Modifications and Panel Completion

Chilly weather this past weekend made good project weather.  I had two primary projects that I have been looking forward to completing, the dash panel and modifications to the 48 volt charging system.

Charging Modifications

When I first installed the 48 volt charging system, I made use of a 12vDC -120vAC inverter that I have had on a shelf in my shop.  This inverter served us very well for years, installed on our boat but in the WattCycle I was getting poor results.  I would find that the 48 volt charging system would only trickle charge the batteries when plugged into the inverter but operated fine when plugged into utility power.  The reason, the sine wave output that was produced by the inverter.

Inverters - Modified Sine Wave or Pure Sine Wave
An electrical sine wave is the repetitive oscillation of voltage from negative to positive and from positive to negative.  This sine wave or oscillation makes our common AC electrical work.  An inverter can either make a pure or modified sine wave depending on the technology incorporated.

Modified sine wave
The output of a modified sine wave inverter is similar to a square wave output except that the output goes to zero volts for a time before switching positive or negative. It is simple, low cost and is compatible with most electronic devices, except for sensitive or specialized equipment.  Most AC motors will run off this power source albeit at a reduction in efficiency of approximately 20%.

Pure sine wave
A pure sine wave inverter produces a nearly perfect sine wave output (less than 3% total harmonic distortion) that is essentially the same as utility-supplied grid power. Thus it is compatible with all AC electronic devices. Its design is more complex, and costs more per unit of power.

The inverter I first installed was a modified sine wave inverter that powered up a coffee maker, charged cell phones and even operated a microwave but it was clueless when it comes to a 48 volt smart charger.  I upgraded to a pure sine wave inverter and now my 48 volt battery pack gets full power whenever I need it. 

Dash Completion

Cutting, drilling, fairing and sanding followed by priming, sanding and painting.  The dash needed completion to finish off my project and also protect everything that I have assembled.  Now that all the dash parts are put into place and the finish is applied, the project is taking on a completed look.  I wired the last switching circuit for the next project, lighting.  I now realize that I forgot one valuable option...cup holders!

Dashboard

Watts Up had another very successful, emissions free, electric day.  I had the chance to ride farther and harder than I have done in the past, pushing the batteries and charging system to the limit.  Trips to marinas, vendors and even a trip to the bank and grocery store before my day was done still left me with enough power to get back home.  Never was I without power even when I put another 60 lbs of groceries in the cargo box.  After leaving the grocery store, I had to motor into a 15 mph wind with additional weight of goods.  I noted that my power consumption was 20 - 25 amps while loaded down and heading into a stiff wind.

While waiting for a left turn signal at an intersection, a trucker asked me "You got a motor in that thing?".   When I replied yes, his response was, "Thought so, you was going too damn fast!".

The New Dash
My mission tonight, once my day was done, was to make a dashboard for all the metering devices and power switches that the cargo bike needed.  The project started as just a prototype but turned into the actual dash once I saw how easily it was coming together.  With some scrap 1/2" birch plywood that I had in the shop, I was able to come up with a basic dash that would accept all the gauges and switches that I had anticipated.  The dash would be installed just forward of the handlebars and just behind the solar panel located on the cargo lid.

I have installed a main power switch on the far left, the Ganz solar charge controls, power meter and a light switch on the far right.

Watt's Up Meter
I was needing to monitor voltage and amperage consumption on the 48 volt propulsion system, something that would act as a fuel gauge and tachometer that you would find on a typical automobile.  I was searching online for digital or analog gauges when I stumbled across the Watt's Up Meter.

OK, what are the chances that Watts Up Marine would find a voltage/amperage meter that is called the Watt's Up Meter?  How could I say no to such a purchase?  It turned out to be a very successful find. 

This device was designed for radio controlled electric cars, planes and boats but has some very high voltage and amperage spec's.  I was nervous at first, worrying about the amperage demand that I needed to run the power hub.  The Watt's Up Meter is rated for up to 60 volts and can handle up to 100 amps of current draw.  The WattCycle is rated for a maximum of  30 amps at 48 volts, the new meter should be more than I need.  The display reads amperage draw, battery voltage, amp hours consumed,  peak amps, watts and watt hours.

The only complaints that I have with the Watt's Up Meter is the size of wire and length of wire that they supply.  I have wired the WattCycle with 10 AWG wire to handle the 30-40 peak amps that the hub will be drawing, however the Watt's Up Meter comes standard with 14 AWG.  To me this looks like a weak link in my chain.  The length of the standard source/load wires are only about 6" long, you do not get many chances to make waterproof connections without running out of wire leads.

I now have the beginnings of a dash panel.  I intend to complete the box, fiberglass it and give it a complete coat of Awlgrip just like the cargo lid that it will attach to.  I would like to have a completely sealed unit by the end of the week.  It is all coming together.

Full Day at Work

Today was Watts Up Marines first full day of using the WattCycle as our primary service vehicle, it was flawless.  I am proud to say, not an ounce of fossil fuel was consumed to get me from my home, shop, vendors and clients.  I could have put the bike into operation last week however mother nature did not give much of a weather window, it rained heavy or was threatening many of the days.

Kemah, TX

Kemah is a great city to live in, it is a small coastal community with great eats, entertainment and convenient shopping.  As a sailor, it gives me the ability to live within a couple miles of my boat, minutes from great sailing and access to the Gulf of Mexico.  One shortcoming however, is that they do not offer a friendly environment for bicycle traffic. 

There are no bike paths down the major thoroughfares, the roads were built without bike lanes and many of the streets are narrow.  If a sidewalk does exist, it is about two feet wide, weaves under overgrown vegetation and likely comes to an abrupt end in a block or two.

While out riding the cargo bike, I often encounter some rather aggressive motorists that have love affairs with their horns.   On one particular four lane road, they could easily move over to the left lane to go around a bicycle however they find that their horn is somehow a much more satisfying solution to their frustrations. 

...All smiles

What really amazed me today, was my ability to travel down heavy traffic streets and maintain enough speed so I did not annoy most of the gas guzzlers.  I even had the power and speed to dart across busy intersections that normally I would have had to wait for the most opportune moment. 

Today did not offer perfect conditions for a solar charging system, it was an overcast day with small bursts of hazy sunshine. I am happy to say that even with the minimal direct sunlight, the solar panel was filling my charging batteries with enough power to keep my 48 volt propulsion system charged all day. The sunny summer months here in Southern Texas should give me everything that I was hoping for in a zero-emissions vehicle. 

My typical day consists of several short trips to marinas, pick up supplies, meet with customers and runs to the shop, broken up by longer durations camped out, in a sunny marina, working on a yacht.  For the most part, this would be great solar charging conditions. 

As time allows, the next projects are building a dashboard for gauges, meters and a key switch, adding lighting and getting the company graphics applied to the box.  The company logo might have to be first on the priorities, maybe then it will put an end to the request for hot dogs, Popsicles and cerveza...no, I doubt it.

Today was a great start!  It proved that I can operate my business without the need of fossil fuels for transportation.  There will come days that will require me to pull out the gas burner but this is one step closer to freedom!