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battery temp in extreme climate


By birdhouse, Section Controls
Posted on Sat Nov 14, 2009 at 10:48:00 AM MST
trying to keep batteries from getting to hot or too cold...

hello all-

i'm nearing completion of my wind turbine and have 400 w worth of solar i'd like to install all of this up at my ranch.  the place is off the east flanks of mt. adams.  4,000 ft above sea level.  in the summer it can get above 100 degrees F, and in the winter can get well below zero degrees F.  

i realize this will play major havoc on my battery bank.

here's the plan:  

create a battery box that is inslulated with rigid polyisuciornate scraps i have. include a small vent on the top to let out charging gasses.

install a HVAC heat/cool thermostat.

set the heating @ 40 degrees and connect a 100w incandecent light bulb (via relay or something) to keep the batterries from freezing in the winter.

set the cooling to 80-90 degrees.  two computer fans would be connected to this circuit.  they would atach to a long underground run of 3 inch abs/pvc pipe that created a loop.  one fan would push air from the battery box into the pipe, and the other would pull air back out the other end of the closed loop.  both ends of pipe would terminate within the battery box with fans on the ends.  basically a ghetto geo-thermal set-up.  

my place is un-attended for up to a few months at a time, i don't want the batteries to have to fend for themselves.  plus using wattage out of the bank to heat/cool is no big deal since it would be dumped anyways when no-one is up there.      

another thought...  i could put the dump load in the battery box to keep it warm in the winter, but would rather put it in the shed to melt snow off the roof, and keep paint/caulking from freezing over the winter.  

okay, so poke a million holes in my theory!  really!  
i want to do this right the first time!

thank you for ANY replies!

birdhouse

battery temp in extreme climate | 12 comments (12 topical)

Re: battery temp in extreme climate (3.00 / 0) (#1)
by TomW on Sat Nov 14, 2009 at 11:20:46 AM MST

If the thermostat is in the battery box just be sure it is non sparking when it switches. brushless motors in any fans, too. Sparks +hydrogen gas + oxygen == interesting combustion pyrotechnics.

Just a gotcha to consider.

Tom

The Truth is the Truth, even if no one believes it; and a lie is a lie even if everyone believes it




Re: battery temp in extreme climate (3.00 / 0) (#2)
by birdhouse on Sat Nov 14, 2009 at 11:28:22 AM MST

tom-
that is a really good point!  seeings how i don't know how to tell if a thermostat will spark or not (until i already bought it and tested it) maybe i ought to look for thermostats with a remote temperature sensor.

was planning on using brushless fans/motors to eliminate spark.  

i think an explosions of that size could no longer be considered "magic smoke"  :)

thanks!

birdhouse
"let it blow, let it blow"
[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#3)
by Volvo farmer on Sat Nov 14, 2009 at 04:57:38 PM MST

I think you are trying to solve a problem that doesn't exist.

First off, a 100W incandescent bulb running 12-16 hours a day in the middle of winter is gonna use about all the energy that the 400W of panels is going to make. You go away and let the batteries get 60% discharged because of three cloudy, windless days, get a nice chunk of 10-below weather, and you'll have frozen batteries

Fully charged batteries will not freeze until the temperature drops to well below -50F, cold batteries lose some of their capacity, but are otherwise unharmed in cold temperatures, as long as you can keep the SG up over 1.250 or so. If you're not there and there are no loads, your solar and wind should have no problem keeping the batteries up.

100F during the day is not a real issue either. Your batteries have a bunch of mass and will stabilize at a temperature about midway between the high and low temperature of the day if you're not using them.

My batteries have been in an unheated shed, in an insulated box for three years now with no ill effects. We're charging and discharging them every day, but I have never seen the temperature in the box drop below 40F, and we have had days where it never gets above freezing and is 10 below when the sun comes up.

Is that enough holes in your theory? ;-)

Volvo Farmer




Re: battery temp in extreme climate (3.00 / 0) (#4)
by 97fishmt on Sat Nov 14, 2009 at 06:40:25 PM MST

You are right on Volvo farmer,  an insulated box would be on the list of things
to do but don't worry about it if you can't keep them charged.

20 years for me in about the same environment.  The batteries get a little sluggish
at 20 below but you certainly don't want to be draining them to keep them warm.
Just make sure you are charging them enough and they will keep themselves warm.

