Keeping things cool

 I mowed the front yard in 94 degree heat, checked the motor temperature directly after and got 170 degrees on motor and nearby batteries were 140.

I had ordered a 48 volt computer fan on eBay and decided it should be tried out for cooling. 

The fan moved a crazy amount of air, sounds like a jet engine, at one point sucking my t-shirt in and shredding it.

Not wanting to lose any digits, a guard was needed. I dug around and found an old speaker grill that fit, right down to holes lining up with fan mounts. 

I modified the grill for better air flow by removing fabric and cutting some slots.

I made a bracket for the fan and mounted it over the motor, since there was a hole in the metal I used , I installed a disable switch. 

I wired it through a fuse to come on when the drive motor runs, I will check temperature next time I mow, but I’m confident they will be less, just a matter of how much.

We’re going to need a bigger Battery

 Today I evaluated a few things, I originally thought I could get the other 32 batteries under the hood, this won’t work. A second battery set will go in a custom weight box in the front and will weigh 110 pounds, this will aid if I ever pull something.

The added batteries will almost double my run time, so I’ll be able to cut the entire yard in one shot.

The replacement battery relay arrived, so I just need to weld up the new battery box. A new fan was ordered to keep motor cooler, hopefully. 

I finally sorted out the seat switch to work the way I wanted. 

Still on the list, a good solution to charging both batteries without buying another charger, and installing the headlights.

Mowing test

 I finally got the charger in, I wired a plug and tested. I had already charged the batteries in sections so the new charger didn’t charge long and shut off. 

I wanted to do a mowing test even though I didn’t have all the batteries I wanted to install. 

I found the current decreased as time passed, perhaps the grease in spindles became softened with heat.

I mowed for about 40 minutes, probably a bit more than 1 acre. Power use was 78 amps,  about 3850 watts. This tells me my batteries have about 80% capacity at full charge.

I estimate having enough for the entire yard if I add the other batteries. I did note the motor gets pretty warm, can’t leave your hand on it. The spacer to keep batteries away from motor inlet was narrowed, it may help. I may add a fan later.

Some details

 I am still waiting on the charger replacement so in the meantime trying to find places for more batteries. The original plan was 2 sets of smaller batteries in parallel as bank 2. I now see they will not all fit as planned over the bank one set. I may build a box for front or rear to house some batteries. 

I am also waiting on spring for the seat, so my seat switch will work properly. 

I designed the electric interlocking to mimic the gas operation, key on, PTO has to be off, brake on, and seat switch on to “start”. When running, leaving seat or turning off key will stop motor and startup must be repeated. Safe from runaway mower from just turning it on.

I have some new led headlights to install as well

Original goal was proof of concept, combined with a backup for the gas mower. It may need a charge in between to complete yard but I figured that in.

Real world test

 I serviced the deck and got it under the mower. I drove around to check current draw, hydraulic drive eats a lot of power. Drive is about 80 amps, mower engaged amps are 150-170 depending on forward speed.

Things look good so far, but I hooked up charger and it let smoke out, so I’m going to need another.

Wiring

I made a bracket and mounted the combination meter and wired to shunt, tested things, all good.

 I fabricated a tray to hold components and mounted relays, battery contactors and terminal strip.

I wired the 12volt side of things and discovered one contactor in not working. I will address this at a later date,

I decided to add a high voltage fuse in the 48 volt side, just in case. Tested fuse accidentally when cable bridged some batteries, fuse is opened. On a positive note, fuse protected things, bad news is fuse is over 100 bucks.

I had a higher rated fuse I installed until I find another.

I checked connections, I bypassed seat switch due to not installed. I turned on the motor and checked transmission operation and hydraulic lift for deck.

I bolted on covers and parts. Test drive soon and deck install.

Battery install , first layer

 I fabricated some support trays from aluminum and made spacers to raise batteries above hydraulic equipment and get maximum area for batteries in the front.

I ran into a clearance issues, I had to countersink some fasteners and had issues with some batteries were a little bulged and bigger than new battery dimensions.  Used batteries caused a fair amount of frustration.

The bottom set of batteries is a very tight fit! I believe I have adjusted things to work.