Quick Overview
- An opulent off-grid house in an isolated mountain region is entirely powered by 64 Battle Born GC3 LiFePO4 batteries and 72 solar panels, without the need for any utility connection.
- The system, which runs at 48V using 16 banks of 4 batteries, generates sufficient power to operate a fully modern, high-demand home all year round.
- Battle Born Batteries, manufactured by Dragonfly Energy, are a top pick for serious off-grid projects due to their reliability, temperature tolerance, and extended cycle life.
- Lead acid batteries would not have survived in this environment, the reasons why LiFePO4 chemistry was the only viable option for this project are detailed below.
- This case study shows what is truly required to create a battery bank for extreme cold, remote access, and high energy demand, and what every off-grid homeowner can learn from it.
Many people believe that going off-grid involves a sacrifice, but this project demonstrates that the opposite can be achieved.
Eric’s property is located in a remote mountain region, and Battle Born Batteries, made by Dragonfly Energy, allowed it to be completely energy independent without giving up any modern conveniences. This case study details exactly how a professional-grade off-grid power system was planned, constructed, and optimized for one of the most challenging environments possible. Regardless if you’re planning your first off-grid setup or expanding an existing system, there’s a lot to learn from how this one was done.
64 Batteries, 72 Solar Panels, 18 Miles From the Grid
This isn’t your typical weekend cabin. Eric’s off-grid home is a fully modern, high-consumption residence that required a power system that could perform flawlessly through brutal winters, complete isolation, and no access to utility infrastructure. The solution that installer Steven Lewis and Dragonfly Energy’s Stationary Markets Manager Bill Huss designed is one of the most impressive residential off-grid builds on record.
The system is powered by 64 – 12V 270Ah GC3 Battle Born LiFePO4 batteries and complemented by 72 – 405-watt solar panels in three groups of 24 panels on MT Solar Pole mounts. Four Sol-Ark SA-15K Pre-Wired Hybrid Inverter Systems are responsible for power conversion, and three MPPT Solar Charge Controllers manage the energy input from the solar arrays. The system’s sheer size is impressive, but what makes it particularly interesting is the thought process behind each component’s selection.
Understanding the Need for a Powerful System
Eric’s property is more than just remote. It presents unique challenges in terms of infrastructure. To understand why the system needed to be so robust, we need to understand the difficulties the property presents.
18 Miles From the Nearest Power Line
The nearest utility power line is a whopping 18 miles away. The cost of running a grid connection to the property would have been astronomical — much more than the cost of building a complete, permanent off-grid system. For Eric, the decision was a no-brainer. An off-grid power system wasn’t just the better option. It was the only feasible one.
Winter Access Only Via Snow Cat
In the winter, the only way to reach the property is by snow cat, a vehicle designed to travel through deep snow. Being this isolated means that if there are any problems with the power system in January, help isn’t just a short drive away. This system was designed to be as reliable as possible and require minimal intervention. This isn’t a luxury, it’s a necessity for survival.
Every decision made by Steven and Bill was influenced by this limitation. Redundancy, durability, and the ability to function without regular maintenance weren’t just added bonuses. They were the backbone of the entire design.
Why We Never Considered Lead Acid Batteries
Deep-cycle lead acid batteries have been the go-to for off-grid systems for many years, but they have major drawbacks that make them unsuitable for harsh conditions. They need frequent upkeep, lose a lot of capacity in cold weather, and can be irreparably harmed if they are discharged too much. In a place where the winter temperatures often fall far below 0°F and it’s hard to get to, lead acid batteries would have been a problem right from the start.
Unlike other types, LiFePO4 chemistry, which is used in all Battle Born Batteries, does not have these weaknesses. These batteries maintain their capacity much better in cold conditions, require almost no maintenance, and can be discharged to a much deeper level without damage. For a build like this, there was no question.
The Battery Configuration: The Lifeblood of This System
The battery bank is the make-or-break factor in this system’s performance. Steven Lewis didn’t just choose a high-performing battery, he designed an entire system around it to meet Eric’s large-scale energy needs.
What is a 12V 270Ah GC3 Battle Born Battery?
