Pieces of the electric motor puzzle

We've now received all the parts we need to assemble the electric motor system. Electric Yachts sent us the 10kW electric motor and controller system. Lorne from Genco has obtained the deep cycle batteries from Odyssey. The charge controller has been semi-custom made for us by Analytic a supplier of heavy duty and advanced charge control systems. Lorne has also supplied all of the heavy duty wiring for the 48 Volt battery system.

Our plans from this point are as follows:

Remaining internal wiring work - Lorne:
1. 2 x GFI for AC, wiring done, just need to put in to GFI outlets
2. DC panel installation, fixture for galley, electrical to fridge (test if it works)
3. House batteries - we've agreed to buy one additional Deep Cycle Lead Acid battery approx. $130.
4. Battery boxes installed, existing house battery location. - we've agreed to buy 2 battery boxes for approx. $30 each for house batteries (use one of the existing Nautilus plus new Deep Cycle)
5. Bonding / Grounding - complete a few more connections to metal through hull connections
6. (NEW) Automatic bilge pump reconnection and switch to exit through exhaust system through hull.


Electric Motor Install:
1. Paint motor compartment with bilge paint (prepare by sandpapering area) - Ian Wilson
2. Transfer batteries and motor kit to boat by Monday evening, August 16, 4pm. - Ian/Ianito/Claire/John
3. Electric motor battery box assembly and battery box custom made. Receive charge controller for motor batteries. Design and schematics. Current hours documented. Remaining hours and completion dates. Monday August 16. - Lorne
4. Battery box materials. Plywood - 3/4 inch (marine grade mahogany), bolts, washers, hinges, threaded rods, primer waterproofing paint, etc. from Home Depot. Wed. Aug. 17- Lorne
5. Build battery box at Port Credit site. Wed. Aug. 18 - Lorne
6. Install electric motor. Battery box where fuel tank was. 4 Odyssey batteries in series connection for 48 volt system. Electric motor on electric motor mount. Aug 19/20. - Lorne
7. Figure out shifter/binnacle removal and replacement with electric motor throttle system. - Lorne

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Once we pull the boat out for this season.

1. Review motor mount leakage issue. Is it resolved once the electric motor is installed? Reinforce area that is of concern.
2. Review exterior hull scuffs and issues. Determine what repairs/painting/cleaning is required.
3. Prepare batteries for storage with full charge. Consider a solar panel to keep charged.


Before launch for next season:


1. Lighting and radio cable for mast.
2. Switch to a fixed propeller optimized for charging boat batteries when sailing.
3. Rolling furler.
4. Depth, windspeed/direction, GPS installations.
5. Radio for nav station/desk.
6. Review fridge requirements.
7. Determine solar panel (4 x 40 watt) setup and installation, Bimini design.


NOTES:
1. Both charge controllers will be installed in the storage closet near motor. House battery system charge control system is already installed there on the left side. Analytic charge controller for electric motor batteries will be installed on the right side of the storage compartment. All done to minimize chances of these ever getting wet.
2. Keep an eye on the leak near motor mount.

Learning from our mistakes

Tough week. Following on the heels of such a wonderful week of sailing for the first time on our own boat, this weekend was all about having things go wrong. We tried to get out sailing Sunday which was looking like a dream day. We are getting quite handy at the rigging and things were all set for a quick push off the dock, and out for some sailing on such a clear and beautiful day. Waiting for everyone to arrive found the wind coming in stronger and stronger from the north especially after noon.

Looking back I can see that the wind coming in from the north meant that as we came out of our slip pointing east/west, our bow would be pushed heavily to the south away from the direction we wanted to go. It certainly was. Our neighbours powerful boat was, after two attempts able to power through the turn, which was the technique I decided to follow. As it turned out, the wind was too much for our temporary dinghy electric motor mount. The wooden mount failed as I thought I had to up the throttle to try to make ground forward into the wind. I should have worked with the wind and swung south, using the wind, rather than having fought it.  Our sister boat, a 25 foot C&C, with our other neighbour at helm, demostrated just minutes after our failed attempt, just how easy it could be done with a low power dinghy motor by just looping around to the south using the wind to advantage. 

