Tag Archives: sub-panel

2014/09/05 (F) WordPress 4.0

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We awoke to temperatures in the low 70’s this morning and by noon it was forecast to be 85 degrees F with rapidly rising humidity.  We turned our A-C on yesterday and left in on overnight and through the day today.

WordPress 4.0 was released yesterday and just before midnight I updated the four websites I manage, including this one.  I was looking forward to working with the new version today, but first things first.  Darryll called at 8:15 AM to make sure it was OK to come over.  We finished breakfast and then opened the garage and moved a few things that might be in his way. Although we would have liked to continue working in the garage during the morning, before it got really hot and humid, we were glad to have Darryll here working on the HVAC installation.

Instead of working on organizing the garage Linda worked at her desk and baked a loaf of bread while I assisted Darryll.  He wired up the library thermostat and showed me how the wires were connected.  He installed the return air grill, which required some minor drywall trimming, and installed a 6″ combustion air duct in the ceiling of the utility closet.  The duct had a screen on one end with a hood, like a dryer vent, and was open on the other end.  He installed it from the attic side with the hood in the attic and the open end sticking down through the ceiling into the closet.  I may decide to caulk or apply drywall compound to fill that gap between the duct and the hole Darryll made in the ceiling.

Darryll’s main focus, however, was hooking up the four pieces of duct, two rigid and two flexible, that will carry conditioned air into the library and installing the two ceiling registers.  That involved working in the attic which was very hot.  The flexible duct for the two ceiling registers was the same kind of product that was used in the main house; a pre-insulated flexible accordion tubing with an 8″ inside diameter that comes in 25′ lengths compressed to about 3′ for shipping.  To feed the two registers on the lower part of the west wall of the library he cut lengths of 8″ diameter (circular cross section) metal duct and assembled them.  He attached them to the supply air duct (plenum) with flange connectors.  He then slide insulation blankets (tubes) around them and connected the bottom ends of the duct into the back of the register ducts using several elbows to bring the duct around and close to the wall.  Finally, he slid the insulation down and secured it.

While Darryll was doing all of that I finished connecting the AC power to the condenser/compressor. That involved the following:

  • removing the terminal cover panel from the inside of the fused disconnect box
  • knocking out access holes on the right side and bottom
  • mounting the fused disconnect box to the side if the house
  • cutting a piece of 3/4″ plastic conduit for the cable from the soffit to the box
  • running the NM cable through the conduit
  • installing a watertight 90 degree elbow into the conduit
  • attaching the elbow to the side of the box
  • cutting, stripping, and connecting the line wires
  • cutting the plastic armor on the hookup cable to the right length
  • installing a straight screw-in watertight connector on the box end of the armor
  • installing a screw-in 90 degree elbow watertight connector on the condenser end
  • cutting, stripping, and connecting the load wires in the box
  • cutting, stripping, and connecting the load wires in the compressor.

I had Darryll check my work and then installed the fuses in the pull-out disconnect but was not able to get it to plug all the way in.  Darryll bent the blades slightly and got it to seat fully.  (I need to get two different fuses.  All he had were 30A fuses but 20A would be sufficient.  Also, the fuses he had in his truck were notched on one end.  I think fuses with full barrels on both ends would be better as they would have more contact surface than the notched ones.)  I reinstalled the terminal cover panel and closed the box.  I then re-installed the cover panel on the A-C compressor that Darryll had removed earlier.

With the power connected and most of the ducts run, we turned on the 120VAC/15A circuit breaker (for the unit in the utility closet) and the 240VAC/20A circuit breaker (for the compressor/condenser).  Darryll turned the thermostat mode switch to “cool” and the fan switch to auto and the A-C came to life.  Hooray!  I love it when that happens.

While Darryll finished installing the ducts and the registers I connected and mounted the thermostat for the garage furnace and then connected the wires on the other end of the cable to the terminals on the back of the unit according to Darryll’s instructions.  I removed the end panel from the Reznor ceiling-mounted garage furnace, removed the documentation packet from the inside, checked that the gas valve was in the “on” position, and put the end panel back on.  I also removed the protective plastic film from the bottom of the unit.

Darryll gathered up his tools, extra parts, and unused materials and loaded them in his truck. He then pressurized his portable air compressor and used it to pressurize the black iron gas pipe.  It has not been holding pressure, so he pumped it up to 15 PSI and we went in search of leaks with a spray bottle of soapy water.  We used my inspection mirror to see behind and under connections and found three leaks.  One was in a 2″ pipe fitting behind the garage, one was in a 2″ pipe fitting near the end of the run by the generator, and one was at an elbow in the 1/2″ pipe where it exits the utility closet on its way to the garage furnace.

Darryll was checking air temperature readings at the registers and in the main plenum of the library HVAC unit.  The library was 89 degrees F when he first turned the A-C on, and the attic was a lot hotter than that.  He connected his gauges to the compressor/condenser and said the readings were close enough to correct that he did not want to add or remove any refrigerant until the room had cooled down and stabilized at the requested temperature.

I was hoping he would get the job finished today but he needed some equipment, which he did not have with him, to work on the iron pipe and he was obviously tired from a long day working in the high heat and humidity.  He may be back tomorrow; if not, Monday or Tuesday. Whenever he returns, I have complete confidence that he will get it done before the gas meter is hung and that it will all work correctly for many years with very little attention other than changing a filter once or twice a year.

We deferred lunch until Darryll left.  We had chickpea salad on a slice of the bread Linda had baked earlier, corn-on-the-cob, and the last of some fresh pineapple.  Nothing says “summer” like organic, non-GMO corn-on-the-cob.

After lunch I called Bratcher Electric to check on the status of the estimate/quote that Mike was putting together to service our generator, convert it to natural gas, and run a 100A Service Entrance Cable from the transfer switch to the garage panel, converting it from a sub-panel to a main panel.  Karen said they have been really busy but he would work on it over the weekend.

I also called 1-800-Pack-Rat to arrange pickup of the storage container on Friday September 12th.  Steven was not able to schedule the pick-up during the call and said he would contact the local office and get back to me.  I made it clear that we did not want to roll over into another billing cycle and I was calling one week ahead of time as we had been instructed.  He assured me that it would not be a problem.  About an hour later we got a return call and follow up e-mail confirming pickup for Friday, September 12.