The Battle Born 12V 270Ah GC3 LiFePO4 Deep Cycle Battery is one of the highest energy density batteries in the Battle Born lineup. It’s built in a GC3 form factor — slightly larger than a standard golf cart battery — and delivers 270 amp-hours of usable capacity at 12 volts. Each battery contains a built-in Battery Management System (BMS) that protects against overcharge, over-discharge, short circuits, and temperature extremes. These aren’t consumer-grade batteries dressed up for marketing purposes. They’re engineered for exactly the kind of demanding, long-duration application Eric’s home represents.
Creating a 48V System with 16 Sets of 4 Batteries
The system is made up of 64 batteries arranged into 16 sets of 4 batteries each. Within each set, the 4 batteries are linked in series, positive to negative, which increases the voltage but keeps the amp-hour capacity the same. When you link four 12V batteries in series, you end up with 48 volts per set. The 16 sets are then linked in parallel, which keeps the system voltage at 48V but increases the amp-hour capacity across all 16 sets.
What’s the benefit of 48V? When it comes to handling substantial loads, higher voltage systems are markedly more efficient. They lower the current that flows through the wiring, which in turn reduces energy losses and enables the use of smaller, cheaper cables over extended distances. For a home-scale system that uses four inverters and has high power requirements, 48V is the best choice. Moreover, it’s the industry standard for significant off-grid residential projects.
Keeping the Battery Room Over 40°F Even When It’s Below 0°F Outside
LiFePO4 batteries have an optimal temperature range. Although Battle Born batteries can discharge at temperatures as low as -4°F (-20°C), they need temperatures above 25°F (-4°C) to charge in order to safeguard the cells. In a climate where temperatures can drop far below zero for long stretches of time, managing the temperature of the battery room isn’t a luxury — it’s a necessity.
Steven solved this problem by placing the battery bank in a room that is well-insulated within the building. The insulation, along with the heat that the batteries naturally produce when in use, keeps the room warmer than the lowest safe operating temperature even in the coldest winter weather. This design choice safeguards the batteries’ lifespan and guarantees that the system continues to work when the outdoor temperatures are extremely cold.
The Complete System Overview
All the parts of this system were chosen to operate together as a high-functioning unit. Having the best batteries is pointless if the inverters can’t support the load, or having the best solar panels is useless if the charge controllers can’t handle the input effectively. Steven and Bill built this system from scratch with that combination in mind — and the outcome is a system that operates like a well-tuned engine.
The Role of 72 Solar Panels in Powering the Battery Bank
The solar power generation component of this system is equally as impressive as the battery bank. 72 – 405-watt solar panels are installed over three arrays, each containing 24 panels, on MT Solar Pole Mounts. The decision to use pole mounting is intentional for areas that experience snow — panels that are mounted on poles can be angled more steeply than those mounted on roofs, which aids in the removal of snow accumulation and maximizes the capture of winter sun when the sun is lower on the horizon. The three separate arrays feed into three MPPT Solar Charge Controllers, which transform the variable DC output of the panels into the exact voltage and current required by the battery bank for safe, efficient charging.
The Role of Sol-Ark Inverters in the System
The power conversion chain is centered around four Sol-Ark SA-15K Pre-Wired Hybrid Inverter Systems. Each Sol-Ark SA-15K can continuously output 15,000 watts, giving the system a theoretical combined inverter capacity of 60,000 watts. The inverters are set up to share the load across the home’s circuits, providing redundancy. This means that if one inverter needs to be serviced, the other three can still power the home.
It’s important to note that the term “hybrid” is used here. Hybrid inverters have the ability to manage input from solar panels, a battery bank, and a backup generator at the same time if one is available. They smartly prioritize solar energy first, use the batteries when solar production decreases, and can accept generator input during long periods of low sunlight. This layered approach to energy management is what makes the system so robust in a setting where weeks of cloud cover or heavy snowfall are realistic possibilities.
The following is a summary of the system components:
- Battle Born GC3 LiFePO4 Battery: We used 64 units of this battery, each with a capacity of 12V / 270Ah.
- Solar Panels: We installed 72 panels, each capable of generating 405 watts.
- Sol-Ark Hybrid Inverter: We used 4 units of this inverter, each with a capacity of SA-15K (15,000W).
- MPPT Solar Charge Controllers: We installed 3 units of this controller, each capable of handling 3 arrays of 24 panels.
