Station Wiring Considerations

1. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Station Wiring Considerations Steve Jensen – KE7GXC -- AEC for special projects Station wiring Considerations to support HAM radio emergency communications. 08-March-2009, Rev. 07-March-2012 Steve Jensen – KE7GXC -- AEC for special projects Station wiring Considerations to support HAM radio emergency communications. 08-March-2009, Rev. 07-March-2012

2. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Emergency Communications Station Wiring Batteries Power Sources Plug in power supplies (house current) What is practical ? What is safe ? Batteries come in a many varieties As do portable generators. Solar panels ? Wind mills ? Power supplies plugged into sine wave power generators ? WHAT IS PRACTICAL ? Batteries come in a many varieties As do portable generators. Solar panels ? Wind mills ? Power supplies plugged into sine wave power generators ? WHAT IS PRACTICAL ?

3. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Fire Hazard – computer monitor fire 2004 A monitor caught fire at a well know UK company’s test lab… Electronics do fail, generally if UL / CSA / VDE recognized --- this sort of failure will not occur.A monitor caught fire at a well know UK company’s test lab… Electronics do fail, generally if UL / CSA / VDE recognized --- this sort of failure will not occur.

4. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Fire Hazard – Li-Ion batteries Flaming Dell in 2006 We’ve all heard of the flaming Dell laptop lithium battery problem a couple of years back.We’ve all heard of the flaming Dell laptop lithium battery problem a couple of years back.

5. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Manual connect & disconnect Parts available from DCPwr.com:: Power Splitter/Adpater, Four way output -- $21 + shipping & handling, dcpwr.com/products/product.php?id=97 Power Cube -- $55 + shipping & handling, dcpwr.com/products/product.php?id=114 Grey 50 amp Anderson connectors, Housing & Contacts, Gray, 50 AMP, SB 50 Series -- $6 each + shipping & handling, dcpwr.com/products/product.php?id=85Parts available from DCPwr.com:: Power Splitter/Adpater, Four way output -- $21 + shipping & handling, dcpwr.com/products/product.php?id=97 Power Cube -- $55 + shipping & handling, dcpwr.com/products/product.php?id=114 Grey 50 amp Anderson connectors, Housing & Contacts, Gray, 50 AMP, SB 50 Series -- $6 each + shipping & handling, dcpwr.com/products/product.php?id=85

6. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Automatic connect & disconnect

7. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Automatic connect & disconnect Anderson SB50 connectors should be added to connect to the diode isolator/combiner. Current flow notes: when the batteries are at float voltage level, little or no current flows to the radio from the batteries. Switching the power supply off causes current flow from the batteries. During “bulk” charge of the batteries by the battery charger the voltage is 14.6 volts – should the power supply and radio be turned on, current flow from the battery charger will supplement the current flow to the radio. During the “bulk recharge” portion of the recharge cycle it is best to have the radio switched off.Anderson SB50 connectors should be added to connect to the diode isolator/combiner. Current flow notes: when the batteries are at float voltage level, little or no current flows to the radio from the batteries. Switching the power supply off causes current flow from the batteries. During “bulk” charge of the batteries by the battery charger the voltage is 14.6 volts – should the power supply and radio be turned on, current flow from the battery charger will supplement the current flow to the radio. During the “bulk recharge” portion of the recharge cycle it is best to have the radio switched off.

8. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Charging Batteries CARES recommended chargers: Japlar-Schauer 12v 5 Amp Charger, Model: JAC0512P, $80 + s/h BatteryStuff.com Allows recharge of the 80-100 Amp hour AGM batteries in 24-30 hours www.batterystuff.com/battery-chargers/12-volt/gel-cell/BM12248.html BatteryMINDer 12 Volt 2-4-8 Amp Charger/Maintainer/Conditioner now including FREE Battery Temp Sensor! Part: BM12248 Price: $109.00 Dimensions: 5.5" L x 5.5" W x 2.25" H Actual Weight (lb.): 2.2 Shipping Weight (lb.): 4 Output Banks: 1 Max Current, During Bulk Charge: 8A Absorption Voltage: Variable AC Input Volts: 120 V AC Input Volts Freq.: 50/60 Hz AC Input Volts Range: 90–140 V AC Input Amps: 1.8A Desulphation Pulse: 100 +/-10 hz Float Voltage: Variable Float Current: Variable Operating Temperature: -10 to 40 °C Storage Temperature: -10 to 80 °C Over Temperature: auto-reset thermal breaker Temperature Compensation: At battery temp sensor Regulatory Approval: Built to UL 1236 standards Manufacturer: BatteryMINDer ---- www.batterystuff.com/battery-chargers/12-volt/multi-volt-input/JAC0891-49.html Japlar-Schauer 12v 5 Amp Charger JAC0512r Part: JAC0891-49 Replaces: Soneil 1212SR Price: $79.00 Dimensions: 7.0" L x 3.5" W x 1.8" H Actual Weight (lb.): 2.2 Shipping Weight (lb.): 3 Enclosure: Aluminum Case Output Banks: 1 Max Current, During Bulk Charge: 5A Absorption Voltage: 14.6 AC Input Volts Freq.: 50/60 Hz AC Input Volts Range: 100–240V Float Voltage: 13.5 Operating Temperature: 32°F to 120°F Regulatory Approval: CE, UL Listed Manufacturer: Japlar Schauer Description Protection provided: Reverse Polarity, Short Circuit, Over-Voltage, Over Current and AC Surge. Soft Start and Stop; Starts and stops gradually. No sudden in-rush of current. This protects both the batteries and any other circuits connected to the charger. Japlar Battery Charger transforms the 100 to 240 VAC into 12 VDC at about 100,000 Hz (3333 times faster than conventional charger), which requires a much smaller transformer and therefore results in a unit of smaller size, low weight and improved efficiency. The JAC0512 uses sophisticated electronic circuitry with microchips. All present day computers use switch-mode technology. Stage 1: Constant Current Mode (CC) The charger changes to constant current 5.0A. When the battery voltage reaches up to 14.6v, the charging stage changes from (CC) Constant Current to CV (Constant Voltage) mode. Stage 2: Constant Voltage Mode (CV) The charger holds the battery at 14.6 and the current slowly reduces. The moment the current reaches 0.5 C (C= Battery Capacity), is called the Switching Point. The Switching Point is one of the great features of this battery charger that it can adjust the current automatically according to the battery capacity. Other chargers without microprocessors are not capable to adjust the current automatically. Stage 3: Standby Voltage Mode The charger maintains the battery voltage at 13.5v and current slowly reduces to zero. Charger can be left connected indefinitely without harming the battery. This charger typically ships with ring type connectors, allowing the customer to adapt the charger to their specific needs. Features * Totally Automatic Switch-Mode Battery Charger * Suitable for Sealed (AGM) and Wet Lead Acid Batteries * Suitable for use anywhere in the world. * Automatic input sensing: 100/240VAC 47 to 62Hz * Automatic Cut Off and then True Float. Can be left connected indefinitely without harming the battery. * Two color LED to indicate charge status * Mean Time between failures 30,000 hours * Zero Current Drain when AC power is off * Fan cooled circuitry * Optimal 3 Step Charging * Built-in Mode Indicators * Reverse Polarity Protection * Over Voltage Protected * Short Circuit Protection * Overload Protection * Fan Control * Thermal Protection * 2 Year Warranty Comments This battery charger is a replacement for the Soneil 1212SR. Not for true Gel batteries. Schauer Fully Automatic Constant Current Electronic Charger, charges faster and more accurately than conventional chargers. Charge control is constant current charge to a constant voltage and then to a float standby. The float charge holds the battery at 100% ready state. The charger can be left on indefinitely without worry of undercharge or overcharge. The Schauer charger can be used world wide; charger automatically accepts and operates on voltage range of 100 to 240 VAC and 50 or 60 