Late afternoon I checked on the library A-C to make sure it was not freezing up.  Everything looked OK.  The thermostat was set to 76 degrees F and the temperature was down to 77, so I bumped the setting up to 78 to let it cycle off and on.  Although Darryll did all of the heavy lifting on this project (literally) I spent my fair share of time in the attic on warm days installing the pull-down folding ladder and working on electrical wiring and attic lights.  It was very gratifying to see that all of this work—his, mine, and Linda’s—finally result in something that operated correctly.

We were relaxing and reading when severe weather watches and warnings for our area started arriving on our iPads.  Naturally we went outside to see what was going on.  We were both born and raised in the Midwest, the St. Louis, Missouri area, to be exact, and as kids in the 1950’s, threatening weather was a form of summertime entertainment.  Not that we were stupid; we learned from the adults around us when the show was over and it was time to head to the basement.  When I was about 5 years old we lost a plum tree in our backyard to a close encounter with a tornado.

The gathering storm. The clouds were very dramatic in all directions.

The gathering storm. The clouds were very dramatic in all directions.

The clouds were very dramatic but eventually gave way to a formless mass of gray with swirling winds and a few raindrops.  We checked the Weather Channel app and the Weather Underground Wundermap app on our iPads.  The radar returns showed that we were likely in for some rain, and we got some, but as often happens the worst of it passed north and south of us.  The rain we did get was very welcomed.  We had heavy rain on Monday (Labor Day), Keith mowed the grass on Tuesday, I spread grass seed around on Tuesday and Wednesday, and a flock of six wild turkeys feasted on the grass seed on Wednesday and Thursday. We needed a nice light rain to help the seeds germinate and take root rather than be eaten or washed away in a thunderstorm.

Storm clouds looking east.

Storm clouds looking east.

Around 7:30 PM our power flickered several times and we received e-mail messages from our generator letting us know that utility power had been lost and then quickly regained.  We decided to check the Kohler OnCue software to see what the generator was doing.  We thought sure we had installed the software on Linda’s computer, so we could monitor it from her desk in the kitchen/dining area, but it wasn’t there.  After much searching and head scratching we checked my old laptop and there it was!  When we thought about it we realized that the generator had been installed about a week before Linda started configuring her new Samsung laptop, so there was no way we had put the software on her machine.  We’ve been very, very busy the last 20 months, so it was not surprising to us that we had forgotten the exact sequence of events.

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Approaching from the southwest the clouds got more ominous.

The severe warnings expired at 8 PM and the severe watches at 9 PM, but that did not mean the rain was done.  A big fetch of moisture was located south of Chicago, Illinois and moving through southwest Michigan in our general direction.  The rain was forecast to continue into the early hours of tomorrow but be done before sunrise.  When the rains finally came it rained hard for a while.  Tomorrow is forecast to be a perfect Michigan day and I plan to buy another bag of grass seed to spot seed the areas that got washed away, again.

 

2014/08/07 (R) Endings And Beginnings

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I did not sleep well last night.  I was a bit worked up about the landscaping and a bit worried about the iron gas pipe installation which looked to me like it would be difficult no matter how Darryll decided to do it.  We were both awake at 5:30 AM and finally got up at 6:45 AM and had breakfast.

The landscapers arrived early, before 8 AM, and got right to work.  Steve brought three guys and got them busy right away.  Linda and I walked the site with him, but he immediately saw more problems than we did.  There was no arguing or convincing; he seemed determined to make sure it was done right and that we were happy with the end result.  He stayed and worked alongside the crew to make sure stuff got done correctly.  They finished up around 11 AM.  We took one last look at the work and paid Steve the balance of what we owed him.  He said he would check back in 2 – 3 weeks to spot seed and fertilize the new grass.

Linda took off for the post office and grocery store around 8:45 AM and I started routing and stapling the sub-panel ground conductor along the edge of the deck by the rear library doorwalls.  Darryll (DCM Heating and Cooling) showed up a little after 9 AM with his nephew, Alec, so I took the next 30 minutes to walk through the gas pipe installation options.

Darryll decided to go with the original plan of running the pipe from the southeast corner of the house down the east side, around the corner across the back of the house under the upper deck, dropping it down and going under the middle deck, across the back of the garage just below the bottom piece of siding, around the northwest corner of the garage and up the west side of the garage to its end point behind the whole house generator.  There will be a T-fitting on the garage side of the middle deck, to supply gas into the garage for the two new furnaces, and another T-fitting at the end of the run.  One branch of the end T will have a shutoff valve and cap and will be used to supply gas to the generator.  The other branch will be capped and available should we ever decide to run a gas line to the (future) bus barn.

I determined where I wanted the sub-panel ground wire to enter the basement and drilled a 5/16″ hole an inch to the right and an inch below the water faucet that comes through the west wall of the house about 16″ back from the northwest corner above the lower deck.  This allowed me to route the ground wire around an inside corner to the hole and will allow me to tuck it up under the bottom piece of siding.

I wanted to get the ground wire into the main panel but I could not turn off the main breaker as Darryll was using electric power tools and Linda was working on her computer.  The connection will have to wait until no one is using power.  Once the ground wire is tied into the main panel I will remove the bonding screw in the sub-panel.

Linda made a different kind of bean salad sandwich spread for lunch using Great Northern beans and various other yummy ingredients.  We had some grapes and green tea to go with our sandwiches.

Having run out of construction projects for the moment I decided to work at my desk for a while, but my mind was elsewhere and I just wasn’t feeling the love.  The steps at the back door of the garage were going to be in the way of the iron pipe, so I removed them.  As long as I was out there I hung around to watch Darryll and Alec get the pipe under the middle deck.  It was a challenge, as expected, but for reasons that were unseen until Darryll tried to drill holes through the end boards.

First he encountered wet wood that kept fouling his hole saw.  Then he hit a nail, which did not enhance the performance of the saw.  It also bent his extension shaft slightly which he had to stop and straighten.  He then encountered joist hangars on each end and had to bend those out of the way.  Finally able to feed the pipe through, they encountered wood sleepers and a couple of large rocks.  They managed to go over the sleepers and push the rocks out of the way and got the pipe through.  Darryll and Alec put in a long, physically demanding day and got most of the 2″ pipe installed.  Two inch iron pipe is very impressive stuff and we were very impressed with the work required to install it.

