Wiring Suggestions Please

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Jan 13, 2012
48
Catalina 30 Steppingstone, NY
Hi,

This is the current battery configuration I inherited when recently purchasing a Catalina 30 (1980 Tall Rig:)

What I would like to do is add a dedicated third STARTING battery, use two batteries for HOUSE and install a solar panel charger as well.

I have identified a nearby location for the 3rd battery and have one on hand. Solar Panels have arrived as well.

My question is how would you amend the current configuration to allow for the additional battery and solar panel. Would you remove the auto charging switch altogether? Wire the solar panel directly to the starting battery?

The alternator puts out 13.5 volts at idle and the battery cables will be replaced when I rewire (possibly switches as well but probably not).

Thanks,
Alex K.
 

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Jun 6, 2006
6,990
currently boatless wishing Harrington Harbor North, MD
Probably easier to think of it as adding an additional house battery than trying to add a starting battery and moving the current start bat to house duty. FWIW.
How big is the solar panel? And how much storage (Amp hours) do you have total?
I will not comment on "auto chargers" as I'm not a died in the wool believer. I took the blue pill not the red one!
A solar panel of much size will need a charge controller so you don't cook the bats.

Standard three bat hook up is:
both house batts in parallel (+ to + and - to -) together with the + to the A term of one 3-way (only 1 three way in this set up BTW) and the start bat + to the B term of the same 3-way. the start - is connected to both the house - and the engine ground.
The Common term of the 3 way then powers everything (panel, starter, alternator, but not the bilge pump and stereo memory wire as those need to be "hot wired" to the house bank).
So you switch to (this example) B and start the motor then switch to both as you motor out of the harbor topping off all the bats as you go. Once you get the sails up and stop the motor switch to A to isolate the start bat and keep it charged and run off the house bats. Not really a big deal on a day sail and I can make an argument that "both" all the time is better but I'm an old Army guy and risk and I are old friends.
In this set up you really don't need an auto charger as you are flipping switches anyway so why not just manage the charging with the switches also. One less thing to go bad over the week and ruin a weekend IMHO.
You would then hook the solar panel + to the charge controller and hook it's + output to the common term of the 3-way and the negative to the common - all the bats are on. To charge both house and start turn the switch to both. to charge the house only (this example) turn the switch to A, to charge the start only turn to B. Course you can't charge the start and run on the house in this setup and some find that unsat. Which is why I ALWAYS wire all the bats I can lay my hands on into one big bank and just don't drain them to the point that i can't get the motor started. Course if you have a solar panel this is sort of a moot point as you are able to get the bats charged eventually and get the motor started.........you probably need to be on sail time to make that work though.
 
Jun 6, 2006
6,990
currently boatless wishing Harrington Harbor North, MD
With all that said I would make the following observations:
Battery life is directly related to how deeply they get discharged to and how many times they are discharged. Batteries that are discharged deeply a lot don't last long, batteries that are not discharged much last longer.

Assuming the number of AH you consume is a constant the amount of storage is directly related to the amount of discharge the battery bank sees. A larger bank will be discharged less than a small bank.

Solar charging can be considered as additional battery storage capacity as it "takes up the load" during the daytime. so if you only run the reefer during the day and use it's holding plate to "coast" through the night the batteries do not see as much load in total as you are consuming it as you are making it. That is to say you are not taking the juice out of the batteries but taking out of your solar batteries (panels)

Battery state of charge (for lead acid batteries) is directly measurable with a volt and amp meter. Quite a few folks on this site don't seem to believe this but I suspect they don't have calibrated eyes to tell 12.1 from 12.05 volts on an analog meter. if you take an interest in monitoring the battery voltage you will notice that when something is turned on and you draw power from them the voltage drops. When you turn off things the voltage rises. You do not have to wait for 12 hours with no load to tell how charged the batteries are.
http://www.scubaengineer.com/documents/lead_acid_battery_charging_graphs.pdf
you do need to know the load on them so an ammeter is also needed (also with a calibrated eye)

Soooooo
get the largest battery bank you can, wire it for house and start, throw away all the fancy auto chargers and leave the 3-way on both in all situations except when you see the whole bank voltage/amps getting low and you are not expecting to start the motor or get some solar charge soon. In that case shift to house only and preserve what you have in the start battery. Then shift back to both when the sun comes up or shift to start and get the motor running then shift to both to charge all the bats up.

