Building of Fringelab, part 3

Written by peterkienle on November 29, 2016

Even though you sometimes see buildings and trailers wrapped with this Tyvek stuff exposed for longer periods – maybe the funds ran out before adding the siding – I liked to have a little more protection from the elements. As per recommendation by my good friend and indispensable advisor Dave Weber, I decided to use cement fiber board. I borrowed the truck once again to get a load of 4×8’ plywood panels for the interior and about 50 7”x14’ cement fiber planks. I thought loading these on the truck would be easy. But they are just about 6′ longer than the truck bed. And these panels are very elastic – or “floppy”. I wasn’t worried I would loose my load like a few months ago but going through potholes the boards would swing vertically enough to touch the road. But I made it home.

The key, again, was to figure out a way how to hold these 14’ boards up with one hand, at the correct vertical distance to the previous board, and keep it straight, while being high on a ladder – and then lift the nailer and pull the trigger… My muscles were very sore for a few days (I lost about 8 pounds of weight, too.)

October 11. Installing siding on this wall was relatively easy. No openings. Just straight up. You should always start with the easiest task, right?


October 12. Cutting and installing these window frames on a good old miter saw was such a relaxing job in comparison.


October 18. Monika was already on her Europe trip but I think the kids wouldn’t have been surprised to see me walking around in the house like that.


Of course there is always something that doesn’t quite line up. That’s when you improvise.


October 29. Most of the extra crucial exterior stuff was done and I started adding insulation and interior panels. I thought about using drywall but considering that I would attach countless racks, holders, shelves and other stuff to the walls plywood panels seemed a better choice.


Wes and his assistant, my electricians from Atomic Electric, had already laid cable and installed boxes for the outlets, light fixtures and switchbox. In the picture below you can see my desperate attempt to fill some gaps with insulating foam. I guess this is easier when used with a sprayer machine of some sort but doing it through the flimsy plastic applicator that comes with the can is an insult.


October 31. The final wall was paneled on Halloween. I used wood filler in the gaps. Hoping that Atomic Electric would soon have a day to connect the power so I could stop using that long extension cord.


November 4. As long as I had been putting off starting this project, late Summer and Fall 2016 proved to be the right time. Probably due to global warming (I regret to say) there was an abundance of warm, dry days. Rarely did I get a break due to the weather.

I didn’t originally intend to build a little roof over the entrance but I thought it would be easier to add the bracing now rather than later have to break through the siding.


At this point all the interior wall paneling was installed and painted. I found out that our local recycling center takes buckets of unused paint that you can pick up for free. Well, they had one white and one purple bucket. It was free. And it’s a nice color combo. I also added some cheap trim to the corners and the base of the walls. Just looks cleaner.


How can you not like the purple?


November 10. Major milestone. Two days earlier Atomic Electric finally had a day to swing by for the final electrical installation. This workshop is geographically at a nice sunny spot on our property but also exactly on the opposite side from where the power lines connect to the house. At first I was afraid I would have to dig a trench for the cable all around the house. But there is so much growing, especially some larger trees with big roots. It would have been a nightmare. So we decided to run the cable in a pipe along the underside of the deck in the back of the house, then along the side wall and finally through a relatively short 20’ trench under the driveway. Trenching under the driveway was hard enough. Very rocky and well compacted soil. My whole body was aching, but especially my hands. I tried to play a little guitar that evening but had no fine motor control left in my fingers.

Then Zack helped me move the workbench from the basement to the workshop. It wasn’t long now. Not October, not November, but it would be done before Christmas.


November 15. One of the last things before a full move-in was insulation in the ceiling. There had been a few colder days and the little radiant oil heater I had to keep the place warm worked fine but you could tell that a lot of heat was escaping through the ceiling. So insulation it was and since you can’t leave that exposed I needed some sort of ceiling. More improvisation ensued. But who ever looks up?