For dinner Linda made a Farro pilaf, after which we sat on our deck and enjoyed a small glass of Riesling wine to celebrate the end of the landscaping project that has had our property torn up for the last five weeks.  We are very fortunate that we became vegans and that Linda took a serious interest in learning about whole-food, plant-based recipes, ingredients, and cooking methods just as we retired.  I shudder to think what our health would be like had we continued to eat the way we did until three years ago where, even as “vegetarians,” our diet contained a lot of eggs, dairy, and seafood, and not so much fruits and vegetables.  We watched Dr. Michael Greger’s annual summary address on NutritionFacts.org and went to sleep without the worries that interfered with last night’s rest.

 

2014/08/06 (W) Arrival And Departure

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Well, almost.  We were up and dressed by 7 AM, had some of the granola that Linda made yesterday (soooo good), and got to work while it was still cool in the garage attic.  Our first task, however, was to straighten up the garage as we were expecting a shipment of HVAC equipment sometime today.  We cleared off the north wall and moved the plastic shelving unit there.  We gathered up various tools and supplies and organized them on the shelves.  Other things got put other places and eventually we had enough space for boxes in the back and pipe on the floor.

While we were working on the garage the landscaping crew showed up but not Steve.  They worked all day trying to finish up the job based on Steve’s verbal directions but they either got bad directions, did not understand what they were told, did not understand what needed to be done, or just did not care about the fine/finishing details absent Steve’s direct supervision.

Our next task was to pull a 50′ 12-2+g NM cable into the attic from the sub-panel location and across to the west side of the attic where I coiled it up and left it for now.  This cable will eventually provide a 240V/20A circuit for the new library air-conditioner condenser/compressor on the west end of the garage.  I will complete the installation of the outside disconnect and connection to the condenser once Darryll sets it in place and gives me the go-ahead.

I turned off the main breaker in the sub-panel and started pulling five NM cables into the panel box and making the connections.  I was part way into this work when a tractor-trailer showed up from Behler-Young with our HVAC equipment and parts.  (B-Y is the largest HVAC distributor in the State of Michigan.)  I helped Bill unload the iron pipe and the smaller and/or lighter boxes.  He unloaded the palleted equipment and heavy parts boxes using the lift gate and a hand truck.  It was a good thing we had cleaned and organized the garage when we did as the boxes of stuff took up the whole east half of the north wall.

By the time Bill left it was noon so we stopped working and had lunch.  After lunch I finished connecting the new circuits in the sub-panel, put the cover back on, and turned on the main breaker.  I tested the west and northwest outlets and discovered that the three duplex outlets closest to the back door had an open ground.  Hummm; I did not see that coming.

I tested all four of the outlets closest to the door and all of them had open grounds.  I went to the next pair of duplex outlets and found that the ones closest to the door also had an open ground but the other two tested correctly.  I turned off the circuit breaker for that circuit and took the cover plate off of the pair of duplex outlets closest to the door.  The outlets were grounded but there was only one cable feeding that box so the problem was upstream somewhere.

The box with one good and one bad duplex outlet was the likely spot.  I took the cover plate off and pulled the outlets out.  The incoming power went to one pair, the hot and neutral were bridged to the other pair, and a cable ran out from the second pair, but the grounds were not bridged through.  Really?  Yeah, really.  So I fixed it, turned the circuit breaker back on, tested various outlets, and everything was now OK.

I had assumed that that power from the attic went to the outlet box closest to the door and then ran around to the southwest corner of the garage but in fact it did not go to either of these first two outlet boxes.  Old houses often have strange wiring configurations.  We have one circuit breaker in the sub-panel that has a wire attached to it and the cable runs up into the attic but we have been unable to find what, if anything, it powers.  I also found a cable in the garage attic yesterday that runs through the attic above the library and disappears into the house attic but is not connected to anything on the garage end.  The cable is not energized and its location suggests that it may have been powered from the sub-panel at one time, but what it might have powered is a mystery at present.

Since the HVAC equipment arrived today as promised I figured Darryll would be here tomorrow to start on the installation.  We still had a lot of stuff in the garage that was potentially in his way so I moved most of it into our temporary storage pod.  It was 3:30 PM and I had apparently accomplished everything that needed to be done today.  That was an odd feeling but with nothing else to do, construction wise, I sat down and had a cup of tea.

Steve (Village Landscape Development) called to make sure it was OK to come by in the evening to inspect the day’s work and, hopefully, collect the final payment.  Linda and I did a walk-around and found so many little details that were unfinished or wrong that I called Steve back and suggested that coming this evening would be a waste of time as he would just have to come back tomorrow with a crew to fix/finish the job correctly.  He agreed.

No longer content to take someone’s word, we found our auto-level, elevation pole, and 100 foot tape measure.  (An auto-level is not a typical homeowner tool, but we have one, so I guess we are not typical homeowners.)  I set the auto-level up on the basement walkout deck and leveled it.  We pulled the tape straight out from the center of the deck 70 feet and took elevation measurements every five feet.  The grade for the first 45 feet was not clearly downhill like it was supposed to be.  At best it was level and rose slightly at two points.  There was an obvious high spot to the left headed up the slope, but I did not even bother taking a reading on that.  I really wanted the landscaping done before the HVAC work started but it looks like there will be at least a little overlap.  That means I will have to split my time and attention.  I spent a lot of my working life “multi-tasking” and now find it tiresome.  I prefer to focus on one thing at a time when possible.

 

2014/08/05 (T) Primary Elections

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The rain started early today with a pre-dawn thunderstorm and continued off and on the rest of the day and evening.  The area beyond the basement walkout deck is a muddy mess, but Village Landscape Development has not finished grading it.  They need it to be dry, so it may be awhile before they can finish it.

Our first construction task today was to pull electrical cable up into the garage attic for three more circuits.  I wanted to get this done early in the day while it was cool and Linda’s knee was feeling better.  I had been mulling this work over last night and realized that I had probably made an incorrect assumption about the location of the 240V/20A service for the new library air-conditioner, so I put a call in to Darryll right after breakfast.  We got a call from Karen at Bratcher Electric around 9 AM to  see if it would be OK for Mike to stop by around 11 AM to look at some electrical work we need done.  He wanted to see the job in person in order to prepare a quote.