My experience (5000 AH storage and 50 watts of solar, reefer, freezer, anchor and cabin lights, Auto pilot, nav instruments, pressure water and occasional night sailing) is that when running under sail we draw about 5-7 amps continiously and I can watch the voltage all day and not see much drop till the sun goes down and the solar batts turn off. I can then watch the voltage till bed time and if it it is below 12.2 and 2 amps (after all the lights are off the reefer is coasting and anchor light is on) we will be able to get through the night with the 3-way set to Both. If it gets below that I isolate the start bat and go to bed. In the morning I always forget to "switch to start" and the motor starts fine on the (now discharged) house bank. When on an extended cruise we can watch the 'bed time voltage" drop a few tenths of a volt each night and when it get to 12 volts we know it is time for some engine charging. Course we usually have to motor some time in there so that situation does not come up much.
 
Feb 26, 2004
23,047
Catalina 34 224 Maple Bay, BC, Canada
Bill's suggestion to forgo an automatic relay is covered in the text in the links provided.

Battery monitors are highly recommended, not because folks can't tell the difference between 12.05 and 12.1 volts, but because of battery acceptance, where the amount of power that is put back into the bank is NOT linear as is the discharge. Most folks cannot tell how much goes BACK IN, which is where the monitors really shine.

Battery Acceptance by Stu http://c34.org/bbs/index.php/topic,4787.0.html

Battery Acceptance (a very good Maine Sail presentation and further discussions) http://forums.catalina.sailboatowners.com/showthread.php?t=114054

Battery Acceptance Observations by Maine Sail
http://forums.catalina.sailboatowners.com/showthread.php?p=674108&highlight=battery acceptance
 
Jun 6, 2006
6,990
currently boatless wishing Harrington Harbor North, MD
I'd agree with Stu. Your calibration on your eyeball has two settings, discharge and charge. Course that is also covered in the article on battery SOC in my first post.
Really guys there is nothing wrong with using all the gadgets but there are less expensive ways to accomplish the task. And what do you do when all the fancy electronical stuff don't work? And more importantly, how do you monitor the monitor to tell if it is working correctly or not. I suspect that it is a "she will not crank" type of diagnosis and that is totally unsat in my mind. Having a working knowledge of charging and discharging voltages (even just a passing familiarity with it) is not a bad idea.
 
Jan 13, 2012
48
Catalina 30 Steppingstone, NY
Bill and Stu,

Thank you! I'll review your posts over the next couple of days and I'm sure come back with some follow up questions.

Also, Stu.. Thank you for your previous comments on flat travelers, I just purchased one from Guido at Garhauer and can't wait to sail with it this summer.
 
Jan 13, 2012
48
Catalina 30 Steppingstone, NY
Hi Bill (and Stu),

I sketched out Bill's suggestions and this is what I have come up with so far:

https://docs.google.com/drawings/d/1VRENYHbv6qBBLnnyforSkuSci7X3w7Uar0T5L6tdx54/pub?w=960&h=720

The goal here was for me to understand what I'll be wiring by drawing it out but two questions remain. One, does the alternator only charge the house batteries and two, does the solar panel (controller) only charge the start battery? Besides those two issues does the sketch seem accurate to what you were suggesting? Also, if I were to add voltage meters where would they go in the drawing?

Thank you,
Alex K.
Primetime
 
Feb 6, 1998
11,709
Canadian Sailcraft 36T Casco Bay, ME
Hi Bill (and Stu),

I sketched out Bill's suggestions and this is what I have come up with so far:

https://docs.google.com/drawings/d/1VRENYHbv6qBBLnnyforSkuSci7X3w7Uar0T5L6tdx54/pub?w=960&h=720

The goal here was for me to understand what I'll be wiring by drawing it out but two questions remain. One, does the alternator only charge the house batteries and two, does the solar panel (controller) only charge the start battery? Besides those two issues does the sketch seem accurate to what you were suggesting? Also, if I were to add voltage meters where would they go in the drawing?

