AIO Gateway Question

13 comments started 2024-09-17 last 2025-07-12
GivEnergy ProductsAC CoupledBattery
J
#1 JasonF

So I now have 2 x AIO, and I’m allowed to use the full input and output capacity. I also have a 7.4kw ev charger.

In theory if I was charging at both at full speed and with my usual house load I’d be pulling about 20kw of power. Ignore the fact that if I did that I’d blow my main fuse, but the gateway is rated for 18kw - so if I try to exceed the 18kw the gateway can handle, what happens?

Will it lower the battery charge rate to bring it under the 18kw? Or will it just trip everything out?

#2 Jase1703

[unknown] it seems to trip out for a few minutes until the demand drops, very annoying, just had this happen 3 times in 4 days after 2 years without a problem.

#3 Jase1703

JasonF it seems to trip out for a few minutes until the demand drops, very annoying, just had this happen 3 times in 4 days after 2 years without a problem.

M
#4 Mouton

@Jase1703 With the AIO firmware A0.013 (maybe even 12) there is a setting for your import max / limit Amps. (GE or installer can set it to the size of your main fuse). This should I think result in the AIOs ramping down as the limit is approached as long as they are on corresponding FW (? A617-D617). I've just had limit set by GE helpdesk after GW upgrade A0.013 became available to me, so need to test.

EV chargers also have this capability, eg my Zappi has a CT to monitor the net grid import and a setting correponding to my 60A fuse, which causes the Zappi to also ease off near the fuse rating.

Lastly for @JasonF I recently picked this up from another forum discussion on 80A fuses being big enough or not, which includes a reference to how slow they blow. (now in bold)


Standardisation of fusing

National Grid Electricity Distribution (NGED) has made the decision to standardise the fuse installed within domestic style cutouts to 80A.

Historically domestic and small commercial connections that have been provided to customers may have incorporated a cutout fused at 100A. This was deemed acceptable where the installation was terminated within an area where the temperature was less than 20°C during the peak demand period and where the earth fault loop impedance was no greater than 0.38 ohms. Although the fuse had a nominal rating of 100 amps, customers would seldom consume a power level near the maximum permitted and would typically have a much lower load.

However, with the inclusion of low carbon technology where the load profile is moving from ‘cyclic’ to ‘sustained’ and where the peak power consumption has moved from the winter to any season. NGED has made the decision to reduce the fuse size installed within domestic style cutouts to ensure that the current flow is restricted to within the thermal capacity of the installed equipment.

How will this affect installations?

Although NGED is not going to offer connections incorporating a fuse of 100A within domestic style cutouts, a customer should see no difference with the short term capacity made available with a supply provided through an 80A fuse. This is because an 80A fuse is capable of permitting the flow of up to 100A for up to four hours.

The characteristics of an 80A fuse can be seen above.

Why has NGED made this change?

The change has been brought about due to concerns that a 100A fuse will permit a greater current flow than that of equipment ratings (DNO, suppliers equipment and consumers tails) and that the Distribution Network Operator fuse should not be used by the customer as the primary method of miting the demand within an installation. The primary function of the fuse is to disconnect the premises in the event of a fault occurring between the DNO and customers apparatus.

What if a customer / installer requests a 100A fuse?

NGED will provide a connection incorporating an 80A fuse because there is sufficient diversity within the installation to not operate the fuse for a loading condition.

When will this change come into force and will NGED honour existing schemes?

The change to policy will be implemented on 1st June 2023. Where a connection has been designed prior to this date, the connection may incorporate 100A fuse/s where the connection complies with the relevant design requirements. Any connection utilising a domestic style cutout that is requoted after the above date will incorporate up to an 80A fuse.

What if a customer requests a capacity greater than 23kVA (100A)?

Where a customer requires a connection with a capacity greater than 23kVA, the connection will be provided via a three phase asset where the phases are fused at 60A. Split phase connections may incorporate 80A fuses.

Seth Treasure

Policy Engineer (System Design & Power Quality) Engineering Policy nationalgrid

nged.engineeringpolicy@nationalgrid.co.uk

Asset replacement

When work is taking place on domestic style cutouts (replacement or maintenance), where 100A fuses are found after the implementation date of this document, these fuses will be replaced with 80A fuses.

Concerns with grading of protection

NGED has determined that there is little risk of the policy change impacting on the grading between DNO and customer equipment. A fault within a domestic premises will primarily be disconnected by lower rated customer owned circuit breakers which are protecting individual circuits.

Upgrading to 80A

Where existing customers have a supply which is not sufficiently capable of providing 80A / 18.4kVA and where the request for an increased demand is due to the inclusion of low carbon technology, NGED will upgrade the fuse or service conductors at no cost to the customer. Existing cutouts may have the fuse increased to 80A where the supplying cable and earth fault loop impedance are deemed to be suitable (i.e. < 0.52 ohms). This may exclude multiple occupancy buildings.