The new cable for the outlets on the west and northwest wall was already in the garage attic but I had to crawl into the low northeast corner to reach it and get it routed in the right direction.  I then had to crawl into the same corner from a different direction to pull it to the junction box I installed last week.  I secured it with cable staples and connected it to the old cable.

Next we pulled a 14-2+g NM cable from the sub-panel to the approximate location where the garage furnace will hang from the ceiling to provide a dedicated 120/15A circuit but did not install an outlet box pending a final location from Darryll.  We then pulled another 14-2+g NM cable from the sub-panel to the north end of the new west utility closet wall.  This cable will provide a dedicated 120V/15A circuit for the new library furnace.  Again, I did not install an outlet box pending a final location from Darryll.

Darryll called back and confirmed that the new 240V/20A dedicated circuit for the new library air-conditioner had to be routed to the location of the condenser/compressor on the outside of the west wall of the garage and there had to be a weatherproof disconnect within three feet of the unit.  That meant another trip to Lowe’s, but not until much later in the day.

Mike Bratcher showed up on time and I walked him through the project.  I want to re-wire the garage sub-panel as a 100A main panel by running service entrance cable from the transfer switch in the southwest corner of the garage to the sub-panel in the northeast corner of the garage.  We may also want to run power to the bus barn if/when it gets built.  Mike suggested that they go ahead and “stub out” the barn service at the same time with an appropriate disconnect.  The plan is to have them do this work at the same time they convert the Kohler whole house generator to natural gas and do the annual maintenance.  Mike also confirmed that they can take care of the natural gas connection to the generator as long as the pipe is located near the back of the unit, has a shutoff valve, and is capped.

By the time Mike left it was after noon so we had lunch.  While we ate we ordered a dual outlet phone/ADSL filter wall plate and a few other things on our Amazon Prime account and researched candidates and proposals for the primary election.  We then went to our polling station, located about two miles from our house, and voted.

This was the first election we participated in since moving to Livingston County.  As Democrats (and liberal ones at that) in this part of Livingston County voting in the primary is an exercise.  The real contest is on the Republican ticket; whoever wins the Republican primary for any given seat will almost surely win the general election in the fall.  Still, we always exercise our right to vote and there were statewide candidates and issues.

The last cable we installed today was another 14-2+g NM to provide 120V to a junction box on the utility closet ceiling.  I mounted a round white plastic junction box approximately 8″ from the east utility closet wall in line with, and slightly in front of, the sub-panel.  I installed a plastic bare-bulb light fixture with a pull chain and 3-prong outlet to the junction box.

I did not tie any of the new circuits into the sub-panel today as we have one more circuit to pull and I want all of the cables at the panel before I cut the power and remove the cover.  We were done with electrical work for today so I turned my attention to drywall surface preparation while Linda retreated to her desk to work on tax returns.  I sanded the drywall compound as smooth as I could and wiped everything down to get rid of the dust.  I then primed all of the new and old drywall on the northeast garage wall along with the plywood platform and exposed 2×12 on the front of the base.

By the time I was done and cleaned up it was approaching 5 PM, we were both tired, and we needed to go to Lowe’s, so we decided to dine out.  We went to Lowe’s first and bought a weatherproof plastic disconnect box, a couple of watertight fittings, a 10′ length of 3/4″ plastic conduit, and a 50′ role of 12-2+g NM cable.  All of this will be used to run the new dedicated circuit for the new library air-conditioner.  We then drove to the Panera in Brighton and used one of our gift cards to have a light dinner.

We were back home a little after 7 PM.  The primer was dry so I decided to paint all of the surfaces I had primed before dinner.  While I painted Linda made a batch of her incredibly yummy granola.  We had a small glass of wine and played a few games on our iPads while the granola cooled and then turned in for the night.

 

2014/07/31 (W) Wrapping Up?

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We were tired and went to bed early last night.  Naturally, that meant we were up earlier than usual this morning.  Linda made her fabulous vegan blueberry pancakes to get us fueled up for a long day of work.  The landscapers were also here reasonably early and had a very productive day.  More on that later.

Our first task this morning was installing a switch controlled dual LED floodlight fixture on the back of the garage above and to the left of the door (when viewed from the outside).  The location was determined by the construction of the rear wall of the garage.  I measured and re-measured the location of the cable hole to make sure the surface mounted junction box ended up in the center (vertically) of one of the siding boards.  I drilled a 1/2″ hole through the back (north) wall of the garage just to the right of the back door (when viewed from inside the garage) and just below the top plate.  I ran a 14-2+g (NM) cable (that I had previously prepped and left in the wall cavity) through the hole in the wall and then through the hole in the back of the junction box.  This was the part of the north wall where I had to remove concrete backer board, a burned 2×4, and singed insulation, so the studs and back side of the exterior plywood sheathing were exposed and accessible.

We moved around to the outside and I caulked the hole around the wire, put a generous band of while caulk around the hole on the back of the junction box, and a half circle of caulk around the top back edge of the box and mounted it to the outside of the house with the center knockout centered over the hole in the wall.  I installed the dual LED light fixture and put a bead of caulk around the top half of the junction box where it met the fixture.  (The heads of the cheap machine screws that now come with electrical fixtures and plates strip very easily making it difficult to get a tight fit.)  I caulked the wire hole from the inside and then dressed and secured the cable.  I turned the circuit breaker on, and checked for proper operation of the switch and light fixture.  It was all good.  I like it when that happens.

Our next task was to install three round blue plastic junction boxes for bare bulb light fixtures; two for the garage attic and one for the garage end of the library attic.  I was originally going to install a switch near the top of the fold-down ladder to control the lights and run power to it from a new ceiling light fixture in the utility closet, but we came up with a better solution.

There was a three-gang electrical box in the east wall of the garage just inside the door from the library.  It had two switches installed and the cover plate had openings for a duplex outlet in the third position, but no device installed there.  We thought this would be a better place for the switch—as there was already power to the box—if we could get a wire through the wall from the attic to the box.  The drywall is missing from the lower half of the wall so we had good access to the underside of the box.  (The drywall was removed by the previous owner to repair the frozen hot water baseboard heat pipes.)  I checked in the attic and it looked like we had a good shot at making this work.  The icing on the cake was that we could install a switch with a pilot light that is designed to fit in a duplex outlet cover plate.  Not only would it be convenient, it would provide a visible indication that the lights were on.

