A POSSIBLE METER FAILURE

The brutal winter may have taken it's toll on one of the meters of my home built Helm instrumentation panel. I noticed also noticed a lot of condensation inside the plastic face of the panel even though I had a weep hole in the bottom of the case. I'll remove the panel and check on the wiring and replace the meter if it does not come back to life.

BLOG UPDATE:

I went back on board a few days later and discovered the meter that I thought had failed during the winter was now working. So it looks like I might be able to take it off the TODO list.

ELECTRIC SAILING: Heading Home

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The Oyster Bay Oyster Festival is over and it's time to start thinking about heading back. Conditions were the reverse of the sail to Oyster Bay I made a week ago. The winds were now expected out of the west in the morning which was good for my easterly journey. Unfortunately, just like a week ago the winds were expected to be light only between five to ten knots. But, the sun would be shining so it would still be a nice day on the water.  But, like last week during my Columbus Day voyage I would need to get an early start in order to ride the last of the ebb current out of the Oyster Bay/Cold Spring Harbor entrance and into Long Island Sound:

Not quite as early as the trip to Oyster Bay. I figured a 6 AM departure would give me enough time to get out into Long Island Sound before the flood current started to enter in the harbor. I would be bucking the flood current for most of the day but, that's a sailor's lot sometimes.

The alarm went off at 5:30 AM. I made coffee and had a blueberry muffin for breakfast. I had everything ready in the cockpit including even having the searchlight nearby. I let go the lines off the mooring at 6:11 AM. I raised the sail  and  fired up the electric propulsion system for a 10 Amp draw and was moving along at about 1.7 knots in the pre dawn of the morning:

A slight breeze kicked in and BIANKA was soon moving along at 2.2 knots. Even though I was motor sailing I could still hear the noise of the traffic along West Shore Road which was over a mile away as the residents of Bayville started their early Monday morning commutes to work.  A solitary Seagull was keeping watch on a buoy and appeared to be checking that things were clear as I headed toward Cold Spring Harbor bound for the sound
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At 6:56 AM I was off Plum Point at the entrance to Oyster Bay Harbor. At 7:44 AM I was at Buoy 1 in Cold Spring Harbor having used 16.4 amp hours and the battery capacity had dropped to 92% .

At 8:43 AM I was in Long Island Sound off of Buoy 2 at Lloyd Point. The XBM battery monitor showed I had used 26.3 amp hours and battery capacity was at 87.4%. the current in Long Island Sound had also turned against BIANKA.

10:22 AM Found BIANKA off Eatons Neck and battery readings were 79.5% capacity and  showed the EP had consumed 42.8 amp hours in four hours of electro sailing. As I rounded Eatons Neck the Northport Power plant stacks hove into view:

They are hard to miss being 600 feet high and part of the biggest gas fired power plant on the east coast.
Here's a little Nav tip from Capt. Mike: When the Northport Stacks line up they point due north.

At 11:24 AM I was directly north of the stacks. BINAKA's electro sailing had consumed -52.7 amp hours and battery capacity was now at 79.5%. Usually by this point I would have fired up the Honda 2000 to start operating in hybrid mode and not draw down the battery bank much further. But, it was such a nice day even in the very light wind and I still was bucking the flood current so I kept motoring along. I had ducked into Smithtown Bay where the flood current was much weaker than further out in the Sound and was moving along at 2.3. knots.

At 12:05 PM the wind picked up from the northwest and I was moving along nicely at 3 knots so I backed down on the electric propulsion.

At 12:35 PM A gentle breeze developed so that I was moving along at 3.4 knots and I shutdown the EP completely after drawing down 65.4 amp hours and having a battery capacity reading of 69%.

Later in the afternoon I spied the Tall Ship MYSTIC that was docked in Oyster Bay for the Oyster Festival just north of BIANKA:

I thought they might be headed back to their homeport of Mystic Connecticut. But, they instead ducked  into Port Jefferson. Probably were on a cruise with passengers of Long Island Sound. 

I sailed on until the breeze started to lighten and fired up the EP once again to minimize the prop drag. By 2:22 PM The battery monitored showed 69% and amp hours used at 63.5.. I set the EP for a 10 amp draw. I continued on this way until about sometime around 4 PM when a nice 15 knot sea breeze made it across Long Island and BIANKA was soon sailing toward home at 5 plus knots which was a real nice way to end the day. At 5:10 PM BIANKA was back on her mooring. Where the final readings for the 20 plus mile electro sail were  85.3 amp hours and battery capacity was 58.9%. Battery voltage was 49.5 volts. I think a lot of the extra amps were to buck a hefty current coming out of the narrow harbor entrance as the current had once again turned a few hours before. Still BIANKA's electric propulsion system made for a delightfully quiet day on the water and showed that 20 mile legs are easily made in light winds without even turning on the generator during the whole trip.
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INSTRUMENTATION PROJECT PART FIVE: Panel Mounting

Now that I had my chosen enclosure in hand it was time to start working on mounting the meters inside the Polycarbonate NEMA 4X Box .  In addition to the box I also bought the optional PNX-91425 Aluminum Internal Panel which is where I will mount the meters.  First I made and outline of the  panel on a piece of graph paper and then positioned the meters where I wanted to mount them:

I then traced their outlines to the paper and cut them out with an  X-ACTO knife . I transferred the outlines for the meters to the panel and cut them out with a nibbler tool:

After fitting checking the fit of the meters:

I removed them and took the panel outside and spray painted it with some Rust-Oleum flat black enamel spray paint to eliminate any glare from the polished aluminum plate once it was installed in the cockpit. Once that was done and I mounted the meters to the plate all I had to do was install it into the box. Since the panel was made to fit the Bud NEMA 4X Box with screw holes already drilled to match up to the ones in the box all I needed was some spacer hardware.  Happily, I was able to recycle these from the old Kings 8001 Loran hardware that I saved.