November 24. By Thanksgiving break I had most of the bigger machines and tools in the workshop. Including the CNC rig. I wanted the basement to look nice and clean for Monika’s return from Europe. While the mechanical part of the CNC setup worked I had just updated the Dell PC I use to control the CNC machine, which has the hot name Fireball, to a newer and different flavor of Linux. The Fireball control interface needs a computer with a parallel port and these old Dells still have them (I have two of the same type, with Linux they are quite usable.) Since the workshop is in clear line-of-sight of my office there is great Wifi reception out there but after the upgrade to Debian Wheezy neither of the Dells wanted to use Wifi. Another few afternoons of research and reinstalling. As so often the cause was obvious once I figured it out. As much as I love Linux but troubleshooting it sucks.


It looks nice now….


I still have to build and install lots of storage for tools, materials and all the stuff. The top of the workbench should really be free of all that crap. But for now it feels like home.


November 28. While there is still some stuff to cover on the outside, painting the outside, maybe installing that little roof over the door…. But this day Fringelab is officially done and ready for full usage.


What looks like playful decoration, the red thing under the ceiling is a hammock. Tried to nap in it but it’s a bit uncomfortable.


November 29. And here is the simple firewood rack I started building earlier in the year, finally finished. The circle closes. The project is done, what do I do next?



Building of Fringelab, part 2

Written by peterkienle on

Back from trip to Germany and Scotland on August 1. After measuring, I noticed that most of my posts had been seriously knocked out of alignment during the cement pour in July. I cut all of them off, except the front two 6×6” posts. Revised my plans and decided to go with a 12×12’ floor and use the front with the posts for something else.

August 28. In the past weeks I spread three tons of #3 crushed stone, built the stairs and we are now ready for the floor panels.



Finally started framing after mounting the 3/4” plywood floor panels on a revised foundation frame. To get the considerable load of heavy lumber and panels from the store to my construction site I borrowed Dave Weber’s red truck a second time. I am not an expert in any of this stuff – apparently especially not in loading studs of various lengths, 4×8’ plywood panels, and 4×4″ posts. On the way from the store, in a shallow curve on the ramp from W 3rd St onto SR37, the whole load decided to slip off the truck. Luckily, it was Sunday afternoon and hardly any traffic. Like in a movie. I felt the load shift and then saw in the rear view mirror how $300 worth of lumber literally fell by the wayside – all in slow motion. Immediately another driver stopped and started diverting traffic. Another guy jumped out of his car and started helping me collecting the dozens of pieces of lumber. Only minutes later a police car arrived and put the lights on. I thought I was going to jail. But the officer made sure other drivers were aware of the situation until everything was loaded back on. Then I found a pair of super heavy duty cargo ratchet straps (or whatever they’re called) behind the seat. The rest of the 12 minute drive went smoothly. Unloading everything did me in for the day.

While mounting the floor panels I hit my left index finger with the hammer. That was the only injury from the whole project. The finger nail turned black and has only recently fully regrown, outlining the timeline of the project.

September 5. The rear wall was the easiest to frame. In all of this I can’t emphasize enough that clamps are super important to hold stuff. Also, Dave had borrowed me his pneumatic nail gun. What a time saver.





Sepember 6. Wall framing is going smoothly.  No wonder, I had the plans and measurements all worked out. I thought I would be done by October….





September 12. It was really coming along and felt already pretty stable with the OSB side panels up. At that point I didn’t know yet what was going to happen with the front wall. I thought I might pick up some random used windows and do something creative. Also at that time I realized that the way I had intended to frame the roof was not going to be strong enough. Originally I had 16’ 2×4”’s with no support in the middle. This is where the improvisation started.



September 15. After two days of building three major cross supports for the roof I realized that there would be a little attic. To come in handy for lumber storage. Also, strong enough to hang a hammock.



September 18. Overall, one of the hardest things in the project was that I only had one pair of arms. While Zack helped me hold a few of the 4×8’ OSB side panels I just couldn’t wait every day until he was home from school. So, clamps again. A whole other adventure were the roof panels. Somehow I had to get four full size and four half size OSB panels on the roof before the next rain (the exposed plywood floorboards started to dislike the little rain we got). 4×8’ OSB panels are not only heavy but also not exactly easy for a single person to carry. Apart from starting the project in the first place figuring out a way to get the panels 12 feet up on the roof was probably the most challenging. I wish I had taken a picture. Where you see the ladder in the picture below, I built a guide at the roof edge using a short 2×4″ and a clamp (see, again). Now I could lean the panel that was going on the roof against the side of the structure and slowly push it up, while climbing the ladder. The critical point was when the center of the panel was balancing on the edge of the roof. One step higher on the ladder, one more push so that the panel was more than half up. Then let go and it would flip up while the guide piece prevented it from sliding down the back. Kinda a dangerous and painful but it worked.

