Adding Solar battery maintainer connectons.

/ Adding Solar battery maintainer connectons. #1  

k0ua

Epic Contributor
Joined
Jun 28, 2009
Messages
30,638
Location
Branson, Mo.
Tractor
Kioti DK35se Hydrostat
i decided to add solar battery maintainer connections to my Kioti DK35se today. I had noticed during 2 week lulls here in winter of not using my tractor that when I did start it up the glow plug cycle sucked the battery voltage down to around 9.85 volts when the glow plug relay first clicked in. Of course it would rise above 10 volts in a few seconds as the glow plugs heated up during the cycle but still this is a bit low. Of course If the tractor was started more often this would not be a problem, but I just don't use the tractor all that much in the winter and would like to keep the battery in better shape. Nothing Kills a battery faster than letting it slowly self discharge in the cold.

I wanted some connections that are within easy reach as I sit in the seat to start the tractor and will pull out on their own if for some glaring omission on my part I don't disconnect them when I drive out of the barn. Therefore I chose Anderson powerpoles. Plus I had them in stock.
Here is the Kioti fuse block with the cover off. I intend to wire up to the fused side of the top fuse in the stack the blue 15 amp one. It is for the horn and emergency flashers. The only accessories that are on constant battery voltage in the tractor.

IMG_20160202_105332429 (Medium).jpg


Lets get the negative battery post off. 10MM nut for those wanting to know. Much safer than removing the positive battery terminal. It doesn't matter if your metalic tool slips and contacts the frame of the tractor:)
IMG_20160202_105357780 (Medium).jpg

Lets take out that fuse and see for sure which side is the battery hot feed and which is the fused side. In this case the left side is the battery hot feed and the right side with the light green wire is the fused side on to the accessories. (the horn and the emerg. flashers)

IMG_20160202_105453709 (Medium).jpg


Here is what it looks like on the back side. Now time to make up the Anderson powerpole connector.
IMG_20160202_110907793_HDR (Medium).jpg



IMG_20160202_111738375 (Medium).jpg



Now installed on the wire I intend to use.
IMG_20160202_112325506_HDR (Medium).jpg


So lets tie wrap the wire up under the dash where it will be semi-protected from any weather if the tractor is left to set out (which I don't do anymore), and be sure to route the wire away from any moving parts and get it connected on to this green wire on the fused side of the circuit. i "tinned" the green wire and "sweat soldered" my new red wire onto this existing wire.

IMG_20160202_114315239_HDR (Medium).jpg


Here is a bottle of liquid tape I intend to coat the soldered connection with, and I used a heat gun down low to dry it and also put a little scotch 33 black tape over it for abrasion resistance, not that there should be any as nothing should move there.

IMG_20160202_114343228_HDR (Medium).jpg


Here is the fuse block back in place with the negative wire terminated in a spade lug under the bright shiny screw at the bottom the the fuse block. I would not do this practice for any high current application, but this very low current charging circuit should be OK with using the tractor chassis for this. If I was looking to pull or push some high current, both wires would have went directly to the battery, fused with its own inline fuse.
You can just see the Anderson Powerpoles peeking out under the plastic "dash"

IMG_20160202_115316897 (Medium).jpg


Finished, tested, and tools put away.

IMG_20160202_120714092 (Medium).jpg


I hope you liked this little pictorial. I made the photo's full size so you would not have to open the thumbnails. I haven't done that before in any of my writeups. The actual solar charger is on order, and of course I will put Anderson Powerpoles on its wires and just plug it in.:) I have used one of these for my lawn tractor for many years and it extends it's battery life several years.
 
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/ Adding Solar battery maintainer connectons. #2  
Nicely done. So your basically back feeding to the battery correct? Are you going to put fuse back in or would that cause problems?
I just want to get everything straight in my head because I'm would like a setup like that for my 1 amp charger.
 
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#3  
Nicely done. So your basically back feeding to the battery correct? Are you going to put fuse back in or would that cause problems?
I just want to get everything straight in my head because I'm would like a setup like that for my 1 amp charger.

Yes, the fuse goes back in to protect the wiring I have added as well as the original accessories and complete the circuit.
 
/ Adding Solar battery maintainer connectons. #4  
Nice clean job. Which battery maintainer are you going to use?
 
/ Adding Solar battery maintainer connectons. #5  
Nice job, and nice installation. I have similar plans, but have hoped to take a short cut.
My DK45 is cabbed and comes with a cigaret lighter outlet. My original plan was to plug my solar charger into the cig outlet, but I discovered that the outlet was energized through the ignition switch, meaning it wouldn't charge when the tractor was parked/shut down. I now need to re-route the lighter outlet so it is constantly connected before I can use my charger as planned...it is still simpler than undertaking a project to install an entirely new circuit for the charger.
 