When the mount broke in half I, fortunately, had thought to attach an emergency line to catch the motor from sinking after the failure (I had even looked at the mount earlier and said to myself it looks like it might be warping...and surely I should have known it would fail sooner or later). Everyone remained calm. I asked crew to prepare to fend off as we began to drift for a couple seconds in the dock area. A familiar face happened to be motoring by in a dinghy, so, calmly, I asked for some help to get back into our slip as our motor had failed. They quickly agreed and began pulling our bow line around. Seeing that assistance was required, our neighbours helped us come in to dock without any further mishap. We also had another member come in as a backup to make sure all was okay. Help others when they are in need as you will surely need their help one day. 

Despite the safety line catching the motor, it looks like the battery may have been damaged by the water...what a sick feeling knowing that. Hopefully the motor system is still okay...I think it will be. I'll get a replacement battery and we'll be back on track with a significantly beefed up temporary dinghy motor mount (ideally, that will not be needed) and a great deal learned about the way to work with the wind especially if your boat is working under less than ideal mechanical repair.

Hard as this has been, and as hard as it is to have to take all the feedback from those that know better, this is what it is all about. Learning from the school of hard knocks is painful and hard to deal with at the time, but the kind of thing that expands your knowledge of the situation deeply and memorably. People will tell you, "I told you so", and they will be right, but they are the same people that would not have tried and would not have learned from those same mistakes. How do you deal with your boat when/if it loses power when going to dock...been there now. How do you deal with high winds coming across your port side when exiting your slip...work with the wind, and feel comfortable looping around to the south rather than always fighting the difficult conditions. Build repairs beefier and with better back up systems than you might initially conceive of. Like in baseball, anticipate what each component will do in a failure situation so that the backup systems handle them better. Think of the forces that will impact any and all of the systems on the boat, from lines, halyards, buckles, shrouds and pulleys, and imagine how well they will hold up under the worst possible weather conditions, not fair/average weather. Obvious stuff but particularly real once you've made mistakes.

When it rains it pours. Our home solar system is being held up from being turned on by the Electrical Safety Authority (ESA) which leaves me holding the bag on an expensive system that is supposed to generate income to pay for itself. After two months of waiting for our supplier/installer to work it out with ESA, still no resolution. Today our electrician has proposed a voltage transformer to try to address the concern. The waiting and not knowing is hard to deal with. You want to do something about it to move things along, you try to push, when things aren't moving, and you instigate a little forward motion, and then you wait some more. Hopefully we'll hear soon, that this will resolve their concern which my installer is telling me should not be a concern. Familiary story.

Similar story with the electric motor for the boat. Much of the current frustration with the electric dinghy could have been avoided had things simply moved along with fewer hurdles and difficulties. Life isn't like that though. Certainly we made mistakes in this process and we'll learn from them as well. Good things take time and they are hard, especially when they are the road less travelled. We are learning more than I could have imagined about things I had not even thought of. I know that all of this will become the backbone of what gets us through the tough stuff up ahead.

My Grandma used to say tough times don't last just tough people. These things will be overcome and the extra difficulties will make them all the more satisfying once accomplished. Sometimes you just have to take it, take it from everyone as best you can, take it from yourself when you are harder on you than anyone else and come back out fighting harder than ever to make it happen. Dreams don't just happen, you have to fight to make them real, and they don't happen without mistakes. Kick yourself and tell yourself to do better next time. Your dream is worth it. 

Sailing is such a joy

Last evening we went out for a sail around Toronto inner harbour with some future sailors. Ian and Claire Wilson, my wonderful crew, easily fell into their roles, helping their cousins  David and Cassie (and aunt Kathleen), get into the swing of raising the sails, tacking and jibing. Such a wonderful warm evening to let each of the younger kids take a turn at helm. Seeing that twinkle of wonder as these youngsters commanded our 35 foot sailboat around the harbour, tacking with just the touch of their fingers. Claire's friend Andrea also took a turn at helm and was handy around the lines and sheets.

With just two or three knots of wind we were able to start raising the main sail on our way out of the dock area at QCYC. Our small electric dinghy motor only needed about a minute of run time before I was able to shut it down under main sail power as we exited the club dock area. A beautiful gentle cross breeze took us directly out of the club, into the harbour area on a close reach. Initram is such an easy boat to sail under light winds, she calms her skipper, and allows her junior mates to learn quickly and safely.