Once I had two panels up I climbed up to nail them down so I had something to sit on. Then I “transported” the rest of the panels up and was so proud of myself. I was going to beat the rain after all. I moved the ladder inside the structure and put all the tools on the roof. Now, when you use a nail gun you want to wear ear muffs to protect your hearing. Also, some safety goggles are good. So my visual and aural senses were well shielded from the outside world as I was nail-gunning away on the roof. It had been cloudy and muggy all day. I was sweat drenched and didn’t realize that a very light rain had set in – until  a lightning bolt came down really close (the thunder was almost instantaneous).  I was one half panel away from finishing but realized that I had to leave it at that. Luckily, I had a few of my clamps (see, again) up on the roof and was able to clamp the loose panel so it wouldn’t fly off in the storm. There was now one 4×4’ opening in the roof – but the ladder was at another spot, not where I needed it. This was when I would have screamed for help but nobody was home. I had to somehow get off the roof. Eventually, I managed to climb into the rafters and under the roof to the front where I could let myself down. Felt like a monkey.



Some of the improvised roof supports.



September 23. Finally, it was save to start storing some of the tools and materials under the new roof. Before, I spent every day half an hour in the morning, schlepping air compressor, nailer, miter saw, table saw, etc. From the basement to the construction site. And the same in reverse in the evening.



September 27. As I mentioned earlier, I was going to think about that front wall and windows when it was the right time (improvising again). Well, the right time came and I picked up three really nice looking windows plus a cool, large door at the Repo Store in Bloomington. Luckily, it was 50% off sale and with other rebates everything was less than $20. It turned out that the windows were unusable because they required a specific frame that nobody knew where to get from. I picked up three plain vanilla windows that were on sale from the hardware store. Then I started adding some (improvised) framing to the front wall. By the time I had put the panels in I needed a lot more studs – the panels need to be attached to something.



September 29. At last. Fully enclosed (sort of) and a panel blocking the entrance opening so that the cat can’t go in to poop.




October 2. I had thought that I might be done by early October. But there were so many little and big things to do, still. Since I wanted this structure to be reasonably dry, heatable and comfy (after all, computers and all sorts of electronics are supposed to be in there, not to mention a hammock for the occasional break) I decided to use house wrap. Sounds easy. But again, a single person has to be very creative to find ways to hold these large, slippery sheets in place while putting the fasteners in.



October 5. By the time I started installing the windows the usefulness of that strange front bracing had itself proven again and again. Strong enough to stand on, lay on heavy boards as scaffolding, and accommodate eventual visitors on camels or giraffes.



I had planned on a wider door because I was concerned that my CNC machine wouldn’t fit through. After some measuring I was convinced that this 30” door from the Repo Store would be fine. Actually hanging the door and making it fit was a bit nerve wrecking.



Adding some extra framing and panels to fill the gap by the door finally gave me a fully enclosed space. Another landmark. I thought I would be done within a week or two.

Continued in part 3.

Building of Fringelab, part 1

Written by peterkienle on

It all started with Dave Weber’s drill press.

After last Winter (2016), I thought I should build a little rack to stack the firewood in our crowded basement. This was from a neat plan in Popular Mechanics magazine. Among other things it required some easy metal working. When I asked my friend Dave what drill bits would best drill through metal he said: “Here, I have this old drill press. Do you want it?” After taking the big, heavy hunk of tool home I realized that it would have to be taken apart, cleaned, oiled and then some. Over the course of a few mild days in March I carried the machine, in various stages of disassembly, outside to do the thing and then back in before it turned too wet or dark. After it was all put together it looked (almost) like new and worked – but where was I going to put it? The large basement room, which was supposed to be a rehearsal and ping-pong facility, was already full of saws, computers, a CNC machine and wood scraps of varying sizes….

This is the point in time when I knew I needed an external workshop where I could paint, and make a mess and noise year round.

