The Junk Sicence 12volt Guide.

Introduction
Converting to a self contained, or self-generated power supply can save a bundle of money over the long haul, but some aspects of it can be terribly expensive. This Ebook will look at both the "accepted" ways to do certain things, and then look again at the "Junk Science" way. the reader can then make an informed decision, based upon solid information and a firm knowledge of the contents of his/her wallet, as to how best to proceed.

One of the best things about a self-contained power system is that it allows us to have all the comforts of being on-grid, without being plugged into an electric outlet. This 12 volt system can be a joy or a headache, depending on how you maintain and utilize it. If you ignore basic maintenance, it'll let you down at the worst possible time! An understanding of the components and principles involved is necessary to get the most out of your 12 volt system. Relax, though... it's "Junk Science", not "rocket science"!.... your 12 volt system is simple and very easy to understand and maintain. Let's take a  look at a block diagram of a typical RV 12 volt system.

 
See.. there's really nothing to it! In the simplest terms, you can have lights and other equipment such as water pump, fans, stereo, etc. that can run on 12 volts, a battery bank that supplies the 12 volt power and some sort of charger to replenish the energy that you use from the battery. Of course, it's possible to add lots of useful components to this simple system to make it more flexible, but the basic 12 volt system starts with the components shown above.

As you read through this information, we will talk about all the different parts of this system and discuss some of the very useful additions and improvements that you can make yourself. Also included will be some highly technical info that you can bypass if it doesn't interest you. So, let's get started by talking about batteries. The battery is the heart of the 12 volt system. No other single component is as critical to the system's functioning as your battery system! That's why a lot of time needs to be spent talking about the care and feeding of your battery(s).

Batteries

Discovering the Battery:
Sure, we all know what a battery is.... it's that thing that goes dead when you leave the headlights on overnight! But, in reality there's a little more to it than that, so a review of battery basics is in order here..

Open Circuit  Battery Voltage
Approximate  State-of-charge
Average Cell Specific Gravity
12.70 / 6.35
100% 
1.265+
12.45 / 6.23
75%
1.225
12.24 / 6.12
50%
1.190
12.06 / 6.03
25%
1.155
11.89 / 5.95
 0%
1.120

Electricity:

Ladies, and Gentlemen! Step right up and learn about the newest idea to come from old ideas! You’ve heard about the industrial revolution, you’ve heard about the sexual revolution, you’ve heard about the political revolution… well, welcome, one and all to the 12-Volt Revolution!

That’s right, ladies and gents, you can join the 12-volt revolution today, and get rid of those annoying electric bills forever! With the simple implementation of a few inexpensive devices, you can be providing your own electricity, at a tiny fraction of the cost you’re paying now!

Okay, enough theatrics… here’s how:

Thanks largely to America’s “melting pot” philosophy, most of us have some amount of Gypsy Blood… which is another way of saying we love to travel! However, we’ve also been spoiled by modern conveniences, which run on electricity… and in order to allow these two facts to co-exist in our space-time continuum, it was absolutely necessary that we therefore invent… the motor home!

A motor home is really nothing but an automobile with comfortable living and sleeping quarters designed into it. And since automobiles in the modern world produce their own electricity, in 12-volt DC, is it any wonder that a whole plethora of devices were then designed to use that form of power while mimicking the operation of common household appliances? Televisions, microwaves, dishwashers, washing machines, hair dryers, toasters, you name it… the list is absolutely endless! And, for those few devices that just don’t adapt easily enough… there is the inverter, which converts 12-volt DC power to 110-volt AC in a flash… so you can run those devices as well!

Now, you don’t live in a motor home, but the cost of electricity and the dependence on a centralized system are both putting you at serious risk. So, a conversion to 12-volt DC might be in order!

There are many ways to produce 12-volt DC in sufficient quantities to power a home that’s adapted to it… Photovoltaics are probably the most expensive, converting sunlight to electricity, and it’s a great system… if you can afford several thousand dollars! But I naturally assume that you can’t, so here’s my suggestions:

First, we’ll start with the small home generator. This machine can run about three hours a day on half a gallon of gasoline (or alcohol, if necessary), and will charge a bank of a dozen 12-volt batteries in that time. A dozen batteries should provide all the power you’ll need for a day, so starting this generator and letting it run for a few hours every day can take care of your electricity needs… and if you do run low on power, during and weather for instance, you can fire it up for an emergency boost, something you can’t do with a photovoltaic system!

