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An Introduction to EV Wiring

An Introduction to EV Wiring. By Charlton Jones Gateway EV Washington, MO. BASIC LOW VOLTAGE FUNCTIONS. Supply 12v to controller with ign key Assure driver’s foot is off the accelerator pedal at ignition Turn on a vacuum pump with ignition, if necessary

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An Introduction to EV Wiring

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  1. An Introduction toEV Wiring By Charlton Jones Gateway EV Washington, MO

  2. BASIC LOW VOLTAGE FUNCTIONS • Supply 12v to controller with ign key • Assure driver’s foot is off the accelerator pedal at ignition • Turn on a vacuum pump with ignition, if necessary • Disconnect both voltages from DC/DC converter when charging or with ign off • Turn on ventilation fans and turn off controller when charging

  3. Relay - a remote switch • The internal workings: • The switch (N/O or N/C) • A magnet coil to move it Single Pole Single Throw - SPST

  4. SPST Cube Relay 87 30 to 87 is NORMALLY OPEN 85 86 Actuating coil is between 85 and 86 30

  5. SPDT Cube Relay 87 30 to 87a is NORMALLY CLOSED 30 to 87 is NORMALLY OPEN 87a 85 86 Actuating coil is between 85 and 86 30

  6. Double Pole Double Throw Relay 7 to 4 and 9 to 6 Are NORMALLY OPEN 1, 4, and 7 make up the left switch 1 3 4 6 7 to 1 and 9 to 3 Are NORMALLY CLOSED 7 9 3, 6, and 9 make up the right switch A Actuating coil between A and B at 12VDC or 120 VAC B Tyco KUHP-11e51-volts (e is either A for AC or D for DC)

  7. CHARGER INTERLOCK RELAY 1 3 4 6 9 to 3 Are NORMALLY CLOSED 7 9 A No voltage at A and B B Tyco KUHP-11A51-120

  8. CHARGER INTERLOCK RELAY 12 volts out to fuse #1 to operate vehicle 1 3 4 6 Apply ignition switch 12 volts at 9 7 9 A No voltage at A and B which is connected to plug B (Ignition voltage will be cut off if charger is plugged in to 120VAC) Tyco KUHP-11A51-120

  9. CHARGER INTERLOCK RELAY 12 volts cut to fuse #1 Vehicle won’t operate 1 3 Power out to Vent fans via fuse #2 4 6 Optional: signal to disable controller Apply ignition switch 12 volts at 9 7 9 12 volts Applied at 7 A 120 VAC at A and B Which is connected to plug B (Ignition voltage cut off if charger is plugged in to 120VAC. Ventilation fans are turned on.) Tyco KUHP-11A51-120

  10. KEYSWITCH RELAY 7 to 4 and 9 to 6 Are NORMALLY OPEN 1 3 4 6 7 to 1 and 9 to 3 Are NORMALLY CLOSED 7 9 A Actuating coil between A and B at 12 VDC B Tyco KUHP-11D51-12

  11. KEYSWITCH RELAY Sends 12v to CI pin 7 For fans when ign off 1 3 To fuse #3 connecting DC/DC (and optional vacuum pump) 4 6 4 and 7 Connect DC/DC to 144v pack, Fuses 4 & 5 7 9 12v from aux battery A B B is chassis ground 12 v from CI and fuse #1 powers coil Tyco KUHP-11D51-12

  12. NEUTRAL SAFETY RELAY 7 to 4 and 9 to 6 Are NORMALLY OPEN 1 3 4 6 7 to 1 and 9 to 3 Are NORMALLY CLOSED 7 9 A Actuating coil between A and B B Tyco KUHP-11D51-12

  13. NEUTRAL SAFETY RELAY 1 3 Ign switch (fuse 1) And N/O PotBox micro 4 6 Terminals 6 and 9 close to power controller 7 9 7 and A connected Together and to N/O PotBox micro A B is chassis ground B (This is a LATCHING Circuit that only actuated When ign on and foot is off accel pedal and PotBox micro is closed) Tyco KUHP-11D51-12

  14. The Low Voltage Components Neutral Safety Relay Keyswitch Relay Charger Interlock 5 Fuse Panel DC/DC 12 volt AUX BATTERY

  15. 3 DPDT Relays • Disconnect DC/DC from Traction Pack • Disconnect DC/DC from Aux Battery • Supply 12v to vent fans • Turn on vent fans when charger plugged in • Allow power to controller at ignition turn on only if foot is off accelerator pedal • 5 Circuits are fused

  16. Wire • Use 10 gauge wire on 12v power circuit to DC/DC converter, fuse position #3 • Use 30 amp fuse in position #3 • Use 14 or 16 gauge wire and 10 amp 250v fuses elsewhere

  17. Plan and Be Neat • Draw out your project, chose wire colors and component placement • Use terminal blocks and ¼” spade crimped connectors throughout • Bundle and route wires neatly, use tie wraps

  18. Traction Pack Voltage Wiring

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