Galankin Island - Add Second Battery - Narrative

2020 - 8 - 2   Dave L
Please read the entire procedure before starting. You will need specific tools for completion.

Shelf Diagram



Rear-Views

The wiring harness running from the panel on the front to the rear, must be cut loose, all cable ties removed so wires can be rerouted around the new shelf.
Some wires may go above and some below as needed. See right side, new shelf level in photo above.
Existing cabling to the Power Supply and first battery should already be long enough to reach the new locations.


New Shelf


New Shelf Front View

The Power Supply will be a tight fit and cannot be placed after the shelf is mounted due to the lips front and rear.
You will have to set it in place on the shelf and then mount the shelf in the cabinet.
It will be very secure and give enough room below for the battery boxes to fit with some room above them.
If the fit is too tight, move the Power Supply to the center of the shelf, you may only need to bend the shelf 1/16" or less for it to mount.
Then bend the back of the shelf so the two screws seen below will clear, and the Power Supply will set down flat.


New Shelf Rear View


All power must be shut off to do this shelf addition. Shut off all three breakers. Remove power plug from wall outlet.
Remove the existing battery box and disconnect the wires from it.

Power On Off Diagram

Power Pannel

Galley Power Low voltage disconnect unit will shut off the battery power when the batteries get down around 11 vdc, so they are not destroyed.
When AC power is restored it will turn back on.




Shelf Photo

There must be a 40 Amp in line fuse off the positive terminal of both batteries. This is a safety disconnect if there is a hard short from either battery.
The cross battery wiring harness, shelf mounting screws, and 40 Amp fuses are provided.



Battery Box Modification



Wiring Diagram

Face the two batteries as shown. Bring the cables off the rear openings of the battery boxes so fuses can be reached.

Do not slide the batteries into the cabinet without the box covers on them. The right battery box must go in first to slide around the rear ground bar.
If there is an earthquake, the boxes will keep the batteries from hitting the shelf above them. Be sure the covers latch shut and hold the tops on.



Wiring Method

Battery wiring method, lugs are crimped and then soldered.
This is not a high vibration environment, the solder will add conductivity and prevent corrosion.
Battery grease can be added if desired over all the connections to reduce corrosion over time.



Battery Maintenance

After the shelf and new batteries are wired, cable ties are in order to get any low hanging wires up out of the battery box area of the cabinet.
Battery box wires can be coiled and cable tied to the rear screw hole risers but will have to be cut to remove the battery boxes.

Power Supply Photo

Power supply can now be accessed from the rear, and batteries can be equalized to 14.6 vdc a couple times a year for a couple hours or a day at most.
There is a switch on the power supply to switch from 13.8 vdc float, to an adjustable setting on the adjust knob to equalize the batteries.
It should already be set correctly. A digital volt meter should be attached to the 12 vdc power for adjustment of this voltage.
Try not to hit this voltage adjust knob while doing the shelf addition.

If the equalize voltage is left on too long it will start to lower the water level in the batteries, the water must be brought up using only distilled water.
If the batteries are never equalized, they may begin to run down at reduced rates of time as the cells inside begin to separate in voltage output.
There are six cells in each battery, and water is separated between them. They are each filled up to just below the hole shaft in the top but not touching it.
You can fill the water using a plastic turkey baster, but never take any back out, or it will reduce the electrolyte acid density,
and do not let the tip of the baster contact the acid in the cells. Otherwise a commercial hydrometer can be used.


Note:

If you want me to work on a fan mod, to install quieter fans, and thermal activation, we will have to remove one repeater at a time for modifications.
There are some new fans out there which are much quieter, I may be able to design a small thermal shut down circuit.
At this point I am not certain how many fans there are inside that box. Will investigate.

The fan in the power supply has thermal shutdown already.


End Document

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