I did the attic work while Linda took care of the garage end of this task, passing me parts and tools as needed and helping feed NM cable. We ran 14-2+g (120V, 15A) wire from the attic through the east wall to the existing outlet box.  I pulled the cable over to the location by the library attic, mounted the box, cut the cable, unsheathed it, stripped the wires, ran it into the box, and secured it to the truss.  I repeated that process with the end of the free cable.  The plastic light fixtures I bought very conveniently feature pass-through wiring terminals so all I had to do was hook up the cables, fasten the fixture to the box, and screw in the 100 W rugged service bulb.

I repeated this process for the next box/fixture which I positioned just to the west side of garage ridge 1/4 of the way in from the front (south) wall.  Finally, I repeated most of this process for the third and final (for now) box/fixture which I positioned on the east side of the ridge 1/4 of the way in from the back (north) wall.  Somewhere in the middle of all that we stopped for lunch.

With the attic lights installed I needed to pull the wire that supplied power to the outlets in the west half of the garage out of the rear/north wall and up into the attic.  Easier said than done.  The cable was originally part of the circuit that powers the outlets in the northeast wall of the garage (and now powers the new floodlights on the back wall) but I disconnected it a week ago knowing that I wanted to feed it from a separate breaker.  The cable went through a hole in the top plate and I discovered that the bottom cord of the gable truss had been set partially covering this hole with the cable pinched under it.  I cut the cable from above and ran it into a plastic switch box.  Linda was then able to pull the tail end loose from underneath.  I will run a new cable from the sub-panel to the junction box after I get more pressing work done.

On that note I also realized today that I do not have to get the cables for the new circuits through the top plates above the sub-panel, which was going to be difficult-to-impossible.  The sub-panel is surface mounted and I already planned to box around it.  With the supply air duct coming out of the new HVAC unit and running straight out along the ceiling above the utility closet door I will have 16 inches of clear ceiling space.  The sub-panel is about four inches deep so I will have about three inches of ceiling above the panel and in front of the top plates where I can run new cable into the attic.  Brilliant!

Our last attic task for today was to disconnect two telephone wires in the wall cavity to the right of the sub-panel, pull them up into the attic, reroute them, and reconnect them.  One of them turned out to be the main phone/data line coming into the house from the AT&T box at the southwest corner of the garage.  There was a telephone wall outlet to the right of the old sub-panel that this line ran to before continuing on to the rest of the house.  The wires are very small gage, are unshielded, and the cable is draped through the attic over multiple 120 VAC cables.  I need to replace this with a single run of much better (shielded) cable when I have time.  Perhaps we will get less static on the phone and faster Internet data transfer rates.  (Nah, probably not.  It will still be an AT&T landline.)

While I started working on re-wiring the three-gang box in the east garage wall, Linda made a run to Lowe’s to get a 32′ roll of 16″ x 3.5″ (R-13) insulation and a switch with a pilot light.  I got the box rewired, we energized the circuit, and everything worked.  Yippee!

The landscapers today consisted of Steve (the owner), Spencer (his nephew), and Tommy.  Steve used the excavator to place four large boulders on the sides of the new front steps.  That was the last work to be done in front that required the excavator so he used it to back blade (level off) and compact (with the bucket) the pull-through driveway.  He was not able to return it to its existing condition but did the best he could with the equipment he has.

He took time out to use his chain saw to cut down a dead pine tree, cut it up into 4′ lengths, and carry the pieces back to his truck with the excavator.  He then used it to fill/grade a large low spot just southwest of the garage.  This was the route they used to get the excavator to the back yard.  It was also where all of the construction debris was piled until yesterday, and the excavator really tore the ground up in that area over the last four weeks.

Spencer and Tommy worked in the back hand-grading the slopes beyond the retaining walls and the area that was trenched for the drain tiles.  They worked in a layer of good topsoil, spread grass seed, and covered it with straw.

Steve plans to lay the brick pavers for the front sidewalk tomorrow and have the whole project wrapped up by the end of the day.  It looked like they were on track to accomplish that until Spencer informed us that there was apparently a leak in the drain tile somewhere in “the valley.”  Leak was an understatement; we had an area at least 8′ x 12′ that had turned into a pond.

It appeared that the drain line for the sump pump was somehow discharging its water at this point rather than it flowing all the way down to the drains at the back of the yard.   Spencer dug up some of the line coming down the slope and found several holes on the top side, but it did make sense that these were the source of the problem.  Our guess is that that line, which is not one continuous piece of drain tile, has become disconnected at the valley floor allowing all of the water to escape at that point, and/or crushed, causing the water to back up through a connector (which is only designed for water to flow one way).  Fortunately we kept the original PVC discharge extension pipe from the sump pump outlet so we temporarily disconnected the buried drain line and reconnected the extension pipe.

Whatever the cause of the leak, we are sure it will be found and fixed, we’re just not sure that will happen by the end of the day tomorrow.  I had thought about “testing” the system by using a garden hose to put a significant volume of water into each of the drain lines.  As of now, I will definitely be doing that.

Our final task was insulating a section of the rear/north wall.  We got three of the four plus cavities filled and ran out of steam.  Besides, it was dinner time.  Linda made one of her “go-to” dishes; angel hair pasta with onions, garlic, mushrooms, sun-dried tomatoes, basil, and mixed baby greens lightly sautéed in olive oil.  This is a dish she can throw together from ingredients on hand without a recipe and it is always delicious.  We had a small glass of Leelanau Cellars Summer Sunset wine while she cooked and a small glass of Meiomi Pinot Noir with the dish.  No salad and no dessert; just a great pasta dish and nice wine.  I got cleaned up and we watched the first episode of season five of Doc Martin.  As we were drifting off to sleep we thought we heard the distant howl of a coyote.

2014/07/30 (W) Winter In July

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By the time we started breakfast the landscapers were back.  Steve started to dig a trench for a drain line from the end of the lower deck and hit 2×8’s on the flat about 2-3″ below the surface, so he abandoned that work and moved the excavator around front to the trash pile.