Not that it was such an original idea. A few years earlier I had toyed with the idea and even staked out a small plot next to the garden shed. But that project then fell by the wayside because it looked for a time that we might actually move and sell our house. But the stakes and the marker lines where still there – I mowed around them every time I cut the grass.


Like with every project of that size I dreaded getting started. Like the kitchen remodel from 2012, once you start you have to finish. And this one would be seen by every one of our neighbors. Nevertheless, in late May 2016 I broke ground. The first holes on June 30, 2016….


2016 turned out to be a dry Summer and work progressed quickly. My wife Monika left for a longer stay in Europe in early June while younger daughter Jasmin and I were to follow for a two week stay on July 16. The plan was to have the foundation done and concrete poured before the trip and finish after in August.

July 1 saw me setting and aligning posts. At that time I hadn’t really planned the rest of the structure. Rather I thought I was roughly going to follow a plan from an issue of MAKE:, which called for a 12×16 foundation. My maximum size was 12×14 feet and I hoped to adapt their plan.


July 5. If I could travel back in time I would tell myself that these holes really should be better aligned. Boards and panels are 4×8’ for a reason and your foundation should take that into account.


July 7. Looks good so far.



July 12, the evening before the cement delivery, I realize that I also need some sort of stairs. Extra digging ensues.


July 13, morning. One last picture before cement truck covers everything.


July 13, afternoon. Why would I use long 6×6” and 4×4” posts that would make it nearly impossible for the cement truck operator to navigate the chute through – in the process throwing off my careful alignment? I had finally decided to not go with the MAKE: plans. They were using some sort of arch/girder system to make sides and roof. It would have required 11 of these pieces in my structure. Each piece comprised of four large OSB side pieces cut from a 4×8′ panel by a huge CNC machine (or a hand saw?) This would have been 44 large, complicated pieces, cut by hand. Glad I abandoned that idea. I was going to go with a more normal framed structure. But I wanted to incorporate the foundation posts, at least the 6×6″ corners. And now they were knocked out of alignment.


July 13, evening. Our little puppy Joy looks at the mess (construction site and constructeur).  That day, with the frantic last minute hole-digging and 90 minute non-stop concrete pour did me in. I haven’t been drinking much alcohol since a few years, but I thought I would drink a cold one that evening – and promptly passed out on the couch.


Two days later off to Germany. We’ll deal with the kinks when we come back.

To be continued in Fringelab, part 2……..

Solar Power update (part 8)

Written by peterkienle on February 3, 2010

(continued from part 7)

So here we are. February 2010. We had our solar array online for close to a year now.
What are the first year impressions of our life with a 1.2kw solar array in our front yard?

First, if you read the initial installment of my solar power posts you will notice that we built a post with a mount laid out to hold 12 panels. Because 200W panels aren’t cheap we only populated half of the array at first. These six panels were actually only 195W a piece, so to be correct they only add up to 1170w total. Since going online on February 11 2009 we made 1361kwh as of January 31 2010. The array has been producing power for just over 4010 hours. The power output during the course of a nice sunny day starts up around 8:30am (in the winter) with just enough wattage to turn the inverter on, typically 10 watts or so. Around 11:30am, when the sun clears our roof and hits the panels full on we are up to 800 watts which will quickly ramp up to 1050-1150 watts just around noon. It stays there until 2:30pm or so and slowly creeps back down to 50 watts around 5pm. On a sunny, cloudless day this will produce between 4.5 and 5.2kwh. In the summer we get up to 7.5kwh on some days. Of course if we have a very cloudy sky the power never exceeds 50 watts. January around here is like that sometimes. Total electricity usage in our first year with the solar panels was 14,320kwh. That means the panels contributed a little under 10% of the electricity used at our house.

As it turns out my installer, Alex Jarvis from Solar Systems of Indiana, helped me to sign up with a company by the name of Sol Systems which brokers SRECs (Solar Renewable Energy Credits). Based on the size of your system you get a yearly check for offsetting carbon output. I actually did get a check of a couple of hundred dollars for the first year. More than the $85 I saved on my power bills.