Thank you,
Alex K.
Primetime
My suggestions would be:

#1 Use the house bank for everything including starting, keep it simple..

#2 Use the start bank as an emergency / reserve bank. Paralleling a dissimilar battery during discharge is not recommended. During charging it is fine but during discharge I would advise against it.

#3 Battery Monitoring - What works well for Bill generally works less well for the vast majority of boaters. A good battery monitor is $155.00, less than groceries/beer for one weekend. Each 0.1V is 10% of your banks capacity, how accurate is your volt meter? I have yet to see more than 1-2% of boaters who can keep accurate track of battery SOC via voltage alone and do so somewhat well. This is not to say it can't work, but those I know that can do it, accurately, are few and far between.

I have NEVER installed a single battery monitor for acustomer that did not RAVE endlessly about how great it was and how they should have done this long ago, how it is the best value for the money of any boat upgrade they've done, and how now after 30 years of boating finally understand "charging" etc. etc......

I have had customers text me at 2:00am just to say "Got up to check the anchor and glanced at the battery monitor. Everything was so good with the bank I decided to leave the fridge on and not have warm food in the morning, THANKS! Never would have done that without the monitor." The next morning I got another text saying that I just saved him $65.00 in steak, chicken and other foods that his wife would have thrown out had the fridge gone above 40F.

#4 Switching - If you reside on a dock and your batts start every weekend full then just use the house bank and ignore the starter battery until you need it in an emergency. If you only do a one week or two week cruise you can get by with no charging of the start battery as self discharge over two weeks is a non issue. Keep it simple leave it set to HOUSE. Needless switching back and forth leads to errors I call HEF, or human error factor. I am on my way out the door in a few minutes to install a Balmar Duo Charger for a customer who killed both banks last summer by forgetting to switch back to the HOUSE bank after charging BOTH banks.

#5 Charge Routing - Route all charge sources, solar, wind, alternator, battery charger etc. to the house bank. If the alt is still fed through the "C" post of the batt switch using the house bank accomplishes the same thing. DO NOT SWITCH THROUGH OFF with the engine running if the alt goes through the battery switch. I have to rebuild numerous alts every summer due to blown diodes from passing through OFF with the engine running. Have a Yanmar alt on my bench right now with blown diodes.

#6 Charge Management - An ACR, Echo Charger or Duo Charger are invaluable tools for many boaters. They fully automate the charging of the start/reserve bank without the need to ever touch the battery switch. Leave it on HOUSE and the charge management device takes care of the START battery. They never forget to isolate the banks and never forget to charge them. These devices are very, very reliable so reliable that one of them, the Yandina Combiners, carry an unconditional lifetime warranty.

HEF is real (perhaps not for Bill;)), I deal with it all the time and charge management devices, like the battery monitor, is one of those items my customers LOVE..... The cost of these items is small in comparison to changing a battery bank every two to three years or getting towed or burning up a starter due to low voltage/current.

On average I would say my customers who've done nothing but a battery monitor and charge management device get 2-3+ more years out of a bank than they did prior.

An ACR and Victron BMV-600 will run you about $255.00. My advice on this is not from an n=1 pool of data. It is from doing this for n=LOTS of real customers who use their boats in the real world and have had real issues with short battery life, blown diodes from constant switching, HEF etc. etc..

I even had the daughter of a customer come up to me on the dock and personally thank me because her daddy was no longer a "electricity scrooge"....

Keep in mind that starting an M-25 will use fractions of an Ah of capacity from the bank. This is why devices like the 15A Echo Charger never need more than 15A of current to keep a start battery "topped up". Most often a start battery will be taking less than 2A of charge current, after starting, and this usually drops to under an amp relatively quickly...