The major construction work up in the back is nearing completion and the lads were picking up some of the smaller debris, the larger stuff having been moved around front to the trash pile yesterday.  Steve used the excavator to load some of the trash onto the trailer (normally used to move the excavator), where the crew covered and secured it.  He loaded more of it into the back of his pickup truck.  They are still having tire issues with the trailer so I charged up my 200 psi air compressor (150 psi regulated) and rolled it over so they could fill one of the tires.

Steve moved the excavator to the southeast corner of the house to dig a short (10′) shallow trench for a drain line to get water from the downspout away from the house.  I conferred with him regarding the exact location because the main propane line enters the house at that corner, the electrical service for the RV outlet runs under there, there is a tree about 12 feet southeast of that corner, and that corner is where the new natural gas meter will be installed. There will be a similar short drain line at the southwest corner of the garage, but it will be dug by hand as the main electrical service runs directly under there about 2′ below the surface.

The lads continued to work in the back placing egg rock.  They were about 1/2 cubic yard short and I asked Steve to order a full cubic yard and use the other 1/2 yard on the west end of the north edge of the lower upper deck to match what they had done at the top of the west retaining wall.  Steve gave the crew instructions on how to prep that area, add a piece of edging to define where the rock will go, and install landscape fabric.  He and I then looked at the boards he hit in the back while trenching and it turned out there were only three of them 4-6′ long and they appeared to be old construction material that had possibly been used as a step off of the lower deck.

Linda gathered up household trash and recyclables and headed off around 10:45 AM.  I finally got started on my projects for the day around 11 AM, opening the garage door so I would have light when the power was turned off at the sub-panel main breaker.  My first task was to move the new outlet I installed in the utility closet the other day.  The return air duct will be installed against that wall and would cover the current location.  When we installed the door yesterday we did not put any 2×4’s above the door and up to the ceiling.  Darryll is going to run the supply duct straight out from the furnace above the door and then angle it over against the east wall of the garage.

With the outlet relocated I cut some scrap insulation to fill the lower half of the open wall cavities and then stopped while I pondered getting a ground wire into that space.  Linda got back from running her errands about then so I decided over lunch to call Bratcher Electric to see if they could give me an idea of what it will cost to run a 100 Amp service entrance cable from the transfer switch in the southwest corner of the garage to the garage panel in the northeast corner of the garage.  (I estimated it would take 40′ of cable, but have no idea what the labor will be.)

The earliest I will be able to talk to Mike Bratcher is next Monday so I decided that I really needed to run a ground wire from the sub-panel to the main panel allowing me to disconnect the ground wires from the neutral wires in the sub-panel by removing the bonding screw in the sub-panel and giving us a code-compliant, and much safer, sub-panel until such time as it gets re-wired as a main panel.

Linda and I determined that I needed about 40′ of #10 copper wire to get from the sub-panel to the main panel.  Pondering sometimes leads to good things.  I really did not want to stop working to go get wire when I remembered that I had a length of green insulated copper wire I had used for grounding a ham radio and antenna mast at the old house.  It was coiled up on the floor in garage and when we uncoiled it we discovered it was … 40′ long!  I love it when that happens.  I checked the gage and it was #8, so it was actually larger than required for the 60A cable that feeds power from the main panel in the basement to the sub-panel in the garage.

I checked the approximate location for drilling a hole and then drilled a 1/2″ hole from the inside of the garage just above the base plate and out through the siding.  I fed the ground wire through the hole from outside the garage, pulled it up into the sub-panel, and secured it to one of the ground bars.  I dressed it and fastened it to the side of a stud and coiled up the extra outside on the lower upper deck.  I will complete the run to the main panel another day.

With the ground wire installed I was able to install the insulation I had cut earlier and secure it with our staple gun, which I had managed to locate in the tub of tools we took with us out west last summer.  With Linda’s assistance I cut and installed two pieces of drywall from an old scrap piece we had.  I then taped the seams and mudded the screw dimples.  By the time I finished it was 4 PM.  Spencer came to the garage to let me know that they would all be leaving around 4:30 PM due to a severe thunderstorm that was on course to hit our area around 5 PM.

By 4:45 PM we were hearing thunder and I decided to stop work temporarily and help Linda close up the house.  The storm came, a cold wind blew, and it rained hard, but only for a few minutes and we did not get any of the hail that was reported prior to the storm’s arrival at our location.  An hour later we had a lovely summer evening with blue skies.  Linda made roasted winter vegetables for dinner.  It’s the end of July, but we had overnight lows in the mid-40’s two nights ago.  The first six months of this year have been the coldest in 21 years, so winter vegetables were appropriate for dinner even though it is the end of July.

I had planned to do a lot of other electrical work today, but it was a full day and everything that got done was something that needed to get done.  It was also work that had to get done in the order in which it was accomplished.  My original plans were obviously too ambitious, and today’s work involved details that required time to figure out and execute.

 

2014/07/20 (N) Company

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The landscapers were back at 7:45 AM as promised.  We were up and ready for them and I was back working on the new sub-panel in the garage by 8:30 AM.  I finished the work (for now) and cleaned up the mess as best I could.  Electrical work, especially panel wiring, is very physical and tends to produce a lot of scrap.  Once the garage was cleaned up I applied the same treatment to myself.  By 1 PM I was ready for part 2 of my day, which began with a load of laundry, and then off to my desk to put a little time into our much neglected blog.

I have been taking photographs and writing daily blog posts all month but have not been taking the additional time to select and process the images and upload the posts to our WordPress site.  The last blog post on our website is from July 6th.  During the early afternoon planned to upload a few of the posts while we waited for Ron and Mary to arrive.  I ended up filing and deleting e-mails, which I have also neglected for the last few days.

Ron (Linda’s brother) and Mary (Ron’s wife) arrived at 3:30 PM.  They are on their way back to Pennsylvania after a week in Madison, Wisconsin participating in day-long bicycle rides.  They are fairly serious bicyclists; a few years ago Ron rode from Seattle to Boston with a large group over the summer.  This was their first visit to our new house so they got the full tour of the house and the property.  We were sitting on the deck enjoying cool beverages and good conversation when the landscapers returned.  They were still working with their heavy equipment, so we went back inside to talk.