One other thing is that my system over-produces sometimes. In other words it makes more power than we use in the house and we get credit for it from our utility company. Unfortunately the credit that we get back is a little more than half of what we pay (we pay $0.0631 per kwh while we only get $0.03357 for a kwh that we feed back in.) Unless we overproduce during peak times – then we get a credit of $6.67 per kwh! During last summer we were actually able to still produce around 500 watts during evening peaks and it turns out it is a good time to turn off everything non-essential in the house for an hour to feed back as much as possible and get the peak time credit. If you can feed back half a kwh on 10 days in a month it adds up to a $40 credit on your power bill – pretty substantial.

Then, on January 5 2010 Alex came over and we added six more panels for a whopping 2370kw. This what our array looks like now:

Why, you ask, would I spend another $4,500 to add six more panels? I mean, I really *only* made about $285 last year. If nothing else happens, nothing changes, the price of electricity stays the same or the days become longer it will take me 33 years to break even, not counting at least one inverter replacement for about $2k in that time – and that calculation does already include a 30% tax break.

The answer isn’t exactly simple.

1) While looking at my power bills, we developed strategies to use electricity when we get it for free from the panels. We learned that dishwasher, washing machine, dryer, computer tasks involving multiple computers, etc. are better done during the day to use power from our solar panels rather than the grid.

2) With the help of a Kill-a-watt, which shows you how much energy a connected appliance draws over a given time, I was able to locate some real energy wasters in the house. For one, the dehumidifier in the basement is now turned off – that things sucks 300-400 watts! That’s about 3000kwh in a year! The solar panels make me really conscious about that stuff.

3) We have about 4-5 months in which we can actually overproduce and feed back power during peak times. With 12 panels we should be able to maximize our credits considerably.

4) While at the moment the 1/2 ratio between what we pay for a regular kwh ($0.0631) and what we get credited for ($0.03357) seems quite unfair, this will change eventually. Even in Indiana the law says utilities are required to pay retail rates for power fed back into the grid. It’s just that our power company is a coop and they are still excluded.

5) While our initial six panels were $1200 a piece and rated at 195w the new ones we put on just three weeks ago where $800 and are rated at 200w. So prices have dropped.

Today was really the first full day of sunlight since we installed the additional panels. Just before shutting down the inverter read 10.41kwh produced. And that’s pretty cool. Considering that on average we use about 39kwh in a day that’s about 1/4 of total electricity from solar. I am sure we will find more holes to plug in the walls and more ways to save energy. It should be an interesting year.

Solar Power bucket of salt (part 7)

Written by peterkienle on March 7, 2009

(continued from part 6)

After all the good vibes coming out of our solar installation I really need to reinforce something I knew long before I decided to spend almost $15,000. You can’t really predict the weather so we can only estimate our yearly average power production. Right now, in mid-February, on a cloudless day my PV system produces about 5.5Kw from sunup to sundown. Let’s assume during the summer we might get up to 8Kw per day. That’s an average of 6.75Wh and for simplicity round this up to 7Kw. If we have 365 cloudless days we would produce 2,555Kw in a year. At a cost of $0.105 per Kwh that should save me about $268 in a year. I realize that I can only get realistic numbers after monitoring my power output for a year but this amount is pretty close.

Here are two facts to consider about PV panels and alternative energy:

1) If I can produce all the electricity I need at my home during the day with my panels I will still need power after the sun sets. There is just no way around it, I will need the power from the grid until something better comes along. My PV installation will only cover about 15-35% of my usage unless I increase the number of panels four or five times and buy a few tons of batteries for storage. A system of that magnitude would cost me close to what I paid for the house.

2) Driving through my rural neighborhood I notice that many homes have outside lights. And more than half of them are on whenever I drive by. Day or night.
Now assume that’s a 200W bulb in there. Leave it on for 24 hours and your meter will move by a whopping 4.8Kw. That’s almost as much as my PV system makes at the moment in a day. If you leave that turned on 24/7/365 it will use 1,752Kw in a year. Now throw in another 100W for phantom loads such as VCRs, DVD players, cell phone chargers – all stuff that’s not turned on but still sucks a few watts while it is connected. All of a sudden you are looking at 2,628Kw per year that you could save just by switching that outside light off and investing in a few switchable outlet strips. That’s $263 in a year. Pretty close to what I save with my panels! And you almost get it for free!

