diy solar

diy solar

SSR testing

UPDATE ~ Sorta !
Jason & I have been exchanging detailed email's in regards to the documentation I am reworking. Of course the Relays & the Delay board came up and with some back & forth, I lit a fire under him. Starting next week they will be doing their own testing on SSR's from a couple of companies, as well as Energy Saver Contactors as well. I've provided connections to a couple of manufacturers to him that seem to suit the needs.

Some background. Until Jan.2019 the Delay board did not exist, it was created to fill the need (use case) for EV applications. The fellow at AZLithium (who did the YT Video with the Nissan cells & the BMS16T) is the one who instigated it. Until that time, Chargery only recommended Relays and did not offer them as "additional optional components" but client demand had to be filled, so they went with Known Good reliable contactors that do the job, to address the need quickly. At that time SSR's were extremely expensive (still are in many cases) but that picture has changed considerably over the past year.

The Chargery BMS' are designed to meet all kinds of loads, Inductive, Capacitive and Resistive or others. As a result, it is difficult, even impossible to provide one or two solutions (use cases) to meet all of the varied requirements. The Delay Board is optional and may be helpful for pre-charging an Inverter depending upon the Inverter. The Delay board option is not an essential component, it's "need" is determined by the customer, although customers maybe don't know this, they have to consult their Inverter Documentation and/or other "load" devices to make this determination. The delay board was designed more for EV Support as the loading and operations are considerably different than for non-EV use.

-- Side Note... I am in contact with OEMS in regards to the SSR's and the Energy Saving Contactors and it will be a few days of back & forth before I have much information to share (also passing info up to Craig to help him in his testing too). The legwork is underway.

In closing a ponderance for folks. FAN's a big deal ? Seriously ! take 12VDC 100CFM box fan @ 0.015A (like those used in computers) the power draw is minimal. How many people leave an LED lightbulb on all day ? No matter what you do, there will always be some overhead with whatever gear you are using. For $3 a thermostatic control can be added so the fan only runs on set thresholds. We are not talking about 100W or even 10W LED Lights use between 3W-12W @ 120VAC. Don't get overly distracted with Minutia, you'll lose sight of the bigger picture. BTW, If you fear a relay draining your system will be the end of the universe, then maybe a rethink of what you are doing and how you are doing is warranted. Overhead Cost has to be built into the design of your solar system. If one has to nitpick, consider the Inverters at 85% efficiency versus those with 92% or higher efficiency, the less efficient inverters waste far more than any lame relay ! Pick you battle carefully and with wisdom.
 
FAN's a big deal ? Seriously ! take 12VDC 100CFM box fan @ 0.015A (like those used in computers) the power draw is minimal.

The problem isn't really the fan (and 0.15 A is closer to the reality than 0.015 A), it's the fact that if it's needed it's a sign the SSR dissipate a lot of power.

If one has to nitpick, consider the Inverters at 85% efficiency versus those with 92% or higher efficiency, the less efficient inverters waste far more than any lame relay ! Pick you battle carefully and with wisdom.

Yes, but it cost a lot more to improve the inverter efficiency than the SSR one. Wasting 50 W just because the manufacturer wanted to save 10 dollars makes no sense...
 
I have to admit that I have an archaic hatred of "power thieves" stemming from back when solar was expensive and I was groveling around in the woods with barley enough power to keep the fridge cold. Just like how I learned to program with a tiny amount of memory and I still write as if I had few kB to work with even though I have gB. Things have changed, solar is cheap and so is memory but I just can't let go of my dislike of "thieves", memory or power. I don't leave even an LED light on if I'm not using it. Chargers on the other hand seem to multiply on their own like rabbits...

The problem isn't really the fan (and 0.15 A is closer to the reality than 0.015 A), it's the fact that if it's needed it's a sign the SSR dissipate a lot of power.

Exactly. If you need a fan on it you are pushing it. If the fan fails you will lose the relay and the system. And I still at least count the wattage into the equation. Although the idea of a thermo switch is a good one. But I still would rather not have a mission critical unattended device need a fan and it sounded like the OP needs just that.

