A couple of months ago we realized the batteries which provide our electrical power needed to be replaced. And like all things involved with this house, that meant we had to accomplish three others things first, before we could get to the batteries.
What happened… First, last year the propane generator died, and we switched to our old 27 year old Honda gasoline generator, which wasn’t strong enough to run the well pump. We decided to use a transformer and convert 110 volts to 220 volts to run the well pump, and only would pump water on really bright and sunny days. The method we used for pumping water resulted in the batteries we were using being drawn down too low on voltage, and overheating at the same time. This was not a good thing to do, and they no longer hold a charge like they are supposed to. Too many amps were being drawn from the batteries at one time, for too long a period of time, and they couldn’t handle the strain. Live and learn. It was one of those “it seemed like a good idea at the time” sort of things.
So, first we had to replace the generator since we needed a strong enough generator to pump water. That was accomplished.
Then we ordered new batteries, and we decided to use a different type of battery, one that would allow us to draw them down a bit deeper, and also to give us a slight increase in storage capacity. And then we had to get them into the house and into the basement. Each battery weighs in at a hefty 120 pounds. With the help of friends, that was accomplished.
Then we had to build a new battery box as these new batteries are ‘flooded’ batteries, which means we have to be able to inspect each one and refill them with distilled water on a regular basis. They could no longer be behind a wall.
The bottom and two end pieces of the battery box being dry-fit before we got too far along.
So, carpentry was the first order of the day. Much sawing of lumber and plywood ensued. The old batteries were sealed batteries, and each was 12 volts, so they needed to be in pairs to make 24 volts, and then they were linked together in four pairs to provide our storage. The wiring part got a bit complicated.
The new flooded batteries sitting in a few rows, waiting to be installed in their new box.
More carpentry, and construction of the box was completed. Everything fit into the space in front of the old battery bank and beneath the inverter, controller, circuit breaker box, all that good stuff hanging on the wall.
The battery box needed to have a completely removable front, in order to be able to slide the batteries out someday and slide new ones in. It's not intended to be used as a seat or table, so the plywood itself is providing a lot of the structural strength for the box.
Now that battery box was ready, we removed it and the scary part of the process started – disconnecting the old batteries. The most critical part of that process was to make sure that none of the metal tools being used would touch the metal racks the batteries sat on, nor touched any of the other battery parts when disconnecting one end of one of the battery interconnect cables from either the positive or negative battery terminals.
Dan used a small sock to insulate the wrench, and it did exactly what he needed it to do. In fairly short order, the batteries were all disconnected from each other.
Next step was to move the battery box back into position and start moving the new batteries into their new home. We had to keep in mind the positioning for positive and negative terminals on each battery in order to make it easy to hook them up again. Each of these batteries is 2 volt, instead of 12 volt. With twelve of them wired in a series instead of in paralell, the wiring was much simpler.
All moved into the box, and the fluid level in each battery was checked. Ready to proceed!
Moving the new batteries around was hard work, but not scary.
The heavy battery cables are hard to bend, and getting them hooked up was hard work. Again, we had to be very careful not to touch anything metal to anything else.
A bit more wiring was necessary, once the batteries were hooked together, to feed the power into the circuit breaker panel, and connect a couple of sensors for heat, and also to get a fan ready to go into a pipe to vent the batteries to the outside of the house. Flooded batteries generate an explosive gas (if it is really concentrated), and just generally speaking it’s not something we want to be breathing.
The front piece of plywood was put into place, and then the top was laid into place.
The plywood which had concealed the old batteries contributed to the top of the battery box, and the remainder has been slid into its former location, but needs to be permanently attached. We still need to drill a hole in the exterior wall of the house for the vent pipe, and then I want to do something to make it all look finished and nicer. But since the whole basement room needs that to be done, there’s no particular hurry on that front. We also need to put a gasket underneath the lid on the box, and silicone around the holes in the back where the cables go that connect the batteries to the breaker box, And some other minor trim work.
We flipped the breakers, and we had power again! Woo hoo ensued.
Then Dan had to reconfigure the controller between the batteries and the solar panels, the inverter since the amp hours for storage was different, and a meter which helps us to keep track of where the batteries are in terms of charging and capacity.
So, we are back in business.
A pair of Golden Eagles has been hanging around lately, soaring and claiming their territory. One morning before it was very light, one of the pair was sitting on the large Ponderosa Pine tree down the hill from our house.
Poor Opal was not at all pleased that this particular bird was sitting on that particular tree on that particular morning.
I dare say it is “shocking” to see just how much work my older brother is capable of performing! I thought he preferred the computer! Haha!!