Linda started pulling dinner together at 5:30 PM with Mary’s assistance.  We had a green salad with cut up vegetables and seitan stroganoff served over white rice the way I like it.  A glass of Merlot balanced nicely with the richness of the stroganoff.  Linda, Ron, and Mary went for a walk after dinner while I loaded and started the dishwasher.  When they returned we talked into the evening and Mary showed us pictures from family gatherings and their just-completed bicycle rides.  Linda had baked a vegan chocolate cake this morning and served slices with fresh cut strawberries and vanilla coconut milk ice “cream” for dessert.

 

2014/07/19 (S) A Busy Day

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At 7:30 AM we were about to leave for our usual Ham radio club breakfast in South Lyon when we realized some of the landscaping crew was already in the back yard.  I talked briefly with Steve to see if he had any questions for us and to let him know we would be gone for the morning.  We arrived at the Senate Coney Island a little later than usual to find a big group, some of whom were not regular attendees.  We would normally have lingered and enjoyed conversation over coffee, but we needed to get to Ann Arbor for a quick visit and to pick up my socket wrench toolbox from our son.

When we arrived at Brendan and Shawna’s house Madeline was outside pushing her push toy around the front yard.  As soon as she saw us she took off down the sidewalk towards the park.  Shawna retrieved her and got her stroller ready while Brendan and I transferred things out of and in to my car.  We then walked to Burn’s Park where Madeline played for about 45 minutes before we headed back to their house.  We had hugs all around and left.  We stopped at the Whole Foods Market in our way back to US-23 and then headed for home.

Back at the house, four landscapers were working, including Steve, and lots was getting done.  Hurray!  I got busy working on the electrical sub-panel in the garage while Linda made a run to the recycling center.  When she got back she did a load of laundry, which is normally my job, while she cleaned the lower level of the house.

I had to make a trip to Lowe’s for electrical parts and Linda had to make one in the evening to buy some 15 Amp single-pole circuit breakers, but I managed to get the old sub-panel removed, the wires labeled, the new panel hung, and all but one wire reconnected.  That wire needs to be replaced and I will do that first thing in the morning.  We turned the breaker on in the basement that feeds power to the sub-panel in the garage, turned on the main breaker in the sub-panel, and then turned each branch circuit breaker and checked to see that it was working correctly.

The reason Linda had to go get 15 Amp circuit breakers is that I discovered the old sub-panel had 14 gauge (AWG) wires “protected” by 20 Amp circuit breakers.  14 AWG wires are only rated to carry 15 Amps.  If allowed to carry more than that for any length of time they will overheat which could melt the wire insulation and lead to a short or worse, arcing, which can start a fire.  I will be placing those circuits on 15 Amp breakers in the morning.

 

2014/07/16 (W) Rat Packing

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Today was not a trip down memory lane, although some good Rat Pack music would have been a nice accompaniment while working.  Tim called around 8:30 AM to verify the delivery details for our 16-foot Pack-Rat storage container and confirm that we would be home around 10 AM.

We wanted to get the container as close as possible to the garage while still being able to open the doors.  In that location it would also be out of the way of the pull-through driveway in case we wanted/needed to get the bus out.  The potential problem with this location was that the container had to be unloaded underneath and then behind the main phone line that hangs across our driveway.  The vertical clearance from the driveway to the phone line is just under 12′ 6″.  I was told when I ordered the container that they needed 13′ 6″, minimum.

We had not seen any landscapers by 9:00 AM so I called Steve at VLD and left a message.  The previous owners of the house left a large (bulky) projection TV which we had the movers bring up from the basement and put in garage when we moved in last year.  Linda called Alchin’s,  our trash collection company, to see if they would pick it up.  They said they would so we rolled it out to the curb with the rest of the trash.  I called Steve (VLD) on his cell phone and found out he was in our backyard.  Apparently he arrived just as we finished putting out the trash and went back in the house.  The landscape crew was supposed to have been there at 9:00 AM.  He called them and then left.  A Two-man crew showed up a little while later.

I placed our 8′ fiberglass (non-metallic, non-conducting) stepladder under the phone line and used an 8′ 2×4 and some short pieces (as blocking) to temporarily raise the line to 13′ 7″.  Tim showed up right on time and, after taking care of the paperwork, surveyed the situation.  He said it would not be a problem placing the container where we wanted it and it turned out that lifting the phone line was not necessary.  Here’s why…

The truck that delivers these containers is very specialized.  It has a built in crane with two long arms, kind of like a forklift, that extend down the sides of the truck and then make a 90 degree bend and connect to the main telescoping mast.  The mast is normally just behind the cab when the container is loaded and ready for transport.  To unload the container the arms are swung out away from the sides of the truck a couple of feet and then raised.  Four lifting bars are inserted into the base of the container, two on each side, and attached to the arms with chains.  The arms are then raised, lifting the container free from the truck bed (after it is un-strapped).  The entire crane assembly then slides backwards until the container is clear of the rear bumper, allowing it to be lowered.  Before final placement, however, the truck can still be moved back and forth.  (This is only true if the container is empty.  If it is loaded, the rear stabilizing jacks on the truck have to be lowered, preventing the truck from moving.)

I helped Tim position the truck so the crane mast was just in front of the phone line and the front of the container was just behind it.  We are only using the container for on-site storage so it will be empty when we finally have them come back and pick it up.  Positioned where it is they can retrieve it without raising the phone line so we won’t necessarily have be here at the time.  We will be, but it will still be less work for us.

With the container in place we started moving things out of the garage.  Some went into the container, some went into Linda’s car to go to the recycling center, some got set aside for donation or sale on Craig’s List, and some got designated to go in next week’s trash pickup.  I really hate throwing anything away that might be useful, but our limited experience with things like Freecycle have not been good, and selling things on eBay or Craigslist has never seemed worth the effort the small monetary return.

Around noon the landscapers wanted to know if we knew of an urgent care facility nearby.  That’s not a question you want to be asked on a construction site.  One of the guys was bitten by a spider and thought it might have been a Brown Recluse.  When they first started working on the retaining walls in the back they identified what they thought was a Brown Recluse (fiddleback) spider.  Although Michigan is farther north than their normal range they do occur here, so it was possible that’s what bit him.  The nearest medical facility we knew about was a hospital about five miles away, but Steve wanted them to go to an urgent care facility because he through they would get quicker service.  (They had called Steve before even asking us for assistance.)  Linda got on her computer and located one in the same area as the hospital.  They left to seek treatment and did return.

