My new system is up and running.......thanks everyone!

porch13

After much planning, re-planning, sore backs, and busted knuckles, our new off-grid solar setup is finally up and running.  We did everything ourselves and I learned a ton in the process.  Thank you to everyone for patiently answering question after question and a special thanks to the good folks at NAWS for guidance in product selection, etc.  They really have a great group of people over there.  Here are a few photos of the finished work:

Array:


Batteries:


Equipment:  (this is all in a room under the cabin that stays nice and cool year-round.  I installed a Trimetric in the cabin so I don't have to run downstairs to monitor things)  


Have a great day everyone!

mcgivor

Very nice instalation, don't become too complacent and forget the batteries, you'll have to go down there once in a while with flooded to check the SG, hope everything works out, nice of you to share and not be a stranger, good luck.

porch13

Thanks, @mcgivor!  I'm actually somewhat obsessive about maintenance and have already started my log of SG's.  I'm looking forward to continually tweaking things to keep those batteries fat & happy!

BB.

Very clean install!

Thank you for letting us see your final system.

-Bill

mcgivor

Yes it's a marrige, you'll probably spend more time with the system, at least I seem too, my wife undestands, she always asks first if she wants to use something with a large consumption, well trained I guess

Surfpath

Howdy Porch13,
Nice, clean job.  My solar room used to look like that.  Now it looks like a regular semi-messy project-tool room.

I also have a FP1 (48v).  It looks like you ended up with just the one string of Rolls (468 amp hrs) - cool.  I don't know if that particular battery was available when I got my bank (Trojan RE-B's 370 amp hrs), but if I were aware I would have considered it.

I am 4.3 years into my batteries and currently cycle down to 55% SOC at dawn (my fridge is getting old and inefficient - I'm looking to replace it this summer in order to keep the bank a little longer).

Out of curiosity what's your panel set up?  I have 30v grid connected panels (220w) at 3 panels a series, total of 12 panels (4 series). It looks like you could have that plus one more series? 

Again, well done!

porch13

Thanks @Surfpath!  I do just have one string of the 605's.  I'm only cycling them down to about to about 85% SOC every day so I hope I can keep them healthy for a long, long time.  As for my array, I have five strings of three Kyocera KU-270's, so my array produces around 100V / 40A.  I get great sun in Northern Arizona so I'm typically floating well before noon.  Now I just need to figure out how to use all of that extra power I'm generating when the bank is floating!

westbranch

Did you use any 'electrical  grease' on the terminals to inhibit corrosion? You can get it at most automotive stores, or you can use Vaseline if needed.

jonr

Is there any cooling advantage to a gap between/under the batteries?

Maybe monitor summer humidity to avoid corrosion in the electronics.  Vapor barrier paint on the walls and floor should help with this.

mike95490

jonr said:

Is there any cooling advantage to a gap between/under the batteries?

For sure, yes.

porch13

I'm really lucky in that my battery room stays cool year-round.  @westbranch I didn't put any protection on the terminals.  I was under the impression that, with proper ventilation, it's not strictly necessary.  With the Zephyr fan on the box, I'm hoping I won't get any corrosion.  I also added Water Miser caps to the batteries.  Not sure how much water I'll save, but I sure like the flip top cap....makes it easy to check the SGs and water levels.
 

Surfpath

Out of my bank of 8 batteries (4+ years now) I only see corrosion on one of the (16) terminals.  it's on the last battery in the bank. 

Basically, it looks a little green in between and a bit around around the 'joint' between the battery cable and the terminal.  In a few weeks I plan to a toothbrush and scrape it off.  Maybe use some vaseline, as mentioned above, to stop further greenery?  

Surfpath

porch13 said:

As for my array, I have five strings of three Kyocera KU-270's, so my array produces around 100V / 40A.  I get great sun in Northern Arizona so I'm typically floating well before noon. 

Just out of curiosity Porch, what is the AWG of the wire that goes from your combiner box to your charge controller (ie. to handle those 40 amps)? 

porch13

Hi @Surfpath.....The wiring from the combiner to the CC is 2 AWG welding wire.

Lumisol

Those components seem a bit crowded, they might be happier with a little more breathing room between them.
Be careful around that array with those loose wires on the ground.
I'd also put an inch or two between those batteries for better air flow there. They are butted right up to one another in the picture.

Lumisol

porch13 said:

I'm really lucky in that my battery room stays cool year-round.  @westbranch I didn't put any protection on the terminals.  I was under the impression that, with proper ventilation, it's not strictly necessary.  With the Zephyr fan on the box, I'm hoping I won't get any corrosion.  I also added Water Miser caps to the batteries.  Not sure how much water I'll save, but I sure like the flip top cap....makes it easy to check the SGs and water levels.
 

I'd put a coat of dielectric grease or molylube on the connections anyways, it can't hurt and will help.
Don't forget to re-torque to 75% of original torque after a year.

Lumisol

porch13 said:

Hi @Surfpath.....The wiring from the combiner to the CC is 2 AWG welding wire.

Is that a 20 meter run of cable?

porch13

Roughly 22 meters.