- MT Solar Pole Mounts: We installed 3 arrays of these mounts, each capable of holding 24 panels.
- System Voltage: The system operates at a voltage of 48V (16 banks of 4 in series).
These components work together to generate, store, and deliver power efficiently and reliably. This is true even during extended mountain snowstorms when the sun is not visible. The battery bank’s total usable capacity provides enough stored energy to power the home through multi-day periods of low generation without disrupting daily life.
The Design Process of Steven Lewis and Bill Huss
Every successful off-grid system is the result of a team that knows what they’re doing. This build didn’t just happen. It required careful load analysis, component selection, system architecture planning, and hands-on installation expertise — and two key people made that happen.
Steven Lewis, the expert installer who actually constructed the system, provided the hands-on experience necessary to transform a complicated design into a functioning installation. Bill Huss, Stationary Markets Manager at Dragonfly Energy (the parent company of Battle Born Batteries), supplied the technical and product-specific knowledge to make sure the battery bank was correctly specified and set up. Their teamwork sets an example for how large-scale off-grid projects should be tackled.
Why Expert Collaboration Was Necessary for a Project of This Magnitude
Designing a system with 64 batteries, 72 solar panels, and four 15,000-watt inverters is not something that can be done over a weekend with a simple spreadsheet. The electrical engineering required — from calculating wire gauges and fusing requirements to configuring charge controllers and balancing inverter loads — demands a high level of professional knowledge. Add to that the environmental challenges of a remote mountain property and the stakes are even higher. A poor design doesn’t just mean subpar performance. In a location as remote as this, it could mean being without power for weeks.
Bill Huss’s Contribution as Stationary Markets Manager at Dragonfly Energy
Bill Huss brought an understanding that most installers do not have access to, thanks to his role as Stationary Markets Manager at Dragonfly Energy. Bill works specifically with large-scale stationary battery applications, which is exactly what this build is. He has a deep understanding of how Battle Born GC3 batteries perform in series-parallel configurations, how they respond to the charge profiles produced by MPPT controllers, and how to size a bank for worst-case winter energy demands. His knowledge was crucial in getting this system right from the start.
Living with Off-Grid Power: The Ease of “Set It and Forget It”
While the raw power numbers are impressive, the most important result of this build is the day-to-day reality of living with the system. Eric describes the experience as completely hands-off. Battle Born LiFePO4 batteries don’t require equalization charging, water top-offs, or routine maintenance cycles. The BMS in each battery automatically handles cell-level protection. The Sol-Ark inverters manage energy routing without any manual input. The MPPT controllers optimize solar harvest without any need for adjustment. Once the system was commissioned, it just runs — which is exactly what you want when you’re 18 miles from the nearest help and only accessible by snow cat in the winter.
Lessons for Other Off-Grid Homeowners From This Build
Eric’s system is an exceptional case, but the concepts that drive it are applicable at all levels. Whether you’re supplying power to a tiny cabin or a regular-sized house, the choices made in this build provide a useful guide for anyone who is serious about being self-sufficient in terms of energy.
Calculating Battery Bank Size for Harsh Weather Conditions
When determining the size of a battery bank for an off-grid home in a frigid climate, you must consider more than just your average daily energy use. You have to prepare for the worst possible situation — the longest period of minimal solar energy production combined with your highest energy use. This typically involves figuring out your daily kilowatt-hour usage, multiplying that number by the amount of autonomy days you want to have without any solar energy input, and then adding a buffer to account for any reduction in capacity due to the cold.
When it comes to LiFePO4 batteries, the capacity decrease in cold temperatures is much less severe than it is with lead acid. However, it’s still something you should take into account when planning your build. Battle Born’s GC3 batteries are designed to deliver their full capacity down to about 32°F (0°C). They’ll still work below that temperature, but their performance will be reduced. If you’re planning a build for a mountain or northern climate, it’s a good idea to design your bank with a 20–25% cold-weather capacity buffer.