Many ways to skin the cat. I still suggest a battery monitor and then a charge management device if you are on a mooring or off cruising. It seems you already have a charge management device? As long as it is not a diode isolator, I would keep it.
 
Jan 13, 2012
48
Catalina 30 Steppingstone, NY
1- Thank you for the advice. I definitely think a battery monitor would be a great idea. Can you suggest a simple straight forward one which is digital and doesn't require a fancy installation.

2- What are the specific connections for the battery meter (so that it includes the start/backup battery and two house batteries)?

3- Very helpful suggestion regarding switching through "off" position, did not know that, if the alt goes through a charge router does it still matter?

4- Speaking of charge routers attached is an image of what is currently installed. Is this unit one which you like / would recommend continuing with?

5- If I stick with the current charge manager how would I integrate the solar contribution?

Thanks!
 

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Feb 6, 1998
11,709
Canadian Sailcraft 36T Casco Bay, ME
1- I definitely think a battery monitor would be a great idea. Can you suggest a simple straight forward one which is digital and doesn't require a fancy installation.
Victron BMV-600

2- What are the specific connections for the battery meter (so that it includes the start/backup battery and two house batteries)?
Unless your start battery has uses that I am not aware of there is little to no need to monitor a start battery.

This is how to install:
Installing A Battery Monitor

3- Very helpful suggestion regarding switching through "off" position, did not know that, if the alt goes through a charge router does it still matter?
If the alt is directly connected to the starter cable from the battery switch then it can still be fried even with a "combiner"... The only way to prevent this is to route the alt directly to the house bank and then it always sees a "load" no matter what position the battery switch is in...

For more on this subject:
Musings Regarding The 1/2/BOTH Switch


4- Speaking of charge routers attached is an image of what is currently installed. Is this unit one which you like / would recommend continuing with?
I have only seen one of those once. When I did it was just getting ripped out to convert to a different system and I never gave it much thought other than it looked antiquated and sort of cobbled together..:confused: I would call the company and try to get some specifics. You want a "voltage sensitive relay" that makes/combines and breaks/un-combines based on voltage not via a key or any other means..

5- If I stick with the current charge manager how would I integrate the solar contribution?

Thanks!
As I mentioned before all charge sources go direct to the house bank with proper fusing within 7" of the + battery post. If the solar gets the house bank to "combine voltage" then the combiner will combine....
 
Jun 6, 2006
6,990
currently boatless wishing Harrington Harbor North, MD
Hey primetime
Stu just about covered it. HFE is certainly something to consider when designing the system. I try to imagine my brother-in-law taking the boat for a weekend and the things he might do that would get him in trouble (and I'd have to fix later)
I like Stu's starter use concept. I'm an old Army guy so following the procedures is kinda ingrained into my brain. I know others have a more relaxed approach and anything you can do to simplify the process will normally produce good results down the road. That is why I use the voltmeter to track SOC. A battery monitor also works but I hear about folks getting frustrated when it does not "work exactly right" and they have to fuss with it. Voltmeter works for me. YMMV. I don't have a brother-in-law that borrows the boat either!!

The only thing I'd add is keep the number of connections to a minimum by combining things on a buss if possible.
 
Aug 16, 2009
1,000
Hunter 1986 H31 California Yacht Marina, Chula Vista, CA
"I have NEVER installed a single battery monitor for acustomer that did not RAVE endlessly about how great it was and how they should have done this long ago, how it is the best value for the money of any boat upgrade they've done"

Yet again displaying ignorance: (1) What exactly does a monitor measure? (2) When shopping for a monitor, do I have to find one that is compatible with my old Zantrex 2000 inverter/charger?
 
Feb 6, 1998
11,709
Canadian Sailcraft 36T Casco Bay, ME
Yet again displaying ignorance: (1) What exactly does a monitor measure?
Counted amp hours in/out of the bank
Peukert corrected % of charge
Voltage
Time Remaining at load
Current

And a number of other useful tools such as alarms, history etc. etc...

