A selection of recent projects across solar, battery storage, hybrid, and other renewable plants — showing the challenge, the engineering approach, and the measurable result. Project names are anonymised on request.
A large retail mall needed to insulate trading operations from loadshedding, reduce exposure to Eskom's peak-period demand charges, and co-ordinate solar, battery, and diesel assets from multiple vendors — in a live commercial environment where a control failure has direct revenue impact.
A bespoke SEL-based Power Plant Controller acting as the single point of authority for every asset on site. Near-seamless islanding on grid loss, battery arbitrage across off-peak and peak tariff windows, autonomous blackstart and mode transitions, and zero-export enforcement. A client-provided third-party EMS integrates as an enhancement layer over an 87-point Modbus interface.
SEL Power Plant Controller · Bespoke control software · Purpose-built SCADA · Bluelog XC · Huawei Smart ACU · BESS PCS · Modbus TCP/IP · Dual-frequency heartbeat monitoring
A critical municipal WWTW where supply interruption has direct public-health consequences. Energy cost reduction was a parallel priority — requiring grid-compliant PV export, energy arbitrage, and peak shaving across a multi-asset site.
A bespoke microgrid controller managing every energy asset autonomously, around the clock. Structured blackstart on grid loss, BESS restart in off-grid VSG mode, and energy arbitrage on TOU windows. 50% of battery capacity is permanently reserved for backup — the facility is always protected, regardless of trading strategy.
SEL Power Plant Controller · Setcon bespoke control software · Bluelog centralised PV controller · Battery containers · PCS with built-in transformer & RMU · DSE gen controllers
An 11 kV retail mall with a 2.5 MVA municipal incomer that is undersized relative to full mall load — multiple energy sources must always supplement the grid. The selected BESS PCS does not reliably back-synchronise from off-grid to grid, requiring a redesigned transition. Six gensets across three independent banks needed runtime-balanced sequential dispatch.
A bespoke SEL-based controller coordinating PV, BESS, six gensets, and an undersized grid incomer. Where the PCS could not reliably back-sync, Setcon re-engineered the transition entirely — delivering a deterministic, 11-step verified grid return sequence safer than the OEM approach. Runtime-balanced genset dispatch ensures even wear distribution across all six units.
SEL Power Plant Controller · Setcon bespoke control software · Sungrow Logger (PV) · Sungrow Power Titan PCS · Transformer with RMU · DSE gen controllers · Modbus TCP/IP
A manufacturing facility where any supply interruption — however brief — carries direct production-downtime cost. Industrial maximum-demand penalties demanded active peak management, balanced against battery charge requirements. Loadshedding during production shifts represents direct financial loss, and the optimal grid charge setpoint is site-specific with measurable consequence in either direction.
A double-conversion topology means there is no physical changeover on grid loss — the load inverter never stops supplying the facility, so grid events are invisible to production. The Setcon Eta 1 controller manages PI-controlled PV curtailment, maximum-demand limits, synchronous gen start, and BESS VSG sync without operator intervention.
Setcon Eta 1 controller · Purpose-built HMI · Huawei SUN2000 inverters · Bluelog XC · SolarMD battery · Sungrow PCS · DSE gen controllers
A commercial office with two large electronic billboards (30–180 kW each) that generate revenue continuously — any supply interruption is a direct financial loss. The building's electrical incomer has a fixed power limit that the new billboard loads risk tripping during peaks. Excess solar must never feed back into the grid, and the diesel generator must operate strictly between 30% and 80% of rated output at all times.
A Setcon Eta 1 controller delivering seamless on/off-grid changeover via the Huawei Gswitch, active peak shaving on the building incomer, real-time PV anti-feedback via analog power control, and continuous management of the gen output window. 4G VPN remote access enables off-site parameter control and diagnostics.
Setcon Eta 1 controller · Huawei SUN2000 inverters + Bluelog XC · Huawei LUNA2000 BESS + Logger V5 · Huawei Gswitch (seamless changeover) · DSE gen controller + ATS · Acuvim bulk & load metering · Ewon Cosy 4G VPN
A live retail supermarket with an existing Phase 1 grid-tied PV installation that needed to be brought under unified Phase 2 control without disrupting operation. On cloudy days a static peak-shaving threshold risks battery depletion before the peak window ends, spiking grid demand. Zero export must be enforced in real time.
A Setcon Eta 1 controller with weather-predictive peak shaving — on cloudy days the controller adjusts strategy before the peak period begins, not during it. Real-time PV throttling enforces zero export across both PV phases. On grid loss, the controller safely throttles PV and BESS to zero without interfering with the independent genset.
Setcon Eta 1 controller · Meteocontrol Bluelog data logger · Cloud weather forecast integration · Sungrow SG125CX inverters · Sungrow PowerStack BESS · Existing genset integration (DSE) · Modbus TCP/IP & RTU
We'll walk through the engineering approach, the likely timeline, and honest ballpark costs — before any formal proposal.
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