All it is, as you can see from the photo, is an old three horsepower lawnmower that drives an automotive alternator instead of a grass-cutting blade. The alternator charges the batteries just as it would in a car, and the simple wiring diagram that makes it work is shown in the figure below. Even if you don’t have the parts, you should be able to get them and build this… or have one built… for under $100.00. The battery mounted on the generator provides a source of portable power when you need it, as well.

The wiring diagram to the right shows how to connect the alternator so that it charges the battery. On the back of the alternator, you’ll find three posts, and they’re marked A, G and F. Wire them as shown in the diagram.

 

The hot wire running to the field post will provide the initial startup charge that energizes the field when the engine is running, producing electricity.

While the diagram does not show it, a simple toggle switch should be placed somewhere between the positive post of the battery, and the field post of the alternator. Turn this switch on to charge your batteries, and off when the engine is not running, to prevent any drain of your power by the alternator itself.

If you have large AC-powered devices that you absolutely cannot live without, such as washers and dryers, well pumps, or air conditioners, you can still use this method, but you’ll have to make two adaptations… first, use a larger engine, at least eight horsepower, and second, locate a five horsepower (or larger) single-phase, 220 volt AC electric motor. Run both the auto alternator and the AC motor with the engine. When you want AC power, you’ll have to start this engine, and idle it so that the motor is driven at its rated RPM. At this speed, it will produce about 90% of the electricity it would normally consume. The wires that lead from it can be fed into your breaker box… but be absolutely certain that you know what you’re doing, and that you have the main incoming power disconnected before you do it! With this system, you can run large appliances or tools… but you’ll be burning gas all the time you’re running them, so I strongly recommend looking into 12-volt or other alternatives (for instance, did you know you can still buy a gasoline powered washing machine???)

Batteries: A battery bank is the next part of your home power system. As any DC electrician will tell you, the biggest problem most 12-volters run into is excessive battery drain. Using automotive batteries is possible, and if you have a source for them at little or no cost, then by all means go for it! But what you really need is marine or golf-cart batteries, and here’s why!

Marine and cart batteries are designed to be run dead, then take a charge again! An automotive battery isn’t, and if you run it completely dead a few times, it’s gonna reach a point where it won’t come back! Deep-cycle batteries can be bought at most boat supply stores, golf pro shops, even Wal-Mart, and if you’re going to be using this for your primary power system, they’re well worth the investment.

Your battery bank should be set up in a location that can be ventilated! Many batteries give off hydrogen and sulfuric acid fumes, and this can be an explosive mixture when it meets oxygen! I’d store the battery bank in a small ventilated shed (which can be built from pallets, like our OFS  in the last section), on a porch, or in a garage with a vent opening just over the racks that hold the batteries.

Wiring: Your household wiring will carry 12-volt current, but you’ll need to change outlets and light fixtures. There are 12-volt light bulbs that can screw directly into your normal sockets, but they are expensive, and we’ll be going over a much cheaper alternative in a few moments. If you’re going to a full 12-volt system, then you can adapt your existing wiring by replacing outlets with automotive cigarette lighter plugs, which you can gather up at a junkyard, or buy from auto supply stores or department stores. If, on the other hand, you plan to keep grid power for backup, you may want to run separate wiring for your DC fixtures and appliances, or you can merely select which circuits from your breaker box will become DC-only, and wire accordingly. WARNING: unless you really know what you’re doing, don’t even attempt to mess with your household circuits! Call an electrician and get it done right!

If alternating current is an absolute necessity, for instance to power a welder or other necessary device, I suggest you look into a small diesel engine. If you’re mechanically inclined, you’ll find that a 3-53 or 3-71 Detroit engine is fairly simple to repair and maintain, and being diesel, it has an advantage that few people will tell you about: it can run on just about any kind of oil! Diesel fuel, kerosene, soybean oil, used motor oil (filtered, of course), even waste cooking oil… it may take a little work to collect and filter the fuel, but it will make that old motor tick right on over!

However, there is more energy there that you can harness! Connect the cooling system to your OFS, running the water that cools the engine through coils in your hot water storage tank before it goes to a radiator for cooling, and you’ll be able to capture all that heat, too. Hook up a water pump to draw water from your well and pump it to an elevated storage tank, to bring water to your home. An air conditioning compressor can provide a boost to your home refrigeration system, or maintain a freezer for meat storage in the hottest part of the year. And don’t forget… the alternator can keep your battery bank fully charged!


OK, now that you know all about batteries and charging, let's put some of that stored energy to use. There are a lot of things that you can do to make your RV home more comfortable and energy efficient. There are even a few projects illustrated to spur your creative urges.