Factors to Consider When Sizing Your Battery Bank for Cold Climates
Factor Why It’s Important Daily kWh consumption This sets your minimum energy requirement Target number of autonomy days This decides how many days you can go without solar power Cold weather capacity buffer (20–25%) This compensates for decreased battery output in low temperatures Depth of discharge limit LiFePO4 can be safely discharged to 80–100% DoD, while lead acid is restricted to ~50% Insulation in the battery room This protects the ability to charge and extends the battery’s lifespan System voltage (48V recommended) This lessens the current and boosts efficiency at high loads
The key point is simple: don’t size your battery bank for average conditions. Size it for the worst week of the year, and you’ll have a system that works reliably every other week without any stress.
Why Battery Insulation is More Important Than You Think
When it comes to off-grid living, a lot of homeowners put a lot of thought into which batteries to purchase, but not where to store them. This is a problem, especially in colder climates. LiFePO4 batteries can discharge in temperatures as low as -4°F (-20°C), but they cannot safely accept a charge below 25°F (-4°C) without causing damage to the cells. In mountainous areas where outdoor temperatures can drop well below that threshold for weeks at a time, having a battery storage area without insulation is not only inefficient, it can also shorten the lifespan of your battery bank.
For Eric’s build, Steven Lewis set aside a fully insulated room specifically for the battery bank. This insulation keeps the room temperature above the safe charging limit even on the coldest nights. The batteries themselves generate a small amount of heat during charging and discharging cycles, which helps maintain the room temperature without any additional heating system. This is a passive solution that costs relatively little to implement during construction but pays dividends in battery performance and longevity for the entire life of the system. If you’re designing an off-grid home in a cold climate, the battery room deserves as much attention as any other part of your design.
Why LiFePO4 is a Better Choice than Lead Acid for Off-Grid Locations
When it comes to off-grid applications in remote locations, the choice between LiFePO4 and lead acid essentially boils down to one key question: what happens if something goes wrong and you can’t fix it easily? Lead acid batteries need regular equalization charges, occasional water top-ups, and careful management of the depth of discharge to prevent permanent capacity loss. These maintenance requirements are not feasible in a location that can only be reached by a snow cat. A single oversight during a harsh winter could result in a depleted battery bank that you can’t replace until the spring.
LiFePO4 chemistry takes care of all these issues. Battle Born batteries come with a built-in BMS that automatically takes care of cell health, requires no regular maintenance, and can be discharged to 80–100% depth of discharge without the capacity loss that would severely damage a lead acid bank at the same depth. They’re also significantly lighter, which matters when you’re hauling parts to a remote property by snow cat. Over a full cycle life of 3,000 to 5,000 cycles, the cost per cycle for LiFePO4 is substantially lower than lead acid, making them the smarter long-term investment even at a higher upfront price point.
Off-Grid Living and Luxury Can Go Hand in Hand with Battle Born Batteries
What makes this case study truly significant is not the watt-hours or the system voltage, but rather what these numbers mean in real life. Eric’s house is not a survival bunker. It is a fully modern, luxury home with all the energy-guzzling appliances, lighting, climate control, and electronics that any grid-connected house would have. The only difference is that the utility company is 18 miles away and has no relevance.
A well-designed off-grid power system can ensure that you don’t have to compromise on modern comforts. This is exactly what this build delivers. With the right battery chemistry, the right system architecture, and the right professional expertise, you can live off-grid without any significant trade-offs. The GC3 LiFePO4 batteries from Battle Born, when combined with the Sol-Ark hybrid inverter system and a properly designed solar array, create a power infrastructure that is so good that most grid-connected homeowners would be jealous of it, rather than pitying it.
Common Questions
- How many Battle Born batteries are required to power a house off the grid?
- Are Battle Born GC3 batteries capable of withstanding temperatures below 0°F?
- What is a 48V battery system and why is it popular for large off-grid builds?
- Which solar panels are most compatible with Battle Born LiFePO4 batteries?
- How long can Battle Born LiFePO4 batteries last in an off-grid system?
How Many Battle Born Batteries are Required to Power a House Off the Grid?
The number of Battle Born batteries you require is determined by your daily energy usage, the number of autonomy days you aim for, and your climate. Begin by determining your total daily kilowatt-hour consumption from all of your home’s appliances and systems. Multiply this by the number of days you want to be able to operate without solar input — typically 3 to 5 days for most off-grid builds, but potentially more in extreme climates. Divide this total by the usable capacity per battery (the 270Ah GC3 at 12V provides approximately 3.24 kWh per battery at 100% depth of discharge), and you have a starting point. Add a 20–25% buffer for cold weather if you live in a mountainous or northern climate, and round up to the nearest full bank configuration that matches your target system voltage.
