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We build the hardware and install the system
Manufacturing
AmpereArc is a manufacturer, not a reseller with a van. The battery packs, hybrid inverters, panel boards and metering that go into our installations are assembled, configured and tested by us, then fitted by us. This page describes what that actually involves, in the order it happens.
Every figure here is the published datasheet value for a named unit. None of it is a plant statistic.
Almost nobody does — cell production belongs to a handful of very large factories, and any company implying otherwise is describing someone else’s production line.
What we do is choose the cells, match them, build the pack around them, configure the management, test the finished result against its rating, put our name and a serial number on it, and then install it. That is the stretch of the chain we control. We would rather be exact about where it starts and where it ends than wave at “vertical integration” and hope nobody asks.
What we build
Four of them have a datasheet. The fifth is drawn for your job, which is why it is described differently further down the page.
Low-voltage residential packs that wall-mount or stand alone, and a high-voltage industrial cabinet for sites measured in hundreds of kilowatt-hours. Same chemistry, same management discipline, different scale.
Newest line
A sealed outdoor pack and its power electronics on a galvanised strut frame that clamps to an existing pole. No ground footprint, no cabinet, no land lease — storage for sites where floor space does not exist.
Single-phase and three-phase hybrids with dual MPPT tracking and battery management built in, configured to talk to the packs they are shipped alongside rather than to a protocol we hope matches.
LV distribution boards, changeover and ATS panels, PV combiner and protection assemblies, control panels. Built to your schedule, not picked from a catalogue — which is why this line has a drawing rather than a datasheet.
AC chargers from a single-phase home unit to a three-phase commercial station, bi-directional metering, and the data loggers that make an installed system legible after we leave site.
Before it ships
Eight stages between a crate of graded cells and a serialised unit on a pallet. Nothing here is optional and nothing is skipped for a rush order.
Cells arrive graded from the cell maker. Before anything is built, capacity and internal resistance are compared across the batch and cells that behave alike are grouped into one pack. A pack performs like its weakest cell, so cells outside the group are held back rather than made up into a unit.
Cells are clamped into the module frame with insulation between terminals, busbars are torqued and witness-marked, and the voltage and temperature sensing harness is landed on every cell group. The witness marks are the point — an inspector can see at a glance whether a joint has moved.
The management board is loaded with the configuration for that model: cell count and arrangement, voltage and temperature limits, charge and discharge ceilings, and the communication protocol for the inverter it will meet on site. Residential packs are 16S1P at 51.2 V nominal and speak CAN and RS485.
Each pack is charged and discharged under load, and measured capacity is compared against the rated figure published on its datasheet. The protections are then deliberately tripped — over-voltage, under-voltage, over-current, over-temperature — to confirm the BMS opens the contactor when it should. A pack that will not reproduce its rating does not get a serial number.
The pack goes into its enclosure, glands and seals are fitted and lid gaskets are set. Outdoor units — the industrial cabinet and the pole-mount pack — are built to an IP55 enclosure specification in powder-coated galvanised steel. Indoor packs are built for a dry ventilated location and are labelled as such rather than left ambiguous.
Ratings plate, terminal markings, warning set and cable labelling are checked against the model. The finished unit is weighed and measured against its published dimensions, and the test record is checked for completeness before anything is closed up.
The unit is issued a serial number and entered into our registry. The number is not a sticker — it is a record with a status, an owner, an installer and a history, and it is what every later conversation about that unit refers to.
The unit ships with its datasheet and its test record, and its serial is marked available for commissioning. When an installer commissions it, the registry records who fitted it, who owns it, and the date it was first activated.
Serialisation
Serial numbers are minted by our own registry rather than written on a label at the end of the bench. The number encodes the line, the model, the build period and the batch, and the sequence runs per batch — so a unit tells you which cohort it came from before anyone opens a file.
From dispatch onwards the record carries the unit’s status. When an installer commissions it, the registry stores who fitted it, who owns it and the date it first came alive. If it is ever swapped under warranty, the replacement is linked to the unit it replaced instead of starting a fresh, historyless entry.
Customers and installers see their own units in the portal. It is the same registry we work from, not a summary of it.
Serial composition
Scheme covers the battery, inverter, EV charger, data logger and metering lines.
What the registry holds
In the box and on file
A pack without its paperwork is a pack nobody can service in five years. These travel with it.
Datasheets are published at a stable URL, so a link handed over on the day of install still resolves after the PDF is revised.
Built to order
A panel board is drawn for one building. There is no model number to look up, so we describe the assemblies we build and what you are handed at the end instead of inventing a catalogue.
Main and sub-distribution assemblies built to your circuit schedule, with the outgoing ways, protective devices and labelling agreed before fabrication starts.
Manual changeover and automatic transfer assemblies for generator or storage backup, wired and tested as a unit rather than assembled in a plant room.
String combiners with array isolation, surge protection and monitoring provision, sized against the array as designed rather than a nearest-standard box.
Bespoke control and metering assemblies for plant, pumps and building services, built from the schematic we hand back to you at the end.
What you receive
Rating bands and enclosure options are quoted against your schedule rather than published as a range.
Send us a single-line diagram, a load schedule, or a photograph of the board that is failing you. We will tell you what we would build and what it would take.
Storage for a house, a cabinet for a factory, a board drawn for one plant room. Tell us the load and the constraint and we will quote against what is actually there.