Tacking back and forth across the harbour was such a joy, my heart leaps at the thought of how we so elegantly slice through the water in our steady and solid boat. Silently gliding through the water, on a gentle breeze, a slight churn of water off our stern proving she makes excellent headway even under these light winds, the beautiful view of the city on our tack north, the quaint Toronto islands on our southern tack, and the odd propeller plane gliding in over our heads towards the island airport. Freedom. The mere thought that at any moment we could make for the eastern gap, exit out of the harbour onto the expanse of Lake Ontario, and head out, and one day, out to the oceans, through the St. Lawrence, to the Atlantic Ocean, the Pacific from the Panama Canal, South China Sea, Indian Ocean, the Med, and back to the Atlantic, all by the power of the wind, and the idea, that yes we can, and we will head out around the world one day soon enough.

Dream. Always dream. And then make your dreams happen. Happiness. Find your happiness. (Have been reading Slocums book about sailing around the world on my iPhone)

First sail on dinghy electric motor

We finally "got off the dock". Today, son Ian, Dad, Leigh, Claire and I went out on our sailboat, Initram, with the dinghy electric motor, a Torqueedo electric outboard, rigged to the back of 35 foot C&C. This is the first time in a few years that Initram has been out for a sail. What a great feeling after so much waiting.

Last Thursday night I spent a few hours jury rigging the Torqueedo, lithium battery powered electric motor to the back of our C&C 35. I basically clamped some hard wood to the swim ladder. We've been using the dinghy with this amazing well built German electric motor for a couple weeks. It has lots of power. I'd read that it could push 14 foot boats and perhaps bigger ones. So, since our Electric Yacht kit is still another week or two away from being fully installed, and we have been aching to get out and sail, we decided to try this temporary solution.

First of all, the boat is new to us so we had to figure out how to rig up the jib sail for the first time. I've worked the main sail up and down a few times at the dock so that was ready to go. We did a double check on all safety equipment, reviewed our plan for taking the boat out, and off we went.

Silently I reversed with the Torqueedo motor jumping a bit as I didn't have the ladder held down in place for reverse. Still, she moved slowly back quite nicely, sputtering a bit but kept moving. Once we'd pulled into the middle of the lagoon, between all the other boats, we hauled in the fenders (not wanting to have to buy everyone at the bar a beer on our first run out), and engaged full forward thrusters captain! Away she went, quietly past our neighbours, to the right of a few sailors coming in to dock, and past the Wards Island ferry dock. A few butterflies churned in my stomach, as I hoped that we would not run out of battery power until we were well clear of the docks and some fellow sailors who have said I am crazy.

Once we'd gotten past the entrance to QCYC, our club, we put the bow into the wind and began hauling up the main sail. After futzing with a double winched line, we got the main sail nicely up and started plowing through the water. I turned off the forward thrust on the electric Torqueedo, to conserve as much battery as possible for our return to dock, and we began hauling the jib up.

She sails beautifully. Smoothe as silk. Feels so well balanced you can hold course with just a finger on the wheel. We had fair winds and so were moving along very well. What a joy to be out in the Toronto Harbour, at last, sailing in a good breeze, with all the other sailors.

After some high fives, hand shakes and self-congratulations we enjoyed a couple hours of sailing. While at the helm the crew mutineed the idea of taking her out through the eastern gap for some open lake sailing. Not yet, apparently not everyone felt ready. What a great feeling just to tack back and forth on this beautiful speedy boat. We all had a blast taking turns at helm.

Finally, we got the word, time to go in. I was a bit worried about whether we'd have enough juice in the batteries to get us back to the dock under some kind of propellor driving power. I was prepared to use the main sail a bit in case we ran out of electric engine power. I kept the throttle in maximum distance setting and we slowly came into the QCYC docks under slow speed, red buoys on the right of course. What a day! The adventure continues. Soon we should have the full blown big 10 kW electric motor kit from Electric Yachts and Odyssey batteries (AGM, 1800 series, rack mountable), and the Analytics super military/marine grade charge controller. Stay tuned.

Ready for electric motor

We've cleaned out the engine compartment with some "green" cleaner that Leigh found in the pile of cleaners on the boat. That, and some extra elbow grease, and the boat is starting to look and smell like roses. Okay, so maybe I washed down the grease in that engine room, all 40 years of it. And now, here you can see Leigh actually cleaning it. Now we are ready to mount the new electric motor. We are hoping to see it arrive this week some time.