I am surprised how warm the earth is in my battery room even when it is below zero outside.  Good Luck


[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#5)
by TomW on Sun Nov 15, 2009 at 03:08:45 AM MST

VF;

Agreed. Perfect example of over thinking the Plumbing.

Heat kills more batteries than cold.

Venting is simple, effective and always a good idea only really needed during charging which makes it easy to control by simply running the fan off the source before the isolation diodes.

I am quite certain that you could waste a lot of effort trying to "fix" this and never gain an AH of storage. Especially if you are using the batteries to run any heaters.

Just build a well insulated, vented box for them and get on with it. Or not.

Just way too many "experts" dispensing advice on the internet these days that seems to serve no purpose beyond folks chasing their tails trying to follow it.

That is all I will say.

Tom

The Truth is the Truth, even if no one believes it; and a lie is a lie even if everyone believes it


[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#12)
by SparWeb on Tue Nov 17, 2009 at 03:17:36 PM MST

"Especially if you are using the batteries to run any heaters."

I gotta laugh.  A couple of years ago, I spend a day rigging one up a heater for inside the battery box, too.  I even put in a thermostat switch so it would come on at -20C.  After I let it run for a while, the voices in the back of my mind finally screamed loudly enough, and I saw the error of my ways.

That little voice that says "no this is stupid"...  You can't always tell if it's common sense or schizophrenia.  Either way it doesn't matter because the whole family thinks I'm nuts.
Steven Fahey
[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#6)
by birdhouse on Sun Nov 15, 2009 at 11:07:26 AM MST

your comments are very welcome.  this is why i posted.  to be able to learn from other's experiences.  

question:  how do the batteries keep themselves from freezing?  i understand that they heat up when being charged or discharged, but little of that would be happening when i'm not up there.  does the electrolite/water combo have a lower freezing temp than water alone?  

i would much rather NOT have to do all the things i talked of above!  i'm just worried and don't want my first set of batteries to have an early death due to cold.  i looked at the record lows for the area over the winter months, and the lowest i found was -21 F.  

so my batteries will be fine with temps this cold if they are in an insulated box?  

the fan before the diode idea is pretty smart.  do you think this is needed even if the "ceiling" of the box is a "gable" or "pent" with the vent hole centered on the peak?  

was also thinking of running both solar and wind through dump style controllers to keep things moving in the batteries during the cold.  does this sound like a good idea?  

thanks for all of your help!

birdhouse
"let it blow, let it blow"



Re: battery temp in extreme climate (3.00 / 0) (#7)
by birdhouse on Sun Nov 15, 2009 at 12:59:52 PM MST

volvo farmer-
sorry, i missed the part about fully charged batteries needing -50 f to freeze.  that takes the worry out of the cold problem, so long as they are fully charged.  i'll just have to be super careful about how much i discharge them when it's really cold out.  

i still might do the ghettofabulous geo-thermal rig.  i found some double ball bearing 24 volt 3" brushless computer fans that claim they can move 42 CFM with less than three watts of power.  i've got all the pipe and elbows sitting around.  would be pretty easy.  

still trying to wrap my mind around all of the ins and outs of a wind/sun RE system.  

another question:  if i make my dump load out of nichrome wire, but set the resistance such that the wire never even gets orange (i've got tons of this stuff) would it be acceptable to place this with the batteries?  just worried about spark ect.  

thanks!
birdhouse
"let it blow, let it blow"
[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#8)
by Volvo farmer on Sun Nov 15, 2009 at 03:51:13 PM MST

You can heat your battery box if you want, but ask yourself this: Why are you trying to heat your battery box? and what advantages are you accomplishing by doing so? Also, what are the disadvantages and costs of trying to heat a battery box, off-grid?

I like more battery capacity as much as the next guy, so I painted the outside of my battery box black and put a couple of south-facing windows in my power shed. It helps a little and is zero maintenance over 20 years.

It sounds like your system is going to be unattended over large periods of time. Maybe by explaining what you are trying to do more clearly, with things like charging sources, battery bank size and voltage, expected loads, etc, you might get more help in wrapping your mind around all of this. It might, in fact, be an advantage for someone to dump excess power as heat into a battery box, but in my mind, it would have to be an unusual set of circumstances.

