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AS 4509.2-2010 AS 3010-2017
The Generator's Role in a Solar-Hybrid System
In a well-designed solar-hybrid system, the generator runs as seldom as possible — only when extended cloudy weather has depleted the battery below a set threshold. Its primary job is to charge the battery (via the inverter-charger's AC input) while simultaneously supplying critical loads. The generator size must be adequate for both tasks simultaneously.
Generator Sizing Methodology (AS 4509.2)
The design requirement: generator must supply the maximum AC input current the inverter-charger can consume for charging, plus the critical load at the same time, without exceeding 80% of the generator's rated capacity.
Parameter | Example Value |
|---|---|
Inverter-charger max AC input (charging) | 3,000 W |
Critical load while charging | 1,500 W (fridge, lights, pump) |
Total simultaneous demand | 4,500 W |
Required generator capacity (÷0.80) | 5,625 W → 6 kVA generator minimum |
The Fuel Efficiency Optimisation
Diesel generators are most fuel-efficient at 70–80% of rated load. An oversized generator running at 30% load burns nearly as much fuel per hour as it does at 70% load — while delivering far less useful energy. The ideal approach:
Size the generator for 70–80% loading under the expected battery charging + critical load scenario
Set the inverter-charger's AC input limit so the generator runs at its efficiency sweet spot
Run the generator in bulk-charging mode (high current for 2–4 hours) rather than trickle-mode (low current for 12 hours) — far more fuel-efficient per Ah delivered to the battery
Use a run-hour meter to track fuel consumption trends — sudden increase in run hours with no load change indicates battery health degradation
Engr. Jason Morales — Founder, SolarEnergyPH
