An AC-coupled solar and battery expansion for the accommodation camp at Balco’s Wannamal production facility, built on the existing infrastructure without affecting site reliability, and ready for more dongas.
Gallery
The challenge
Balco’s Wannamal production facility has no mains connection. It runs on a 1.1 MW generator, supported by an existing 500 kW solar system set up to peak-shave for the generator, and carries a lot of specialised equipment, including presses and direct-on-line motor loads. The accommodation camp ran off this main system but had its own supporting system, isolated so it could revert to the main system if needed, plus its own backup generator.
Demand had grown. The camp system still had usable life, but compatible equipment to expand it was significantly more expensive and lacked the benefits of current technology. Balco wanted to build on what it had without changing how the site operates, so we targeted the uncovered load and modelled likely future loads.
What we did
Our team inspected the site several times and modelled the remaining and expected future loads. Rather than replace equipment that still had life in it, we used the existing infrastructure and AC-coupled the expansion. We prepared the scope of works, the single line diagram, the delivery plan and the system operation plan before anything was ordered.
The expansion adds an extra layer of power without affecting site reliability, while the existing system is still used to its full benefit. The accommodation and units now have a single, centralised main power supply that runs on solar and battery first, with the main site’s larger supply available on demand to supplement any needs. Our crew installed the system in a single week in late May 2026.
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Project package
| Category | Equipment | Qty | Total |
|---|---|---|---|
| Solar panels | Risen 475 W (RSM96-11-475BNDG) | 102 | 48.45 kW |
| Battery inverter | SAJ CHS2-50K-T6 all-in-one cabinet | 1 | 50 kW |
| Additional inverter | SAJ C6 75 kW PCS | 1 | 75 kW |
| Battery | SAJ high-voltage battery (in CHS2 cabinet) | 1 | 100.3 kWh |
| Controller / EMS | SAJ E-Manager | 1 | Microgrid control |
| Backup | Existing site generator (retained, not supplied) | – | Generator port connection |
| Mounting | S-5! mounting on Trimdek, four donga roofs | – | – |
No pricing shown.
The results
Figures marked ‘Estimated’ are modelled estimates, not measured results. They are based on the installed solar size, typical solar yields for the Wannamal area and an assumed accommodation load, as no metered load data was available. Actual results depend on weather, site usage and how the system is operated.
Take it with you
A print-ready A4 summary, with project photos, of the Balco Hay project. Every copy, printed or shared, carries a QR code that links back to this page.
PDF · 5 pages · A4 · includes project photos
nationalrenewable.com.au/projects/balco-hay
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