There are a few reasons why I got the panels anyway.

1) In the long run – 20 years or so – I’ll break even and then the system still has 15-20 more years which will be savings in my pocket.

2) I wanted to learn how this is done. The digging, the wiring, all of it. There is nothing like some hands-on experience.

3) I wanted to do something else than just donate a few bucks to various political causes.

4) Not a week goes by without somebody stopping and asking about that strange thing in front of my house.

But frankly, unless there are some seriously cheaper and more efficient panels, a modern power grid and practical storage of overproduced electricity I don’t see how solar panels can make a significant impact in the overall energy budget. It’s a drop in the bucket as are many other alternative technologies at the moment. Of course many drops also fill the bucket eventually. But I think whoever claims solar power alone, or wind power alone can replace all the nuclear and coal power plants is delusional. At the same time it’s equally delusional to think that things will just go on as they have been.  Lots has to be done and everyone has to be more conscious about energy usage.

If nothing else, the PV installation in my front yard, and several others in and around my town show that things are changing. People are waking up. We should have paid attention after the oil crisis of the early 1970s. We could have altered our course a bit after 9/11/2001. Instead, we stick our heads in the sand and pretend everything is cool.

To conclude: For me the installation of a PV system in my yard is only a beginning and not the solution – but it can be a seed for a small part of a solution.

(continued in part 8)

Solar Power (part 6)

Written by peterkienle on January 28, 2009

(continued from part 5)

We’re still waiting for some insurance details to be cleared up. But at least finally the people from SCI-REMC, our electric utility, were here to do an inspection and a test run of the system. A nice, warm day (for January) enabled Alex and me to swing the mount to its proper angle of 45 degrees. Now, that really looks imposing. The people on my street finally know what’s happening.

It was very sunny that day and on the test run the inverter showed close to 1100 watts. That’s pretty close to maximum. I plan to keep track of electricity production once our system is officially running. The panels were pretty dusty since the ice, sleet and snow of the past two weeks weren’t able to slide off while the assembly was horizontal. Unfortunately the garden hose was still frozen so I couldn’t clean them.

We did get a new electricity meter. Pretty cool one. When we moved into the house in 1995 they still had to come to the meter, read the numbers and write them down. Then, a few years ago they installed a new meter which sends the reading wirelessly to the person driving by with a truck. This new meter sends its data through the power lines. It will measure how much electricity goes INTO the house as well as how much my PV system generates back into the grid. That probably isn’t a lot most of the time. It cycles through these five modes:
1. Kw – REMC delivered energy in 30 day billing cycle.
2. Kw – Peak or total consumer used kW over the last 15 minute period.
3. Kw – total energy consumer generated back onto REMC’s grid.
4. Kw – peak demand during peak period.
5. Kw – consumer generated energy back to the grid during peak period.

Plenty of numbers to be able to analyze how this will be working out.

I hope to be able to keep you updated on our status.

Solar Power (part 5)

Written by peterkienle on January 24, 2009

(continued from part 4)

Alright, so I’ve been a bit busy. Two weeks ago Alex came over with his friend Ken to put up the mounting brackets for the PV panels. For that they set up the scaffolding.

Here the panels are neatly laid out in our front yard. $1200 a piece! I sure hope none of my neighbors comes around the curve too fast with his truck and flattens these.

Now the electric connectors are put in.

All six panels are mounted! Even though both the brackets and the panels are not that heavy individually together it’s about 200 pounds sitting on top of the post. We didn’t know it at that time but the surface would stay horizontal for two weeks until the final inspection by the power company. Since this is a grid-tied system any electricity coming from the PV array that is not used in the house goes out, through the electric meter, onto the grid. In case of a blackout on the grid they need to be absolutely sure that the inverter will disconnect the panels from the grid so they can repair the line without having their workers fried.

The inside of the inverter while the last connections are made.

This is a pretty cool piece of engineering. It shows you how much power is produced in Watts, displays voltage, daily production (or more correctly from power-up when there is enough current from the panels to shut-down when the sun goes down). It also shows you how much carbon emissions were saved (or offset).