Definitions

Cyclic – Where the maximum demand of a connection is only seen for short periods of time within a 24 hour period and where there is sufficient time between peak demands for equipment to return to the ambient temperature.

Sustained – Where the demand of a connection is more prolonged and where there is insufficient time between peak demands to ensure that equipment returns to the ambient temperature.

Seth Treasure

Policy Engineer (System Design & Power Quality) Engineering Policy nationalgrid

nged.engineeringpolicy@nationalgrid.co.uk

#5 hoggy

The 18.5kW gateway limiter only works on the grid import values I believe.
So (& I admit this is not a very common scenario unless your on Agile) but you need to consider the PV load too. You can still trip the gateway if say your house load from the grid is 15kW and your PV is pushing another 5kW into the gateway.
Ideally you want the gateway to monitor ALL flows in itself as a whole & back off the AIO but I don't believe that is a thing yet?
On a sunny day, an AIO charging, EV charger and an immersion running only leaves you 1 kettle boil away from breaching the gateway limit.

The new AIO2 gateway does seem to have a bit more capacity than these ones.

M
#6 Mouton

hoggy Interesting. So even though net import reduced by PV, still counts towards the 18.5kW in the gateway if wired conventionally? I have a non-standard setup where AIO, EV, and (future) solar are all AC coupled remotely in detached garage due to long distances and requiring less cable bulk (have to have cleverness to stop EV continuing to charge in power cut - contactor fed from grid side of GW), so for me (unusually) GW will only have net grid flow through it (ie generation net of consumption).

#7 hoggy

Unless the spec has recently changed (which they have a habit of doing un announced) then yes it would still count as it's all linked to the same busbar inside the gateway - even though it's not passing through the grid CT being monitored.
I don't have an AIO but I do have a gateway (for some research) and there's various different specs internally that I believe brings us to this limit, despite the grid input being 100A, the grid relays (on mine) are stamped at 90A & MCB for the load going out to the home is 80A / 18.4kW @230V. I guess the software overload is a mix of trying to keep under the relay rating whilst also maintaining the busbars/internal link wiring/PCB tracks at a reasonable temp & not throwing the 80A MCB to home so you have to physically go and reset it.

To be fair this isn't just a Giv Gateway quirk, you can quite easily do similar to a normal distribution board by wiring a large PV system into it & if say you have a 100A cutout fuse easily exceed the rating of the whole board if you try hard enough.

D
#8 duplada

I have 3.84kw of PV, 2 x AIO + Gateway (V11 Firmware and EV charger). Since the EV charger software is not compatible with dual AIO Grid charging (at the moment according to GE) and charges only from the from AIO batteries. Not knowing these facts I ended up charging the AIO batteries at the same time as charging the EV to keep the EV charge coming to a halt and flattening the AIO batteries. This resulted with the house load of the Gateway being overloaded and going into an error state and the whole house power going off. It took with the help of GE support a good hour to get the system back up and running with everything from the main 100amp fuse forward having to be restarted.

Now have the V13 Gateway firmware, with 83amp max current being set by GE support. Since I cannot find a way of limiting the 12kw Inverter charge power to say 7Kw (my portal Inverter power settings don't seem to work) to keep the AIO batteries charged whilst charging my EV, I am thinking of getting my installer out to wire the EV charger so its not included in the GE environment.

I don't really want to do this but GE don't seem in any rush to support Dual AIO EV charging from the Grid and haven't any date for new EV firmware. I would like to hear from any of you who have already solved this dual AIO EV charging problem.

#9 PianSom

duplada
Similar-ish setup here (though 5kW PV, zappi charger). I use Predbat to manage my AIOs and EV charging. I never charge my EV from the batteries.

I am on IOG and use both Octopus-led (for the bonus slots) and Predbat-led (for complete control) EV charging, depending on what I want. Eg at this time of year the bonus slots don't add much value.

Predbat has a not-insignificant learning curve, and I would not regard it as set and forget.

D
#10 duplada

Yes understtod i am getting on in years so any significant learning curve will be a disadvantage. I have found so far understanding the portal commands more than challenging enougth and the fact that GE don't seem to document anything throughly. In fact if anyone has a commands guide with explanations it would be much appreciated.

#11 Jase1703

hoggy this is exactly the situation I had, on Agile pushing the negative rates at midday with the PV export exceeded 18.8kw and the gateway cut me off reset a few minutes later after the ASHP had quit and then faulted due to power outage from the gateway. Should I stop being so greedy or make some other changes? I am with PredBat, and the latest GE firmware for both AiO and gateway!

#12 hoggy

Jase1703 the gateway limit is the gateway limit, so other than just staying under 18kW or moving some of the large loads out of the gateway (such as an EV charger) there's not a lot else that you can do.

#13 TheDragon (GivEnergy)

Jase1703 the latest GW FW can have a hard limit applied, to try and kerb import, if any of it is caused by the AIOs, they can be told to back down.
If the GW does trip, the setting to reset it is now visible in portal, under remote control.
This used to be installers and above only, but weve downgraded it and added a warning message