SOLAR DOCTOR

FROM BROKEN TO BRILLIANT

Health is Wealth, and that goes for Solar Systems too.

Consult the experts and ensure your system is fit and robust. See an example case study of how our expert corrective work fixes and transforms underperforming systems into safe, high-performing solar setups. In solar, how it’s done makes all the difference.

BEFORE

AFTER

HIGH LEVEL SUMMARY

Our solar specialist is the industry’s go-to for fixing botched installations — because expertise matters.

In the BEFORE shot (left), this system was barely surviving under the sun. In the AFTER, it's thriving. Here’s what our Solar Doctor uncovered during the rescue mission...

BATTERY

Battery Quality Confusion
The system used average storage-grade batteries (common in South Africa), which were not suited for the setup. The batteries aren’t pictured because they were constantly being removed and “repaired” in the workshop.
Dangerous Inverter-to-Battery Ratio
The inverter and battery capacity were sized 1:1 — a risky setup. During load shedding, this caused the system to draw too much power, putting the Battery Management System (BMS) at serious risk of burning out.
No Busbar Installed
There was no busbar to evenly distribute power — a major design flaw that compromises safety and efficiency.
Misleading State of Charge (SOC) Lights
The SOC indicator lights gave a false sense of battery health, leading to confusion and poor system management.

EARTHING & WIRING

Fire Hazard Alert
The system dangerously connected DC to the AC earth — a serious safety risk and potential fire hazard.
Code Violation: Mixed Cabling
DC and AC cables were run in the same conduit — a direct violation of SANS 10142 regulations and a major safety concern.
The Mystery DB Box
A third distribution board was installed with no clear purpose — adding confusion, complexity, and potential risk to the setup.

POWER DISTRIBUTION PITFALLS

Unbalanced Power = Unbalanced Savings
A 3-phase home was paired with a single-phase inverter — meaning only one phase benefited from solar, while the other two kept drawing expensive Eskom power.
Certification Gaps
In Gauteng, not all certified installs meet the mark. A SAPVIA Green Card doesn’t guarantee quality — only qualified Installation Electricians (IE) or Master Installation Electricians (MIE) may legally install systems and issue a valid Certificate of Compliance (COC).
Code Compliance Is Non-Negotiable
Installations must meet SANS 10142 electrical standards and follow the NERSA Grid Code to ensure safety, efficiency, and legal compliance.
Engineer Sign-Off Required for Larger Systems
Grid-tied or large commercial systems often require sign-off from an ECSA-registered engineer before municipal approval and connection.

DETAILED REPORT

INVERTER ISSUES:

The system uses a 10 kW inverter with 10.2 kWh of battery storage — but this 1:1 ratio is risky and should be avoided.

During load shedding, the inverter can pull up to 360 amps, which is almost double what the batteries are rated to handle. This excessive draw is what recently burnt out the Battery Management Systems (BMSs).

In Hybrid Mode (when Eskom is available):
The system limits the power draw to safe levels. It only pulls what the inverter and batteries can handle, which protects the components.
In Inverter Mode (during load shedding):
If multiple high-draw appliances (like a kettle and toaster) are used at once, the inverter tries to meet the demand by pulling more power from the batteries.
If the demand exceeds what the batteries can safely supply, the excess load damages the BMS, leading to failure.

WHY THE BATTERY SETUP WAS FAILING - EXPLAINED:

False Readings = Real Problems
In the BEFORE installation, lights were flickering on and off, suggesting flat batteries. Yet the inverter falsely showed the batteries as “full.”
Why? Because the batteries couldn’t communicate with each other — a major flaw in system design.
Undersized Battery Bank
With 24 solar panels, the system should’ve had at least 20 kWh of battery storage. The installed pack was too small to store and supply the energy produced, creating instability.
Storage-Grade Batteries vs. EV-Grade Batteries
Most storage-grade batteries sold in South Africa have a 0.5C rating, meaning they struggle with high power draw.
By contrast, repurposed EV (electric vehicle) batteries are built for high performance — they’re designed to handle bumpy roads, temperature extremes, and heavy acceleration. That makes them perfect for high-draw environments like solar backup, offering better value and durability.
Why REVOV Batteries Are Better
REVOV’s R9 model is rated at 1C (can possibly handle 2C) — meaning it can handle double the load of typical storage batteries.
New lithium cells lose about 5% capacity in the first 3 years. But repurposed EV batteries have already passed this phase, making them more stable with longer usable life.
They also use 16 cells per battery, compared to 15 in standard storage batteries, giving more power and resilience.
Long-Term Warranties That Last
REVOV batteries come with a 10-year or 3,500-cycle warranty — and with proper installation and care, many last up to 15 years.
SOC (State of Charge) Should Be Clear
Clients should know their battery status at a glance — empty (1 light), full (all lights). But here, the blinking lights show nothing, because the system isn't communicating properly.
BMS Conflict = Communication Breakdown
Both batteries had the same IP address, causing a clash between their Battery Management Systems (BMS).
As a result, they couldn’t talk to the inverter or to each other — leaving the system in the dark, literally and figuratively.

INCORRECT DB SETUP & PHASE SPLIT = MISSED SAVINGS

Unbalanced Setup = Limited Benefit
In a 3-phase home, the ideal setup is a 3-phase inverter to evenly distribute solar power across all phases.
In the original setup (see photo), only one phase was connected to solar — so the client only saved on a portion of their usage.
Wasted Solar Potential
With 24 solar panels, the system had serious potential — but it was only powering light plug circuits and battery charging.
Meanwhile, the other two phases — which carry heavier loads — continued to pull power from Eskom and exceeded the 500-unit threshold, triggering higher tariffs.
Our Fix: Balanced Power = Bigger Savings
We reconfigured the DB to split the solar contribution evenly across all 3 phases, keeping each phase below the high-tariff threshold.
This simple change maximised solar savings and made full use of the 24 panels.
Load Shedding vs. Full Efficiency
A single-phase inverter is fine if you're just looking for basic backup during load shedding, but for real savings on a 3-phase system, you need smart distribution.
Neat Wiring = Safer, Smarter DBs
The original DB wiring was untidy and poorly organised. We don’t just fix function — we make DBs look good too, with clean, safe, and professional wiring.

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