We did a little online research and found that there are a lot of spiders that resemble the Brown Recluse, which can range from gray to almost black and from the size of a penny to slightly larger than a quarter.  The name “fiddleback” comes from a pattern on the dorsal (upper) side of the spider, but is not a definitive identifier.  The most definitive characteristic is the six eyes; most spiders have eight.  Unfortunately they crew did not have the spider, so a positive ID was not possible.

After lunch Linda went to the recycling center and did some grocery shopping while I continued to work in the garage.  We had cleared out the east wall and the northeast corner which allowed me to remove wire shelving that was installed there.  I also had clear access to the electrical sub-panel so I removed the cover to have a look inside.  There were 11 load wires connected, nine to single-pole 120 VAC breakers and two to a double-poll 240 VAC breaker.  The power feed from the main panel in the basement was three-wire (2 hot, 1 neutral) not four like it should be, and all of the branch circuit ground wires were bonded to the neutral conductors.  This may have been OK at one time but is absolutely not current national electrical code (NEC).  Grounds and neutrals in an electrical system should only be bonded (connected together) at one point, usually in the main panel or at the service entrance.  For remote sub-panels, such as in a separate building, the ground wires can be connected to a pair of ground rods at least 8 feet long driven into the earth, but this is not an ideal arrangement.  If the resistance is not low enough it will limit the current flow through the ground wire to something less than required to trip the circuit breaker.

After dinner I got a phone call from Gaye, the chair of the FMCA Education Committee.  We talked for quite a while about the committee and RVing in general.  The whole committee has never met for a face-to-face meeting and many of us do not really know each other, so this was a chance to get better acquainted.

 

2104/07/12 (S) Natural Gas

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You might think that this would be a reference to the natural by-product of having breakfast with our ham radio friends in South Lyon this morning at the Senate Coney Island, but that is not the case.  We had a 10:30 AM appointment at the house this morning with Darryll Mech of DCM Heating and Cooling to finalize the work that needs to be done to get the house ready for conversion to natural gas.  The natural gas contractor for Consumer’s Energy (Roese Construction) started installing the main lines in our area a couple of weeks ago and they expect to have the project completed by September 26 (of this year).  That means we will have natural gas to the house sometime between now and then and we need to have everything as ready as we can before they hang the meter so the final conversion will be minimal and quick once the natural gas is turned on.

The work at our house breaks down into three pieces.  The first piece is running black pipe on the outside of the house from the southeast corner down the east side, across the back, under the upper and lower decks, along the back of the garage, and up the west side of the garage.  The gas meter will be installed at the southeast corner of the house where the propane currently enters the house.  The existing house piping will be used to supply natural gas to the house furnace, kitchen range, and outside grill connector.  The whole house generator is by the southwest corner of the garage and is currently on its own propane tank.  After the natural gas is hooked up everything needs to be on a single natural gas service/meter.

As the gas pipe runs along the back side of the garage there will be a T to supply gas into the garage.  That has to do with the second piece of the work.  We are having a ceiling mounted garage heater installed and a small furnace/air-conditioner for the library.  The HVAC unit will allow us to heat the library in the winter without cycling the main hot-water baseboard heating system, which is at the end of a long run through unheated attic space and is not particularly efficient or effective.  More importantly, it will allow us to control the humidity on humid summer days (it’s a library, after all, so it contains a lot of books and other humidity sensitive paper materials).  As part of that work we need to remove a propane space heater that is mounted in the wall abutting the garage and cap the line.  We also need to remove a window mount air-conditioner in that same wall.  Yes, that’s right, the current A-C for that room exhausts into the garage.

The third piece of the puzzle will be disconnecting the propane and converting the appliances that currently run on propane; the kitchen range, the main furnace, and the generator.  We will have Darryll take care of disconnecting the propane from the house and connecting the natural gas to the existing house piping and start up the two new furnaces once the gas is available.  We will then have TOMTEK convert the main furnace since they already service it for us.  Depending on timing we may be without our main furnace and domestic hot water until TOMTEK can complete their work.  I may convert the range, have Darryll do it, or have TOMTEK do it.  Regardless of who does the conversion I will need to get the conversion kit.  Bratcher Electric will connect the gas line and convert the whole house generator and do the annual service at the same time.

While Bratcher Electric is here we are going to have them run a 100 Amp, 4-wire cable from the outlet of the transfer switch in the southwest corner of the garage to the panel in the northeast corner of the garage.  The existing setup has the 200 A main panel in the basement of the house with a 60 A / 240 V breaker supplying the cable that feeds the sub-panel in the garage.  That means the power to the sub-panel goes from the garage all the way to the house and then all the back to the garage.  That’s a lot of unnecessary forth and back.  In part because of that, and in part because of the electrical needs of the new garage furnace and library HVAC unit, I am going to replace the sub-panel in the garage with a 100 Amp main breaker panel in advance of all of this work.

The current sub-panel is a General Electric but the main house panel is a Square D Homeline.  Lowe’s and Home Depot carry both the Homeline and QO product lines from Square D, and Home Depot also carries GE and Siemens.  If I installed a GE main panel in the garage I could potentially reuse the existing breakers and save a little money.  On the other hand, they have been in an unconditioned space for who knows how long, and they are not physically compatible with the Homeline breakers.  Indeed, the four different products are not generally interchangeable.  But the main consideration is selection and availability, and the Square D products win on those criteria.

Once the new furnaces are installed we will still have some work to do.  We will have to repair the walls in the library, insulate the hot air duct in the garage (although Darryll may take care of that), and enclose the library HVAC unit.  Because the library HVAC unit will be installed in the northeast corner of the garage it has to be in its own little sealed room to prevent automotive engine exhaust or other noxious fumes in the garage from being drawn in to the conditioned air or explosive fumes, such as gasoline vapor, from being drawn into the combustion chamber.  The furnace will have its own air intake and exhaust tubes.  The garage heater uses a sealed combustion chamber with a special concentric intake and exhaust tube, so it does not have to be enclosed.

Darryll indicated he could start the last week of July and would need about a week to do all of his initial work.  We have company coming the 20th through the 23rd, so we have the upcoming week to prep (clean out) the garage and library for Darryll.  This is the kind of situation that could give us gas if we weren’t used to it and enjoy it.  There’s nothing like a construction project to get you up and moving first thing in the morning and keep you up late at night.