So now everything is ready to go. But we have to wait with the official commissioning until our electric utility people come for an inspection and some insurance stuff is cleared up. It’s like Christmas: You know where the presents are hidden, and even know what it is…..
(I did turn it on a few times just to see)

(to be continued)

Solar Power (part 4)

Written by peterkienle on January 17, 2009

(continued from part 3)

As a we are waiting to go operational I have some time to ponder the pros and cons of my $15,000 investment, alternative energies in general and solar in particular. Despite my feeling of doing something good for the environment and (maybe) for our bottom line I know that this technology is young, even though it has been around for decades, and like my computer the equipment I am installing might be outdated in a few years. Our calculations still show that we’ll break even after about 22 years. The system has a life span of 35-40 years. It is a very long term investment.

There is lots of talk these days about green energy and solar and wind are usually the first technologies mentioned. The problem with both of these is that you only get electricity when the sun shines or when the wind blows. There are really only two ways to have access to electricity when there is no sun or no wind: oversize your system and store surplus energy in batteries or a grid interconnect. Unless you don’t have access to the grid battery storage is really a bad idea. Electricity storage will have to be much more efficient than what is currently available to a homeowner. If you read Scientific American or MIT Technology Review or do a search on the internet you find many people doing great and promising research. Last summer I had a little test setup in my yard with a small solar panel electrolyzing water into oxygen and hydrogen. Nothing much came of it – maybe the plastic bag I used to collect the gases was leaky. More likely the electrodes were the wrong metal. At the same time I am not sure how safe I would feel if there was half a Hindenburg’s worth of hydrogen in a pressurized tank under my house. No storage then. But then each time the sun goes down you will draw power from the grid instead of your panels. So the power utilities can’t really scale down their power plants. Sure, if you work at home and most of your power is used during normal work hours you might be able to offset that with a solar array. But even if my whole street does what I do and nobody draws a single watt from the grid during the 4-8 hours of usable sunlight the power company still will have to keep their coal or nuclear power plant running. As far as I understand you can’t just flip a switch and turn them on or off. To my knowledge just gas power plants allow for relatively fast on/off cycling. At the same time changes in the electric infrastructure will take people like us into consideration.

Of course there are really cool proposals such as once we all have electric cars their batteries will function as energy storage while hooked up to the grid. One literally ‘cool’ idea I read about was to replace the current wires of the electric grid with superconducting material which is kept at very low temperatures by liquid hydrogen. Superconductivity means that electricity can flow through a conductor without resistance. Usually this is done by cooling certain materials to temperatures close to absolute zero. These would be pretty substantial ‘wires’ but they would function to deliver electric energy and hydrogen and could serve as giant energy storage reservoir. Not cheap, though. (September 2006  issue of Scientific American).

Then we also have the really huge stuff like solar power satellites in geosynchronous orbit around the Earth. Geosynchronous means the satellite is at such a distance from Earth that it appears to be hanging above the same point on the ground even as it is orbiting the planet at breakneck speed. Something like that could collect solar energy day and night. It would have to be huge (as in miles and miles of panels) and the energy would have to be transmitted to the ground using tightly focused microwaves or lasers. Since the US will lose manned orbital access for a few years after the Space Shuttle fleet is retired and NASA’s new rockets are not finished yet it doesn’t look too good for large cargo hauls to 36,000km orbits.

And, really why do I need to set solar panels up in my front yard if the payback is so long term that I can’t even be sure to still be alive to see it? Because it’s something that I can do now! This whole energy thing is made up of so many networked components that we can’t rely on one solution only. And we need to accept that it’s a moving target. Maybe more people would put solar panels or wind turbines up if you could buy them at Walmart. The fact that you can’t and that you have to actively make an effort to find skilled and knowledgeable people to help you with it forces you to learn about energy. I think that even if you end up not installing anything you will be much more conscious about your energy footprint and you will discover ways to waste less – or you stick your head in the sand (from what I understand ostriches don’t actually do this) and pretend that everything is fine and no change is necessary.

(to be continued)

Solar Power (part 3)

Written by peterkienle on January 3, 2009

(continued from part 2)

Together Alex and I started digging in my front yard in early October while our supplies were on their way. There was to be a big 3×3 feet hole, almost seven feet deep.

This was where our steel post was going.

