Adding more LiFePo4 Batteries to Eximius
The two new batteries have been sitting in the boat for a couple of months, they are jambed into the locker but not really secured.
I did have a couple of hours this morning between other jobs, so I started on the project. Step 1: Replace the existing On/Off Battery Switch with a new Off/1/Both/2 switch.
The new switch requires a 2 5/8" Diameter hole and the old switch only required 2 1/2". So I removed the old switch, screwed a piece of plastic on the inside of the bulkhead and marked the center of that, then drilled using a 2 5/8" hole saw. Nailed ! ( Sorry, not a good pun.) The new hole was in the perfect position.
Next I connected the wire from the Battery Bank Terminal block to the #2 position of the new switch and the connected the output wire. Turned off the Solar breaker, reconnected the +ve wire to the new switch and turned it all back on. Worked great, Checked all connections were tight, closed it up. All done.
Ok, next part of this project: Secure the new Batteries
Simple, just make a webbing hold down strap and secure it in place using a couple of footman loops.
The Batteries are 9" high and the two are 15" wide.
So the straps need to be 3" + 7" + 5" and 3" + 16+ a loop in length.
ie. One Strap will be 15" including a 3" loop
the other will be 22" including a 3" loop on one end and a 2" loop on the other.
I'll make the strap at home, then go to the boat, attach the straps to the loops and drill and screw the stainless steel footman loops in place. Easy job.
The webbing restraints are stainless steel and really grip well.
Got them installed. It was awfully hot today. it only took about 20 minutes to secure the batteries with the strap but by then I was really feeling the heat. I should have learned from our trip up to Jensen Beach a few weeks ago.
With the Batteries now secure, next step is to mount the Fused Terminal Blocks.
We'll work on the wiring upgrade in steps.
I'll be mounting the Positive Terminal Block with Fuses on the inside of the new battery box and connecting wires that are the same length as the original 3 battery wires. The intent is to make sure that the voltage drop is the same for both sets of batteries to ensure even charging and discharging from both battery banks.
We have to mount the two Terminal blocks but not connect them to the master battery switch. That will allow working in the cabin in the summer heat with the AC running.
Next, with the Terminal blocks in place, I'll make up the wires and connect the Batteries to the +ve & -ve terminal Blocks.
At that point, the Additional batteries can be connected to the master battery switch. The existing system is designed for a max current of 300Amps, but with the two additional batteries, it's capable of 500 amps ( Each battery wire is protected by a 100Amp fuse. ).
This means that I should upgrade the cables from the Master battery switch to the DC connection of the Victron Multiplus to 4/0 cables. I'm not sure that we'll be able to get the 4/0 cables through the 38 year old conduits from beneath the Nav Table, Under the cabin soul and up to the Battery Boxes. That means we'll have to consider replacing the conduits with larger diameter.
Monday June 23rd. I worked on a canvas project this morning as well as picked up our Mercury Outboard, not working but I have a plan.
This afternoon we went down to the boat and put the sunshades up in an effort to cool the boat for the time we need to work in the cabin.
We, yes, Peggy was a big help, installed the positive and negative terminal blocks and covers.
This pic shows the setup for the original batteries, I used the same type of terminal blocks for the new batteries. Also, just ordered another 4 post 600 amp terminal block for the combined negative connections.
We ran the AC for 3 hours and dropped the batteries to 61% - it ran consistently the entire time. Hopefully the next time we go to work on the boat it will be initially cooler due to the sun shades and we can make better progress. Anyway, the next job is to make the cables for the two new batteries connection to the terminal blocks. The Positive terminals have 100Amp fuses on each post.
Ok, back at the boat, we cut the new 1/0 AWG Red & Yellow cables for the new batteries, but only had 1 pair of 1/0 5/16" ring terminals, all of the others were 1AWG Grrrrr. Ordered new terminals from Amazon while still on the boat.
The AC was running while we did all of the 1/0 cable prep and the Installation of the new 600Amp -ve Power post terminal block -- this will join the two sets of -ve terminal blocks to the -ve connection to the 500Amp Victron Shunt. Remember, the cables from this post will be 4/0 AWG and will easily handle the 500amps available. We're nowhere near that when running the Air Conditioning but it's nice to know that we will not be likely to over clock the wires.
Next time at the boat we'll connect the rest of the cables from the two batteries and the -ve terminal block to the -ve post.
Making progress until a setback today :(
On our last trip, we left the boat with the two new batteries connected in parallel to the fused terminal block (9/+ve ) and the negative terminal block.
Today I made up the cables that connect the +ve terminal block to the #2 connection on the Blue Sea 6007m 4 way selector switch and the able from the -ve terminal block to the single -ve terminal post. Used a 1 1/8" hole saw to cut holes between the old battery bay and the new battery bay. Good progress.
When it came to connect the -ve cable to the single -ve terminal post, I realized that the post would not hold 3 of the 3/8" 4/0Awg ring terminals. Grrrr.
Solution is to replace the post terminal with a 4 post terminal. Already have one in the workshop. Solved.
Ordered a replacement, should arrive Saturday. Looked up the Torque settings: Gemini gave me this result: For the Blue Sea 6007m 4-way switch, the terminal stud torque setting is 120 in-lb (13.56 Nm).
This applies to the 3/8" (M10) tinned copper studs on the switch.
Luckily, I have a Torque Wrench 2 - 26Nm.
Soooo, next trip to the boat I'll be armed with the wrench, the new 4 post terminal block and the new BlueSea Switch.
This means I should be able to actually complete the setup of the new batteries excepting the replacement of the 1/0 AWG wires from the battery bank to the Shunt and the Fuses before the Victron System. That's quite a task and I'll post separately on that part. It does involve in removing the old 1/0 wiring and conduits, reworking the fuse setup and installing the new 4/0Awg wires. They go from under the cabin soul on the stbd side below the Galley sink, beneath the flooring, up into the Port side locker ( home of the holding tank ), up the port side storage cabinets then aft to the Fuses and Victron. Not looking forward to that one.
See you on the water, but not for the next few days - we'll miss going out on the 4th. That will be the first time in many years.