(2) When shopping for a monitor, do I have to find one that is compatible with my old Zantrex 2000 inverter/charger?
No... The monitor does not need to be "compatible" with anything else.. The Victron BMV-600 is currently the best value I know of. Xantrex also makes the Link Lite and Link-Pro but they are about double the money by the time you get it installed.
 
Dec 27, 2011
279
Oday 272 Pensacola
Bill Roosa - I need clarification of your statement - "In that case shift to house only and preserve what you have in the start battery. Then shift back to both when the sun comes up or shift to start and get the motor running then shift to both to charge all the bats up." - will this NOT destroy something electrical? I'm a novice to multi-battery installations, but have heard that switching battery selector switch while altrnator is running will destroy some rectifier/diode or something...

Charles
 
Feb 26, 2004
23,047
Catalina 34 224 Maple Bay, BC, Canada
Charles, if you read the links provided earlier by Maine Sail and me (wiring diagrams and the 1-2-B switch ones) you see that the "trick" with the wiring is to remove the alternator output from the 1-2-B switch and move it to the house bank. Then, you could turn the switch off and no damage would occur. Please, read those first (or again) and then ask again if you have more questions.
 
Feb 6, 1998
11,709
Canadian Sailcraft 36T Casco Bay, ME
Bill Roosa - I need clarification of your statement - "In that case shift to house only and preserve what you have in the start battery. Then shift back to both when the sun comes up or shift to start and get the motor running then shift to both to charge all the bats up." - will this NOT destroy something electrical? I'm a novice to multi-battery installations, but have heard that switching battery selector switch while altrnator is running will destroy some rectifier/diode or something...

Charles
Charles,

Most battery switches are "make before break" meaning they can be switched between banks even with the motor running. WHat you should not do is rotate through the OFF position. To check if you have a make before break switch turn on the cabin lights and switch between banks. If the lights dim or go out during switching then you don't have a MBB switch...

As Stu said there are ways to eliminate blown diodes and one of the most simple is to turn the switch into a use switch only and not a "charge directing" switch by adding an ACR, Echo Charger or similar....
 
Sep 5, 2007
689
MacGregor 26X Rochester
Alex

FWIW, my Hunter 340 was wired very simply, with two deep cycle batts as the "A" house bank, and a third start battery on the "B" of the A/Both/B/Off switch. A Xantrex 3-bank charger (circa 1998) with two banks combined on the house batts, and the third on the start batt.

I only ever ran it on the house batts, including starting (27 hp Yanmar), and kept the start batt for emergencies. I never used it except for testing.

The only thing I would have changed would be the addition of an ACR (or other such device), and maybe a monitor. The shore power charger would keep the start battery up, when I used it, but the alternator would not. I didn't cruise in that boat, but long weekends were common, almost always with shore power at the end of the day.

I would commonly sail 12 hours with the cold plate fridge (assisted by a couple of bags of ice), autohelm, pc for real time nav (on an inverter, but powered down to standby most of the time), instruments (wind, water), some music, pressurized water, etc., and always had plenty of house bank left over to start the diesel. Oh, these were group 24 deep cycles, bought at the same time so I wasn't pairing strong with tired.

It wasn't the optimum setup, but it was butt simple, and I like things that way. While the batt switch was MBB, I never switched it with the engine running. The standby was only charged by the shore power charger. Adding an ACR would have been a good addition to keep the standby start batt up, with the alternator wired direct to the house bank, or through the batt switch as it was when I bought it. But anything fancier would have been overkill for me.

A monitor would have been good, more for extending battery life than knowing remaining capacity as I didn't spend nights on the hook due to passengers who wouldn't be passengers if they couldn't step off at the end of the day, but that's my burden (as it is with my present trailerable day sailor). :neutral:

Edit: I should add that I really never had an idea how much energy I drew from those batteries, as I'd get to my desination and plug into shore power for the night. Flying blind, so to speak, but always made it to the other side with enough left over to start the engine. Probably wouldn't be so lucky if spending the night on the hook, at least without running the diesel for hours at the end of the day, which is not something I'd want to do. Defeats the purpose, as in peace and quiet on the hook or at the dock.
 
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