This is exactly why I am testing them. The whole purpose of the thread find a good SSR that works as we need with low current draw. And is efficient.

This is exactly why I look forward to your results!
 
Ohh my, I started programming on Mainframes, then 8086 PC's in assembler and forward... so long ago... remember $55 per meg of DRAM ? $800 for an 80 meg mfm FH room warmers.... Kinda like a PTSD trigger ! LOL. I wrote SAS programs to run on multiplexed IBM-3090-500's Frames which I found I could completely stress out crunching the stats. Gosh those things were horrid.

Exactly. If you need a fan on it you are pushing it. If the fan fails you will lose the relay and the system. And I still at least count the wattage into the equation. Although the idea of a thermo switch is a good one. But I still would rather not have a mission critical unattended device need a fan and it sounded like the OP needs just that.
And the simple solution is ? Use a larger relay and you won't be pushing It to the edge of it's specs. So if you "need" 150A get a 200A or 210A relay. General rule of thumb I was taught, was take Max add 20% and your good. Mission Critical, add 25-30% over "must have value".
 
Ohh my, I started programming on Mainframes, then 8086 PC's in assembler and forward... so long ago... remember $55 per meg of DRAM ? $800 for an 80 meg mfm FH room warmers.... Kinda like a PTSD trigger ! LOL. I wrote SAS programs to run on multiplexed IBM-3090-500's Frames which I found I could completely stress out crunching the stats. Gosh those things were horrid.

You poor bugger. :) My coding started a little later than that with the 8051.

And the simple solution is ? Use a larger relay and you won't be pushing It to the edge of it's specs. So if you "need" 150A get a 200A or 210A relay. General rule of thumb I was taught, was take Max add 20% and your good. Mission Critical, add 25-30% over "must have value".

Agreed. Although with the SSRs of dubious origin I'd probably go to a 50% derate. At least until I had some time on 'em.
 
So you are trying to disconnect the batteries in the event of over charge or low voltage. Isn't the solar charge controller capable of doing this?
 
The SCC should do that.

The point of the BMS is to do it only if the SCC fail to do it. It's for redundancy.
 
So you are trying to disconnect the batteries in the event of over charge or low voltage. Isn't the solar charge controller capable of doing this?
Yes but the problem is if a cell gets out of balance the SCC can see the whole packs voltage but not each cells voltage.

for instance 3.0+3.0+3.0+3.0 = 12 and in this case everything is fine.
but 4.0+3.0+2.5+3.5= 12 if the cells get out of balance the SCC can not tell but your pack could get destroyed.
 
Yes but the problem is if a cell gets out of balance the SCC can see the whole packs voltage but not each cells voltage.

for instance 3.0+3.0+3.0+3.0 = 12 and in this case everything is fine.
but 4.0+3.0+2.5+3.5= 12 if the cells get out of balance the SCC can not tell but your pack could get destroyed.
Then isn't that a BMS's function?
 
Then isn't that a BMS's function?
The SCC & Inverter read the "Whole" battery bank voltage, they generally do not have a way to interact wit the BMS nor do they now what each pack and what each cell within a pack is doing internally. Most of the time this is no problem and everything just ticks along. BUT should one or more cells trigger a fault condition in the BMS (under/over volt or temp etc) the BMS has the job of being the Gatekeeper and will shut off the pack. Guard Dog duty if you will and it is the last stop if something happens.

Some SCC's & Inverters CAN interact with a BMS. Depending on the device & BMS different actions can occur. For example Victron can communicate with a BMS through it's interface. If using Victron Batteries then I gets the rich data and acts accordingly BUT if the BMS is not supported then it as limitations.
 
UPDATE ~ Sorta !
Jason & I have been exchanging detailed email's in regards to the documentation I am reworking. Of course the Relays & the Delay board came up and with some back & forth, I lit a fire under him. Starting next week they will be doing their own testing on SSR's from a couple of companies, as well as Energy Saver Contactors as well. I've provided connections to a couple of manufacturers to him that seem to suit the needs.