Volvo Farmer


[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#9)
by birdhouse on Sun Nov 15, 2009 at 05:25:23 PM MST

VF-
thanks for your help.  i was speaking of still using geo thermal only to cool the box in the summer.  after re-reading your post and realizing it takes -50F to freeze a full battery i'm not too worried about the cold.  

as far as my system...  nothing is going as of yet. i'm hoping to install most in the spring seeings how i can't get up to my place during the winter.  many many feet of snow.  i've learned my lesson by getting stuck in 4 wheel with chains on all four tires more than once.  

i'm still unsure of voltage for the bank.  iv got two 200 watt panels, so those could go 12 or 24 volt.

my turbine is made from a 3phase brushless servo motor.  i benched it for 12 volt and got 140rpm for cut in.  i'd rather go 24 volt, but have yet to bench it for that seeings how my machinist friend is making my blade mounting hub.  i wanna bench it for 12 volt jerry rigged too.  so that is still up in the air.  at 12 volts, i think it may make between 200 and 500 watts???  getting anxious to do a truck test.  8.5 foot diameter tsr 6.5 blades.  50 lbs motor.  2000 rpm, 144 volt, 20 amp.    welded into a hugh style furling rig.  this is all finished.  i kinda got the egg before the chicken if you know what i'm saying.  

bank:  new sams club 6 volt.  4 of em.  wired for 12 or 24 still not sure.  

loads:  lights in the cabin.  ideally halogen dc lights 12 or 24 volt...  only a few.  stereo:  if 12 volt, i'll use an old car stereo, if 24 volt, i'll prolly run one off an inverter.  
plus anything else i can run off it without draining the system: small power tools during the heart of the solar day ect.  

controller(s)- tri-star 60 for wind and something else for the 400 w of solar.  

so this is where i'm at and trying to find all the bits to complete a system so when spring rolls around i'm ready to go for it!  

thanks again!

birdhouse.

"let it blow, let it blow"
[ Parent ]



Re: battery temp in extreme climate (3.00 / 0) (#10)
by Ungrounded Lightning Rod on Mon Nov 16, 2009 at 05:06:57 PM MST

Batteries self-heat when charging and discharging.  (Also a tad from leakage.)  And they have a LOT of thermal capacity so they heat and cool slowly.  In cold weather the thing to do is insulate the box and insure the ventilation is only enough to avoid explosion risk.  If you have extreme seasons, use adjustable vents and open them in summer to let the (still insulated) battery box cool by convection.

Sulfuric acid does the same thing to water as ethylene glycol, salt, sugar, fertilizers, and many other solutes that act as "antifreeze":  Disrupts the crystal formation, thus lowering the freezing point.  In fully charged batteries virtually all of the sulphate ions are in the electrolyte, equivalent to a LOT of antifreeze.  In discharged batteries much of them are in the plates so the electrolyte is more dilute and freezes more easily.  But it's still good to well below the freezing point of unadulterated water.

Thus it's fine - better - to leave them unheated rather than discharge them keeping them warm.  If they get 'way cold their output voltage will be somewhat lower at first when you start using them after they've been sitting idle for many hours (i.e. morning load on a solar-only recharge system).  But they'll warm up with use.

You only want to heat them with their own power if it's VERY important that you have full voltage available for a sudden use and you have LOTS of power available to keep them charged.  But if you have power to keep them charged, the float current will keep them warm.  Heating with their own power is mainly for things like a military vehicle starting battery in a very cold environment - where you need the power to start the cold engine but will run it regularly to keep the battery from running down.



Re: battery temp in extreme climate (3.00 / 0) (#11)
by birdhouse on Mon Nov 16, 2009 at 09:29:23 PM MST

thanks UGL and all others who have helped me!

alright i got it, don't worry about them freezing if they are full.

UGL-  you're explanations are very helpfuly to visulize whats happening within a cold bank.  

now i just need to get my butt in gear to finish my turbine!  my machinist called today and said the blade mounting hub is done, so soon i'll post how my motor works under 24 volt load and maybe even 12 volt jerry when i get a little time to crack the case and switch wiring stuff around.  

thanks so much for all of your help!

birdhouse

"let it blow, let it blow"



battery temp in extreme climate | 12 comments (12 topical)
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