 With the meters mounted into the panel I could now start on the wiring of the instrumentation project.

INSTRUMENTATION PROJECT PART FOUR CLICK HERE

 INSTRUMENTATION PROJECT PART SIX CLICK HERE 

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INSTRUMENTATION PROJECT PART TWO: Rethinking the Paktrakr

I guess I should explain why I am doing this instrumentation project. When I first converted to electric propulsion I had a Xantrex XBM battery monitor. I ordered it with with the Asmo Marine Thoosa 9000 electric propulsion system. It worked well except for the fact that even though the specifications claimed it was "splash proof" it did not say anything about it being sun proof. So I had to move it to a location in the cockpit where I could still see it but, was not view able without opening one of the cockpit hatches.
In addition it could only read the battery pack voltage and current. It did not read the individual battery voltages.

 
In my researching for an electric propulsion system I came across postings for another battery monitor called a Paktrakr.  It had been used by a number of electric vehicle enthusiasts. Unlike the XBM it could read the individual voltages of the four batteries in BIANKA's 48 volt propulsion bank. Here it is showing the voltage of battery number one in the 48 volt string:

It  could also show the entire pack voltage in a digital display and as a fuel guage:

It would also even tell you the temperature of the battery compartment:

It provided a lot of information in a small package.  It could with an additional sensor also read current and also had the ability to download battery data (with an optional cable) into a computer for analysis. I thought it would be a good backup the XBM since monitoring your battery bank in a boat with electric propulsion is like having a fuel gauge on a boat with a diesel engine. So a year after I converted to electric propulsion I bought a Patrakr and installed it in the main cabin so I could keep an eye on the battery bank without having to go out into the cockpit to look at the XBM monitor. It had a nice small display and it fit very nicely on the door to BIANKA's  wind, depth and speed instraments:

It worked well for several years. At first I just used it for voltage measurements of the battery bank. But, soon I ordered the current sensor so I could see how the battery bank was charging too. A few years later I ordered the data cable. So I could see how the battery bank was charging over the winter layup with the solar panels.
Then early last spring I went on board and found out one of the 8A4D AGM batteries in my 48 volt string was not completing it's charge cycle. I could not see a reason why this battery would suddenly time out when charging. The only thing different between this battery and the other three is the Paktrakr takes it's power from this battery. Even though it's only drawing 25 milli amps of current for the basic unit I had recently added the data recorder and so it might have been drawing more. How much I don't know but, I decided to disconnect from the battery bank full time. I was able to eventually get the troublesome battery to accept a full charge. But, I decided that I needed an alternative battery voltage and current monitoring system to the Paktrakr. One that does not take power from one individual battery like the Patrakkr did. That's the reason I embarked on this instrumentation project.

INSTRUMENTATION PROJECT PART ONE CLICK HERE

INSTRUMENTATION PROJECT PART THREE CLICK HERE

INSTRUMENTATION PROJECT PART ONE: Plan A

Back around Earth Day last year I mentioned that I was planning on recycling the now obsolete Kings 8001 LORAN unit. I have come up with a new instrumentation project to monitor BIANKA's propulsion battery bank. The  weather proof case of the Kings LORAN will fit nicely into my plans.  The back of the Kings unit has a few connectors on it which might come in useful:

The coaxial LORAN antenna connection might come in useful for some type of video feed.  The AMP 25 pin connector might also prove useful. But,  first I have to  remove some of the internal electronics. This King 8001 LORAN unit sold for about $600 in 1985. In today's dollars that would be over $1,100. Opening it up I could see why:

Ed King sure put a lot of electronic technology inside the box:

Including some LSI (Large Scale Integration) chips for the display board and some nice conformal coating to help protect the circuity from the marine environment:

It's no wonder this unit was working right up until the Coast Guard shut down the Loran transmitters. Probably would have kept on working for many more years if they had kept the transmitters operating too . Oh well at least some of Kings design will live on at least on BIANKA. Even if it is only the case:

 I knew the case for the Kings Loran would be good to use since it already had a home and mounting hardware in the cockpit and was pretty weather proof.  But, I also hoped to recycle as much of the existing hardware as possible. The first thing I thought I could use is the metal shield that was used  between the some of the circuit boards inside the Loran. I thought it would make a good mounting plate for the meters and switch.

Well, after buying some of the metering components I soon found out that my original plan was just not going to work out.

Using paper cut outs of the meter dimensions I soon realized that the Kings Loran case would be to small to house all the instrumentation I wanted at the helm. It looked I could fit the four battery meters and the switch that controls them. 

But, I could not also fit the more important current meter inside too. Even though it looked at first like it would:

But, in the end I could see it was just not going to work out:

So it's on to Plan B!

 INSTRUMENTATION PROJECT PART 2 CLICK HERE