Voltage: 65.5V (expected for system configuration).
- Current Clamp Test Failed: Not sensitive enough to measure individual panel outputs.
- Alternative Testing Needed:
- Option 1: Install switches to isolate solar panel strings for individual testing.
- Option 2: Install current shunt resistors for accurate millivolt readings (messy, but effective).
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Water System:
- Tank Capacity Calculated: ~1,500L
- Level Indicator Works Well: Meniscus visible in clear tube.
- Pump Performance:
- Kitchen pump fine.
- Shower pump underpowered—may need an upgrade.
Next Steps & Fixes:
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Electrical:
- Install big diode on UPS power feed.
- Build dedicated UPS switch panel to separate loads.
- Investigate why 13.8V converter stays on when switched off.
- Determine best way to measure individual solar panel current flow.
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Water System:
- Consider higher capacity pump for shower.
- Continue monitoring tank usage rates.
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Final System Testing:
- Conduct a full overnight test to simulate real-world battery usage and check power management.
General Summary:
- System is fundamentally sound, but has inefficiencies.
- Load testing gives a clear picture of power consumption.
- A few wiring mistakes need correction.
- The UPS needs proper isolation to prevent backfeed issues.
- Solar panel current distribution is unknown—we need a better way to check it.
- Shower pump may be too weak.
All in all, good job catching these issues now rather than later. This was a long-overdue professional-level diagnostic, and it’ll pay off big-time in system stability and reliability.