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#6  
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#7  
Nice job, and nice installation. I have similar plans, but have hoped to take a short cut.
My DK45 is cabbed and comes with a cigaret lighter outlet. My original plan was to plug my solar charger into the cig outlet, but I discovered that the outlet was energized through the ignition switch, meaning it wouldn't charge when the tractor was parked/shut down. I now need to re-route the lighter outlet so it is constantly connected before I can use my charger as planned...it is still simpler than undertaking a project to install an entirely new circuit for the charger.

Keep in mind that a cig. lighter male plug has an exposed positive center conductor and an exposed negative conductor. If it should come into contact with metal on both of those conductors at the same time, it would short circuit your charger. This may or may not be a problem. Just something to consider. With the Anderson powerpoles both conductors are recessed in the plastic housing on both halves of the connection.
 
/ Adding Solar battery maintainer connectons. #8  
You mentioned that you are not leaving the tractor "out" any more, are you using a long line from the solar charger to the inside tractor? I assume that the solar charger is outside.
 
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#9  
You mentioned that you are not leaving the tractor "out" any more, are you using a long line from the solar charger to the inside tractor? I assume that the solar charger is outside.

The solar charger will be inside the barn mounted in a southwest facing window at an angle. Much like the one in my other barn that keeps the garden tractor battery in good shape. Sure there are some losses in dirty windows etc, but you just need something to keep the battery from self discharging over time, and these small chargers are enough for this. There are waterproof outside solar chargers available of course for a few dollars more.
 
/ Adding Solar battery maintainer connectons. #10  
Nice, i wish I had one of these on everything I have, being gone to work a month at a time they sure would help. Good job! LUTT
 
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#11  
The Sunforce charger came in late today, so I added to its cord length, and put on some matching anderson powerpole connectors. Note, these connectors are hermaphrodites. Each end of the connection are neither male nor female. This allows for no exposed connections on either the battery side or the charger side, both of which are "hot" with voltage and current capability.
Here is the unit in the box

IMG_20160204_1(Medium).jpg



A quick check with the meter reveals it is putting out voltage, even under shop lighting. Do you like my analog meter? I have had it for almost 50 years
IMG_20160204_2 (Medium).jpg



Some Detail on how the Anderson powerpole connectors go together.
IMG_20160204_4(Medium).jpg


Finished powerpole connector, note the crimped on ends are inserted into the plastic bodies and are retained by a flat spring inside the body.
Once inserted, they are practically impossible to remove without damage. Listen for the "click" and get it right the first time :)
IMG_20160204_5 (Medium).jpg



Original cable and new cable with connectors on end spliced with automotive butt splices with Scotch 33 tape added for strain relief
IMG_20160204_6 (Medium).jpg



Finished product ready for mounting on the window frame in the barn. Note the 45 degree wooden blocks added so that the panel will tilt back and face the sky instead of being perpendicular.
IMG_20160204_7(Medium).jpg


Once this is mounted on the window frame I will route the cable over to the tractor on a simple swing arm I made out of piece of scrap metal. The purpose is so I can swing this cable back towards the barn wall or out closer to the tractor for connection. More pix to follow when I get it all connected up.
 
/ Adding Solar battery maintainer connectons. #12  
What type of wire crimper did you use on those?
 
/ Adding Solar battery maintainer connectons. #13  
You do very nice work Mr. James.:thumbsup::)
 
/ Adding Solar battery maintainer connectons. #16  
You can see it here:
Thanks, I missed that. The crimped connectors you showed looked so clean the way the collar was rolled down into the wire, I thought maybe it was done by a special tool.
 
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#17  
Thanks, I missed that. The crimped connectors you showed looked so clean the way the collar was rolled down into the wire, I thought maybe it was done by a special tool.

Nope, just cheap tool and lots of experience.:D
 
/ Adding Solar battery maintainer connectons. #18  
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#19  
Looks like a T&B crimper I have.

I went and looked at it and it is apparently a Gardner Bender GS88. I am not sure where I got it, but maybe Lowes in the electrical department, I think they sell a lot of Gardner Bender stuff
 
/ Adding Solar battery maintainer connectons.
  • Thread Starter
#20  
Thanks, I missed that. The crimped connectors you showed looked so clean the way the collar was rolled down into the wire, I thought maybe it was done by a special tool.

They make a high dollar special tool just for crimping on Anderson Powerpoles connections, but I don't have one. This seems to work well.
 

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