My ZAP is almost a real car now

Puppyjump

100 W
Joined
Sep 3, 2008
Messages
190
I've finally got the 84V wired up. The performance is noticeably improved. It will hit a reliable 40 MPH now with higher speeds up to 43 on flat roads when it's in a good mood. The mid speed power between 15 and 35 is quite improved and keeps up with general traffic, and I even gently pass about half of it now.

There were a couple cars though that I had been pacing, who when they figured out I was driving an EV, they floored it to speed away at probably 55-60 on the 40 MPH posted road. Making a point, I guess that only ICE is 'merican and rules and how dare someone drive a silent EV that looks like it fell out of a cereal box. This did not happen to me when I was slower at 72V.

Going 41 on flat road I encountered a large overpass hill where the speed slowed but held steady at 35 on the incline. Going down the other side I sped up to 50 and it stayed at high speed back on the flat. After a mile, the speed had slowed to 46 and seemed to be holding (or at least decaying very very slowly) there except I came up to a light and had to stop.

The range is better now probably due to more battery capacity but also the Peukert effect whereby I draw fewer realtime amps while cruising.
The red Lo-Batt light used to come on while under heavier loads after 10 miles at 72V, but I drove 15 miles at 84V and the light had not flashed yet. Note that the Lo-Batt circuit is still only connected to the original 72V pack. The extra 7th battery is only connected between the 72V pack and the motor controller. The whole cab and 72V wiring still only sees 72V, so that fact that the Lo-Batt light did not come on means the original 72V pack is draining more slowly now.

This upgrade project seems to be well worth the effort.
 
vanilla ice said:

Wow, 96 would be something for sure. From what I've read, though, 96V is pushing the Curtis controller a little too high.
One big improvement I could still make would be to get rid of the truck's bed and cover the batteries with a sheet of fiberglass or acrylic. Another guy did this and reported a noticable improvement I think the bed weighs at least 300 pounds. I'd still need an elevated platform for my solar panel though. If I lowered the panel down to where the bed used to be, then it would often by shaded by the cab.
I kinda like the looks of the bed though, and plus I've used it to haul stuff.
 
fechter said:
How about some pictures :wink:

Here is my youtube link that shows the foundation of the upgrade.

http://www.youtube.com/user/Puppyjump

It shows the the 7th battery and its dedicated charger but not wired up yet and the two affected batteries (#6 and #7) did not have a tiedown bar yet, but that's done as of today. I plan to edit that video when the ZAP is fully completed. At present the 84V system is now fully functional, but I am adding, mounted into a panel running along the top of the dash:
-Cycle Analyst computer (with the large "OEM" screen).
-Paktraker with large Woodward display to read voltages for each battery.
-20A analog Ampmeter to show consumption of the onboard battery chargers.
-2A analog Ampmeter to show output from solar panel.
-300A analog Ampmeter to register load on the batteries (help to moderate how far I step on the "gas" pedal).

Also not shown in the video are some aluminum platforms bolted onto the frame behind the Delta-Q charger. These platforms will be used for mounting various bussbars, terminal strips, Packtraker remotes, shunts, and maybe a future battery balancer.
 
Shopping for 120 v controllers yet? Sounds nice I envious as hell.
 
dogman said:
Shopping for 120 v controllers yet? Sounds nice I envious as hell.

I am satisfied completely now at the 84V setup so I'm not going higher. My ZAP still won't match the performance of an ICE Yugo, but it's plenty fast for what it is. Any faster and I don't think it would be safe. It really is just a city or local commute car. Even the speedometer shows red above 40 MPH and that's leftover from when the ZAP was an ICE vehicle in China. It was designed for medium speed only.

Plus, I can feel the added weight of the 7th battery. The ZAP is a little more bouncy when cornering "hard", indicating the point at which it will flip is now at a lower speed. I'd expect a couple more batteries would make this even worse.

I will post a video when I get all my dashboard instrumentation done. I've been busy running wires and stuff. I'll get a video of it hitting 50 going down that steep overpass, too :)

Nobody has to be envious; ZAPs can be pretty cheap on the used market and as you can see from my video they are easy to work on and upgrade. Non techie people buy them with false expectations and then end up dumping them when they find out, for example, they can't do a 40 mile commute, or they can't handle the little quirks inherent with this niche vehicle.
 
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