You can see that the water is a couple of inches higher on the water with the gasoline engine removed. We'll see how the battery and electric motor weigh in. 

I also went around the entire set of lifeline railing on the boat and tightened up all the uprights as some were actually popping out of their hold fittings. 

To the left are pictures of before and after the engine compartment was cleaned. What a relief to get that old crud out.

Gasoline goes, electric is on the way

Today we removed the Atomic 4 gasoline engine that had given our boat 40 years of service. This paves the way for cleaning up the space for our electric motor. Thanks to Paul and Lorne, the process went very smoothly. Paul used his dinghy to push us to the crane. We then hooked up the cranes hook to a special U shaped piece of metal for pulling engines out of boats recessed engine compartments. We hooked up a steel chain to the old Atomic 4 engines circular hole in the center on top. Up she went and then out. What a relief. Now the fun begins. We'll clean up with sunlight and then paint to get ready for the electric motor that should arrive this week.

Dad (to the right) did all the hard work of cranking the cranes hook up and down, as well as side-to-side. Lorne, in the top picture, takes care to keep the engine from going astray as we move it onto shore. With the old gasoline engine out of the boat we can now see what 40 years of burning gasoline leaves behind (see photo below).

We're getting close on the choice of batteries. Getting quotes from my solar system provider and a local distributor of Odyssy batteries as recommended by Electric Yachts. Lorne is narrowing in on a military grade charge controller. New elelectrical work is being completed by Lorne to upgrade AC and DC wiring to latest requirements as required for our insurance. Lorne has new electrical panels ready and will do final hookup shortly. Lorne has also got a plan for a battery bank platform and box to ensure the batteries are firmly secured. We are looking at a fairly heavy set of 4 x 12 volt batteries that may come in at about 500 pounds. So with the electric being about 200 pounds lighter than the gasoline engine and removal of gas tank we should be about even on the weight.

Electric motor conversion

Now comes the hard but exciting part. Replacing the forty year old Atomic 4 gasoline engine. We are replacing it with an electric motor to be provided by Electric Yacht. The plan is to haul the Atomic 4 out with the clubs crane, along with the fuel tank and other elements related to the gasoline engine.

Once removed we'll clean up the space, prepare it for the electric motor and batteries. While at it we'll be upgrading the electrical systems on the boat in order to comply with requirements for insurance. In order to do this our survey suggests several areas that need work including re-wiring the AC shore power systems, adding a GFI outlet, updated wiring that complies with marine code, a new electrical panel, updated DC systems wiring, and electrical wiring and systems to support the new electric motor, battery system and house DC power systems.

The future systems making our sailboat a truly "green" transportation option and vision for the future of electric powered boating include:

1. Electric Yacht 10 kW, 200 Amp brushless electric motor
2. Eight deep cycle (Trojan?), rechargeable batteries (upgradeable to 16 in future if required)
3. Charging systems from AC shore power.
4. Charging system support for propeller driving electric motor as a generator while under sail.
5. Four solar panels (4 x Siemens 40 Watt solar photo voltaic panels) mounted as a bimini on the back of the boat. Charging for electric motor battery or house batteries (switchable or automatic).
6. Two deep cycle batteries for house power separate from electric motor. Switchable in emergency to be able to provide electric motor power.

Future Add Ons:

1. Wind turbine for charging electric motor battery system.
2. Small gasoline generator for backup/long haul electric motoring.

All of these systems are designed to test and learn how well electric motor systems work for sailing. What we learn will be used to design, plan and eventually build a system for a future 36-40 foot catamaran sailboat we'll be upgrading to sail around the world on 100% renewable energy from solar and wind (gasoline generator will be for emergency use only). Catamaran upgrade to electric motors will require the use of two motors mounted in replacement of two diesel motors.