Some background. Until Jan.2019 the Delay board did not exist, it was created to fill the need (use case) for EV applications. The fellow at AZLithium (who did the YT Video with the Nissan cells & the BMS16T) is the one who instigated it. Until that time, Chargery only recommended Relays and did not offer them as "additional optional components" but client demand had to be filled, so they went with Known Good reliable contactors that do the job, to address the need quickly. At that time SSR's were extremely expensive (still are in many cases) but that picture has changed considerably over the past year.

The Chargery BMS' are designed to meet all kinds of loads, Inductive, Capacitive and Resistive or others. As a result, it is difficult, even impossible to provide one or two solutions (use cases) to meet all of the varied requirements. The Delay Board is optional and may be helpful for pre-charging an Inverter depending upon the Inverter. The Delay board option is not an essential component, it's "need" is determined by the customer, although customers maybe don't know this, they have to consult their Inverter Documentation and/or other "load" devices to make this determination. The delay board was designed more for EV Support as the loading and operations are considerably different than for non-EV use.

-- Side Note... I am in contact with OEMS in regards to the SSR's and the Energy Saving Contactors and it will be a few days of back & forth before I have much information to share (also passing info up to Craig to help him in his testing too). The legwork is underway.

In closing a ponderance for folks. FAN's a big deal ? Seriously ! take 12VDC 100CFM box fan @ 0.015A (like those used in computers) the power draw is minimal. How many people leave an LED lightbulb on all day ? No matter what you do, there will always be some overhead with whatever gear you are using. For $3 a thermostatic control can be added so the fan only runs on set thresholds. We are not talking about 100W or even 10W LED Lights use between 3W-12W @ 120VAC. Don't get overly distracted with Minutia, you'll lose sight of the bigger picture. BTW, If you fear a relay draining your system will be the end of the universe, then maybe a rethink of what you are doing and how you are doing is warranted. Overhead Cost has to be built into the design of your solar system. If one has to nitpick, consider the Inverters at 85% efficiency versus those with 92% or higher efficiency, the less efficient inverters waste far more than any lame relay ! Pick you battle carefully and with wisdom.
I might be wrong here but was looking forward to using delay board to have external switch to turn the main power off as it seems to have that option. Instead of using the display and turning off. Maybe I'm not sure how this works and can use the board for this and with small delay.
 
UPDATE.
i was able to put together a 140 Amp load for about 10 minutes. The terminal where the load cable leads the relay heated up to about 170F.
The relay itself stayed about 50 degrees cooler. Next test i will try and record all the portions of the relay with the thermometer. This is the 240Amp relay.

Im thinking the terminal heat would be the same on the larger 500 amp relay.

Wondering if i could put on a larger connector to help disperse heat.

Also would same heat be created with an automotive style relay?

Thermometer video
 
Well, it doesn't surprise me alot, I said what I thought about those terminals on the first page...

But that's a shame because those SSR seems pretty good on the silicon side, beeing limited by the terminals is a big bummer.
 
You can, but the right thing to have would be a proper terminal on the SSR because here you lose a lot of power (which we want to avoid by using a SSR, so that's kind of counter productive...), well at least it's proportional to the current squared instead of a constant loss...

In the mean time you can use a copper busbar if you have one on hand, it should act as a passable heatsink.
 
You can, but the right thing to have would be a proper terminal on the SSR because here you lose a lot of power (which we want to avoid by using a SSR, so that's kind of counter productive...), well at least it's proportional to the current squared instead of a constant loss...

In the mean time you can use a copper busbar if you have one on hand, it should act as a passable heatsink.
Yes I guess any heat would be a loss of energy. I will talk to manufacture about enlarging connections.

Would a standard relay have same problem?
 
As far as I saw they have a lot beefier terminals (even the cheap ones) so that shouldn't be a problem on those.

Also, I forgot to mention it earlier but soldered connections and heat cycling don't go together very well, so even if you heatsink the external terminal the internal connection will likely still be a problem.
 
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