Hz. The JAC Series charger will act as a power supply in conjunction with a battery hook up. Allows recharge of the 80-100 Amp hour AGM batteries in 24-30 hours www.batterystuff.com/battery-chargers/12-volt/gel-cell/BM12248.html BatteryMINDer 12 Volt 2-4-8 Amp Charger/Maintainer/Conditioner now including FREE Battery Temp Sensor! Part: BM12248 Price: $109.00 Dimensions: 5.5" L x 5.5" W x 2.25" H Actual Weight (lb.): 2.2 Shipping Weight (lb.): 4 Output Banks: 1 Max Current, During Bulk Charge: 8A Absorption Voltage: Variable AC Input Volts: 120 V AC Input Volts Freq.: 50/60 Hz AC Input Volts Range: 90–140 V AC Input Amps: 1.8A Desulphation Pulse: 100 +/-10 hz Float Voltage: Variable Float Current: Variable Operating Temperature: -10 to 40 °C Storage Temperature: -10 to 80 °C Over Temperature: auto-reset thermal breaker Temperature Compensation: At battery temp sensor Regulatory Approval: Built to UL 1236 standards Manufacturer: BatteryMINDer ---- www.batterystuff.com/battery-chargers/12-volt/multi-volt-input/JAC0891-49.html Japlar-Schauer 12v 5 Amp Charger JAC0512r Part: JAC0891-49 Replaces: Soneil 1212SR Price: $79.00 Dimensions: 7.0" L x 3.5" W x 1.8" H Actual Weight (lb.): 2.2 Shipping Weight (lb.): 3 Enclosure: Aluminum Case Output Banks: 1 Max Current, During Bulk Charge: 5A Absorption Voltage: 14.6 AC Input Volts Freq.: 50/60 Hz AC Input Volts Range: 100–240V Float Voltage: 13.5 Operating Temperature: 32°F to 120°F Regulatory Approval: CE, UL Listed Manufacturer: Japlar Schauer Description Protection provided: Reverse Polarity, Short Circuit, Over-Voltage, Over Current and AC Surge. Soft Start and Stop; Starts and stops gradually. No sudden in-rush of current. This protects both the batteries and any other circuits connected to the charger. Japlar Battery Charger transforms the 100 to 240 VAC into 12 VDC at about 100,000 Hz (3333 times faster than conventional charger), which requires a much smaller transformer and therefore results in a unit of smaller size, low weight and improved efficiency. The JAC0512 uses sophisticated electronic circuitry with microchips. All present day computers use switch-mode technology. Stage 1: Constant Current Mode (CC) The charger changes to constant current 5.0A. When the battery voltage reaches up to 14.6v, the charging stage changes from (CC) Constant Current to CV (Constant Voltage) mode. Stage 2: Constant Voltage Mode (CV) The charger holds the battery at 14.6 and the current slowly reduces. The moment the current reaches 0.5 C (C= Battery Capacity), is called the Switching Point. The Switching Point is one of the great features of this battery charger that it can adjust the current automatically according to the battery capacity. Other chargers without microprocessors are not capable to adjust the current automatically. Stage 3: Standby Voltage Mode The charger maintains the battery voltage at 13.5v and current slowly reduces to zero. Charger can be left connected indefinitely without harming the battery. This charger typically ships with ring type connectors, allowing the customer to adapt the charger to their specific needs. Features * Totally Automatic Switch-Mode Battery Charger * Suitable for Sealed (AGM) and Wet Lead Acid Batteries * Suitable for use anywhere in the world. * Automatic input sensing: 100/240VAC 47 to 62Hz * Automatic Cut Off and then True Float. Can be left connected indefinitely without harming the battery. * Two color LED to indicate charge status * Mean Time between failures 30,000 hours * Zero Current Drain when AC power is off * Fan cooled circuitry * Optimal 3 Step Charging * Built-in Mode Indicators * Reverse Polarity Protection * Over Voltage Protected * Short Circuit Protection * Overload Protection * Fan Control * Thermal Protection * 2 Year Warranty Comments This battery charger is a replacement for the Soneil 1212SR. Not for true Gel batteries. Schauer Fully Automatic Constant Current Electronic Charger, charges faster and more accurately than conventional chargers. Charge control is constant current charge to a constant voltage and then to a float standby. The float charge holds the battery at 100% ready state. The charger can be left on indefinitely without worry of undercharge or overcharge. The Schauer charger can be used world wide; charger automatically accepts and operates on voltage range of 100 to 240 VAC and 50 or 60 Hz. The JAC Series charger will act as a power supply in conjunction with a battery hook up.

9. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Charging Batteries CARES recommended chargers: Noco Genius 12v 3.5 Amp Charger, Model: G3500, $60 from Batteries and More in Molalla, OR Allows recharge of the 80-100 Amp hour AGM batteries in 24-30 hours $60 (Jan-2012) www.facebook.com/batterieandmore Available from: Batteries and More 704 E Main St. ( just to the east of downtown a few block ) Molalla, OR 503 829 4060Allows recharge of the 80-100 Amp hour AGM batteries in 24-30 hours $60 (Jan-2012) www.facebook.com/batterieandmore Available from: Batteries and More 704 E Main St. ( just to the east of downtown a few block ) Molalla, OR 503 829 4060

10. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Charging Batteries West Mountain Super PWRgate PG40S Backup Power System Web: westmountainradio.com/SuperPWRgate.htm Includes a battery charger and features automatic power switch over…. To use with Gel Cell or AGM batteries, from the PG40S manual: “Note: Always use a accurate digital display voltmeter to assure accurate readings.” Gelled Cells To achieve optimum battery charging, the power supply should be adjusted to 14.10 volts dc. The charger will now permit the battery to reach a peak voltage of 13.8 volts during the peak voltage cycle. The float state will remain at 13.5 Volts. AGM Cells The charger can also be configured for an AGM type sealed battery. But to do this precisely, the power supply should be re-adjusted to provide 14.50 volts. In addition, a jumper must be installed at J1 inside the Super PWRgate. Take the top cover off. The small blue jumper block should be lifted off the pin and re-installed shorting out the two pins. The charger will now permit the battery to reach a peak voltage of 14.2 volts during the peak voltage cycle. The float state remains at 13.5 volts. I have not tested this unit. $140 plus shipping and handling. Includes a battery charger and features automatic power switch over…. To use with Gel Cell or AGM batteries, from the PG40S manual: “Note: Always use a accurate digital display voltmeter to assure accurate readings.” Gelled Cells To achieve optimum battery charging, the power supply should be adjusted to 14.10 volts dc. The charger will now permit the battery to reach a peak voltage of 13.8 volts during the peak voltage cycle. The float state will remain at 13.5 Volts. AGM Cells The charger can also be configured for an AGM type sealed battery. But to do this precisely, the power supply should be re-adjusted to provide 14.50 volts. In addition, a jumper must be installed at J1 inside the Super PWRgate. Take the top cover off. The small blue jumper block should be lifted off the pin and re-installed shorting out the two pins. The charger will now permit the battery to reach a peak voltage of 14.2 volts during the peak voltage cycle. The float state remains at 13.5 volts. I have not tested this unit. $140 plus shipping and handling.

11. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Charging Batteries CARES recommended chargers: Deltran Battery Tender 12v 1 Amp Charger, Model:021-0156 (AGM), Model: 021-128 (Gel) Allows recharge of the 80-100 Amp hour batteries in 100-150 hours. The model 021-128 that G.I.Joes stocks is has a voltage of 13.2 for Gel Cell batteries. $50 The model 021-156 has a voltage of 13.4 for AGM batteries. $60 I have not yet purchases one of these for my testing & evaluation – but others in CARES have. Battery Tender Plus Gel 12V 1.25A Battery Charger - Item number: DBT021-0156 p/n 021-156 float voltage is set at: 13.4 vdc The Battery Tender Plus Gel 12V is a desktop, portable, 1.25 amp battery charger that is designed to fully charge and maintain gel and deep cycle batteries at proper storage voltage without the damaging effects caused by trickle chargers. Primary Applications: AGM and Gel battery, deep cycle batteries, RV, Golf Carts & general use.Boats, Watercraft & outdoors.specialty, shop, industrial & Multi-Vehicle chargers & accessories Price: $59.99 Allows recharge of the 80-100 Amp hour batteries in 100-150 hours. The model 021-128 that G.I.Joes stocks is has a voltage of 13.2 for Gel Cell batteries. $50 The model 021-156 has a voltage of 13.4 for AGM batteries. $60 I have not yet purchases one of these for my testing & evaluation – but others in CARES have. Battery Tender Plus Gel 12V 1.25A Battery Charger - Item number: DBT021-0156 p/n 021-156 float voltage is set at: 13.4 vdc The Battery Tender Plus Gel 12V is a desktop, portable, 1.25 amp battery charger that is designed to fully charge and maintain gel and deep cycle batteries at proper storage voltage without the damaging effects caused by trickle chargers. Primary Applications: AGM and Gel battery, deep cycle batteries, RV, Golf Carts & general use.Boats, Watercraft & outdoors.specialty, shop, industrial & Multi-Vehicle chargers & accessories Price: $59.99

12. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Charging Batteries CARES REQUIRED TEST EQUIPMENT: Harbor Freight / Radio Shack – inexpensive DVM Check your battery MONTHLY ! Harbor Freight - www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=90899 - $5 Radio Shack - www.radioshack.com/product/index.jsp?productId=2103174 - $20 Harbor Freight - www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=90899 - $5 Radio Shack - www.radioshack.com/product/index.jsp?productId=2103174 - $20

13. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Wiring, Fusing and Isolation CARES recommended designs Upper right – Power Splitter/Adpater, Four way output -- $21 + shipping & handling, dcpwr.com/products/product.php?id=97 Lower right - Power Cube -- $55 + shipping & handling, dcpwr.com/products/product.php?id=114 Left – CARES design: $20 in parts www.remybattery.com/Departments/Cable--Accessories/Terminal-Protectors--Boots/Garden-Tractor-Protec tor-Covers.aspx part number: 5709R 4 - 8 Gauge, Right Garden Tractor Protector, terminal cover - Positive $1.98 part number: 5710B 4 - 8 Gauge, Left Garden Tractor Protector, terminal cover - Negative $1.98 Radio Shack - 30Amp in-line blade ATC fuse holder, 10 GA wire with weather boot. Part number 270-1234 -- $2.69 Grey 50 amp Anderson connectors, Housing & Contacts, Gray, 50 AMP, SB 50 Series -- $6 each + shipping & handling, dcpwr.com/products/product.php?id=85 Upper right – Power Splitter/Adpater, Four way output -- $21 + shipping & handling, dcpwr.com/products/product.php?id=97 Lower right - Power Cube -- $55 + shipping & handling, dcpwr.com/products/product.php?id=114 Left – CARES design: $20 in parts www.remybattery.com/Departments/Cable--Accessories/Terminal-Protectors--Boots/Garden-Tractor-Protec tor-Covers.aspx part number: 5709R 4 - 8 Gauge, Right Garden Tractor Protector, terminal cover - Positive $1.98 part number: 5710B 4 - 8 Gauge, Left Garden Tractor Protector, terminal cover - Negative $1.98 Radio Shack - 30Amp in-line blade ATC fuse holder, 10 GA wire with weather boot. Part number 270-1234 -- $2.69 Grey 50 amp Anderson connectors, Housing & Contacts, Gray, 50 AMP, SB 50 Series -- $6 each + shipping & handling, dcpwr.com/products/product.php?id=85

14. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES Wiring, Fusing and Isolation CARES recommended designs

15. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES More Information… ARRL Handbook ARRL Emergency Power Handbook If you do not know or understand what to do speak with other club members ! If you do not know or understand what to do speak with other club members !

16. Steve Jensen (KE7GXC), Asst. Emergency Coordinator, Clackamas County, Oregon ARES In closing Practical use of surplus batteries Practical charging equipment Questions…. Steve Jensen – KE7GXC@ARRL.NET