Progress Report: System Check & Load Testing

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:

1. 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.

2. 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.

3. 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

4. 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.

5. 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).

6. 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:

• 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.

• Water System:

  • Consider higher capacity pump for shower.
  • Continue monitoring tank usage rates.

• 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.