Are Battle Born GC3 Batteries Capable of Withstanding Temperatures Below 0°F?
The Battle Born GC3 LiFePO4 batteries can discharge at temperatures as low as -4°F (-20°C). This means that the batteries will continue to supply power to your home even in extreme cold. However, it is not recommended to charge them below 25°F (-4°C) unless you have a heated battery enclosure or a battery with a built-in heating element. Charging lithium cells at extremely low temperatures can lead to lithium plating — a type of internal damage that permanently reduces capacity.
Eric’s build utilized a well-insulated battery room, which is the most reliable and cost-effective solution for permanent off-grid installations. For those who need a portable or mobile solution in cold climates, Battle Born also provides a 12V LiFePO4 Heated Battery option that includes an internal heating element to protect the cells when charging in sub-zero temperatures.
What is a 48V Battery System and Why is it Used for Large Off-Grid Builds?
A 48V battery system is one where the total bank voltage is maintained at 48 volts, achieved by wiring individual 12V batteries in series groups of four. The primary advantage of 48V over 12V or 24V is efficiency — at higher voltages, the same amount of power is delivered at lower current, which reduces resistive losses in the wiring and allows for thinner, less expensive cable runs over longer distances. For large off-grid homes with high power demands and multiple inverters, 48V is the standard choice.
In Eric’s setup, every group of four 12V GC3 batteries connected in a series generates 48V. The 16 groups connected in parallel keep that 48V system voltage while increasing the total amp-hour capacity. The four Sol-Ark SA-15K inverters are each built to run on a 48V battery input, making this setup an ideal fit for both the battery bank and the inverter array.
Which Solar Panels Are Most Compatible With Battle Born LiFePO4 Batteries?
Practically any solar panel brand or technology can work with Battle Born LiFePO4 batteries, as long as the system includes an appropriately sized MPPT solar charge controller between the panels and the battery bank. The charge controller plays a crucial role — it changes the variable high-voltage DC output from the solar array into the exact charging voltage and current that the LiFePO4 battery bank needs. Without a quality MPPT controller, solar panels could produce incorrect charge profiles that can stress or damage the batteries over time.
When it comes to big off-grid systems, monocrystalline panels with high efficiency in the 400–500 watt range are the practical norm. The system Eric uses has panels with 405 watts, which is a proven middle ground when considering the size of the panel, its cost, and its energy density. In snowy climates, in particular, pole-mounted panels — like the MT Solar Pole Mounts used in this build — perform better than roof-mounted arrays because they can be angled steeply to get rid of snow and capture sunlight at a low angle in winter more effectively.
What is the Lifespan of Battle Born LiFePO4 Batteries in an Off-Grid System?
Battle Born LiFePO4 batteries have a lifespan of 3,000 to 5,000 full charge-discharge cycles before they reach 80% of their original capacity. If you have a well-designed off-grid system where the batteries are not discharged to 100% depth of discharge on a regular basis, you can expect the cycle count to be even higher. If you consider one full cycle per day, which is a reasonable assumption for a home-scale off-grid system, 3,000 cycles would give you over 8 years of daily use, and 5,000 cycles would give you almost 14 years.
Let’s put that in perspective with flooded lead acid batteries, which usually offer 500 to 1,200 cycles under perfect conditions and even less if they are regularly deeply discharged or not properly cared for in cold weather. Over the course of a well-constructed off-grid system’s life, you may have to replace a lead acid bank three or four times before a LiFePO4 bank reaches its end of life. This completely alters the calculation of the total cost.
For a system like Eric’s, which is designed to be a permanent, long-term residential power solution, the longevity of Battle Born’s GC3 batteries is more than just a convenience. It’s a fundamental part of what makes the system work. A battery bank that lasts for a decade or more without any maintenance in one of the most remote and inaccessible places you can imagine is what energy independence really looks like. If you’re ready to design your own off-grid system with the same level of reliability, Battle Born Batteries by Dragonfly Energy has the technical expertise and the purpose-built LiFePO4 products you need.
