The short version
Key points
- SAJ checks incoming battery cells, circuit boards, sensors and power electronics before they enter production.
- The battery systems use lithium iron phosphate cells, with cell testing, grouping, temperature monitoring and safety features.
- Completed inverters undergo functional testing, heat-based ageing tests and air testing for the claimed IP66 rating.
- The HS5 combines the inverter, battery modules, backup hardware and energy management in one system.
- The HS5 was still going through the Australian CEC approval process when the video was recorded.
From components to finished equipment
The factory process starts before a battery or inverter reaches the assembly line. Incoming components, including battery cells, circuit boards, sensors and power electronics, are checked against SAJ’s specifications. Some parts are stored in temperature-controlled areas before production begins.
The electronic side of the system uses automated machines to place and solder small components onto circuit boards. The boards are then inspected, including through automated optical and electronic testing at different stations. A protective coating is applied to different board types to help prolong component life. These boards control inverter communications and the battery management system, which monitors factors such as cell voltage and temperature.
Building the battery modules
The battery cells shown in the factory are lithium iron phosphate, commonly known as LFP. Before cells are assembled into modules, their voltage, capacity and internal resistance can be checked, allowing similar cells to be grouped together. This is important because the cells need to operate together as a battery, while the battery management system can limit operation if a weaker cell behaves differently.
Cells are positioned, secured and connected using bus bars, with laser welding used for some connections. The modules also include insulation, temperature sensors and thermal barriers. SAJ says its HS5 design includes temperature monitoring, pressure relief and integrated fire protection. The video also states that SAJ reported no recalls in the previous 20 years, although this is presented as the company’s claim.
Testing heat, water and inverter functions
Completed hybrid inverters go through a functional test that takes about 15 minutes. Finished components are also placed in an ageing test room for six to eight hours, where the temperature is raised to identify faults before the equipment is shipped. The video says the setting shown was a medium temperature rather than the highest used by the factory.
Batteries and inverters are tested for potential leaks using an air test. SAJ claims this process supports an IP66 rating for the relevant equipment. The tour presents these tests as part of the checks intended to reduce the risk of faults after installation, including in hot Australian conditions.
The HS5 home energy system
The HS5 is being prepared for the Australian market and was going through the CEC approval process at the time of the video. It combines the inverter, battery modules, backup hardware and energy management into one stack. SAJ is preparing single-phase and three-phase versions with 7 kWh and 9 kWh battery modules, with configurations extending up to 54 kWh, according to the video.
The system includes integrated automatic transfer functionality and a 63 amp bypass. This is intended to support whole-home backup without requiring another large gateway on the wall, although the exact installation outcome will depend on the home and the installer’s design.
SAJ also showed a wireless pro meter that sends small amounts of energy data using LoRa communication rather than a long cable between the switchboard and inverter. SAJ claims communication through at least five walls and up to 1,000 metres in suitable conditions. The video notes that performance in a particular Australian home still needs to be assessed.
Energy management and production logistics
SAJ’s energy management platform can coordinate solar generation, battery storage, EV charging, smart plugs and loads such as water heating or heat pumps. It can use solar forecasts, household consumption and electricity tariffs to help determine when to charge, discharge or retain energy for backup. The platform also supports virtual power plants in Australia, according to the video.
After testing, automated warehousing and traceability help move the correct components to each production line and keep finished products linked to packing and shipping records. This less visible part of the process is important when a factory is producing equipment at scale.
TechManPat’s conclusion
I think the factory tour shows that a home battery is much more than the white box mounted on a wall. The integrated backup hardware, wireless meter and separately managed battery modules are the parts of the HS5 that stand out to me. However, I see the next important step as testing the system in a real Australian home, because a factory tour can show how a product is built, while everyday use will show whether that engineering delivers a good result.
This knowledge-centre summary is based on the linked TechManPat video and reflects the information available when it was published. Check current pricing, availability and policies before acting.