The main hole soon got too narrow for two people and I started digging the 24 inch deep trench for the electric line going from the post to the house. You want to keep that as short as you can. The longer the cable the more power you loose on the way to the inverter. These are pretty hefty cables, too.

Of course, in the pretty Fall weather our two girls wanted to have a part in the fun.

Eventually the digging was complete. Most of the supplies had arrived. The first step was to set the post. This is one hefty piece of metal. Since we didn’t have a crane we devised a way to roll the 16 foot pipe with five people off the flatbed trailer, onto a four foot pipe of the same kind – so we could roll it towards the hole (it was a 20 foot post but since we needed only 16 feet we had one four foot piece left over). After the post was in the hole Alex started to prepare it for a concrete pour.

After that there were two days of electrical installations. There are actually two separate cable pairs going from the post to the house. Only one pair will be used at first. If we decide to add on a second row of panels all the wiring will be in place. These wires go into  the basement and connect to the inverter.

Made in Germany (I am proud to say). This piece of equipment turns the ~400V Direct Current (DC) coming from the panels into 110V Alternate Current (AC). After the actual solar panels the inverter is the most expensive piece of equipment needed. It’s also the one you will have to replace after ten years or so.

Then it got cold and we had to wait for the final paperwork from our power company. We will be the first grid tied solar installation of all their customers. I think they will watch us with great interest.

Currently (January 2nd) everything is ready to go. The panels are in the basement,

the mounting brackets are sitting under the deck,

and the post is waiting for a few days break in the weather.

(to be continued)

Solar Power (part 2)

Written by peterkienle on

(continued from part 1)

Alex, my solar assessor – his company is Solar Systems of Indiana – came over one cold winter day early 2008 with his Solar Pathfinder and a device called a Kill-A-Watt. The Solar Pathfinder is used to determine the best place on your property for a solar installation and how much sunlight you can actually harvest taking into consideration stuff like tree line and geographical location. The Kill-A-Watt is such a good investment that I got one myself and it makes the rounds through my friends’ houses. Do you know how much electricity your refrigerator uses in a day? Your computer? (with all attachments such as external drives and scanners etc. on?) How about your waterbed? Or your cell phone charger (which you probably leave plugged in even while you carry your cell phone around with you)? Even though I have been frugal in my power use all my life (and believe me, my wife and kids hate me for being after them all the time to turn the lights off when they leave the room), after Alex had measured the power usage of some stuff in my house I was able to cut back even more. In retrospect, the sheer process of measuring this stuff, and learning as you go, how much it costs to build power plants, etc. makes you very conscious about waste – and that’s a good thing.

Of course being the only Solar Assessor in my state means that this guy is busy. After his visit to my house he prepared a report for me. Pretty detailed. It turned out that my property had potential if we mounted the panels in the front yard on the ground or on a post – not on the roof. There are other considerations with roof mounting, especially penetration and possible weight issues. In the time from the assessment until Alex finally located some free time to start the actual planning of the installation (around June 2008) I went to a seminar at Indiana University dealing with many aspects of home solar technology. I learned a lot and thought for a while that I might actually learn some more, take a weekend seminar in Wisconsin, get certified and become the second Solar Assessor in Indiana. It didn’t go that way.

I spent most of July in Germany and then August, back home, writing down my energy usage to determine the base load to be able to size the system we were going to get. Base load is essentially all your power users which are on all the time such as refrigerator, computers, whatever. In the hot Indiana Fall, with the geothermal doing the AC,  I was able to determine the base load at just around one kilowatt. Then we started to devise a system.

  • 1)  We never had plans to go off the grid. I didn’t want an over sized six kilowatt solar array ($60,000) and a truckload of lead-acid batteries in the basement and then still face the possibility of running out of juice in the middle of February because of lack of sunlight.
  • 2) While utilities in Indiana are required to pay retail for what you overproduce and feed back into the grid our power supplier is a Co-op and they do not have to do that. They pay wholesale rates. So too much overproduction was not feasible. This pretty much sized our system at 1.2KW. Six panels, pole mounted, in the front of the house.

Then, in late September, came the $15,000 shopping list to the supplier. And early October Alex showed up at my house with a shovel and said: “Let’s dig!”

(to be continued)

Copyright © by Peter Kienle