Here is a video showing an Electric Yacht conversion story:

Here is a 40 foot sailboat conversion story from Electric Yachts web site, check it out:

It was a fortunate day in February 2008. Fortunate because hull number 82 of the legendary Cal 40 came my way and fortunate too because she came without an auxiliary. The diesel had expired and lay ashore somewhere waiting for yet another rebuild and more. Having had a couple of less than pleasant experiences with diesel motors in previous boats I had developed a phobia, an allergy even, to those belching complications. Normally I would go engineless or clamp an outboard on the stern but the Cal 40 was somewhat large and I did not want to remove a very useful Monitor vane to make way for an OMC. What to do?

I had heard of electric motors for sailboats but the task seemed daunting because I am a mechanical klutz and also with the boat in Malaysia and the electric units available only overseas, it appeared a mission impossible. Anyway, I plugged away on the Internet and on an off chance, sent an email to Electric Yacht and as they say, "the rest is history."

Scott McMillan immediately came to grips with the complication of installing an electric motor in the Cal 40. The motor needed to sit backwards and down into the pan which housed the v-drive. It would be tight. Measurements and details went back and forth for a while. Amazingly all my concerns were addressed, all emails were answered and I knew this guy was several steps ahead of me. But was it doable? Scott thought the dimensions might work but was concerned the 48 volt system was too small for my boat, being 15500 lbs displacement on a 30'04" waterline length. The decision was mine. I knew I was in good hands and put trepidations aside and mailed a check for the deposit. It was done.

There was a delivery backlog which gave me time to remove the old tank and its 110 litres(29galls) of diesel, get rid of forty years of crud and grime and cut out the v-drive with an angle grinder. White paint followed and the bilge shone. Scott sent me a photo of my unit with the super short shaft and pretty soon a hefty parcel arrived at RLYC Langkawi. Duty free, of course.

Custom built motor, throttle, percent meter, master switch, 48 to 12 volt converter, custom cableing for the batteries and the controller which Scott had built separately so it would'nt get wet at the companionway foot, detailed instructions ; it was all there. He'd even upgraded me to a dual 48/72 volt system, in case I should need it.

Often times things just fall in place. My South African friend, Faith offered to help. A piece of 2 by 4 drifted by and made a stong back from which to hang the motor on a handy billy and within a week it was all hooked up. No engineering, no dry dock.

Fortunately Trojan T105 batteries are available in Langkawi and with the help of a two young and strong Burmese workers we placed them in the space where the diesel used to sit. Not exactly level but secure and unable to come adrift at sea.

Now for the results:
Conditions; no wind, flat calm, runs up and down tide and averaged. GPS speed.

1.1 knots @ 4 amps,
1.93 knots @ 11 amps,
4.0 knots @ 72 amps.

Cal 40
LOA ----------------------- 39'04"
LWL ---------------------- 30'04"
BEAM ----------------------11'00"
DRAUGHT------------------5'07"
DISPLACEMENT---------15500lbs.
Long fin, spade rudder, flat sections.

The motor limit comes on at 75 amps. The pitch is not quite right. It should go to 100 amps which may deliver another half knot and give a little more torque. The extra pulley Scott sent along for the 72 volt system may do the trick and I will swap it around soon. Otherwise I will have to adjust the Max Prop (self feathering) at next dry docking. Manoeuvering with the electric motor is a snap. Plenty of torque and of course no noise, no smoke. I charge up the batteries from shorepower at the marina via a battery charger. It's only pennies.

I have been in and out of the marina twice and the batteries are down 10%. When I extrapolate the data I come up with an endurance of 20 miles to a 50% discharge level and 30 miles to a 75% discharge level. Underway I will charge the batteries from the Air Marine wind mill; solar panels via Zahn's 12 to 48 volt optimizer. Another option is to change to a fixed propeller which would let the regen work on passage but the price is high; 15% loss could add up to a 30 mile a day deficit. There is a good chance I can do it all without buying a generator.which like the diesel is a step in the wrong direction.

Weight comparison might be of interest:

Perkins 4.107, Walter v-drive, full lube oil and bunkers, 4 Trojan T105, 1 starting battery, exhaust/cooling paraphanelia
Total approx weight…………………………555kgs(1228lbs)

Electric Yacht motor complete, 8 Trojan T105 batteries, Battery charger.
Total approx weight…………………………258kgs(567lbs)

That's it. I wish you, "Good sailing". With emphasis on sailing. Ben Lexcen's famous edict, "Fast is fun" got it right. Sailing is; motoring is not. Electric Yacht is a happy compromise.