Download EV Low Voltage 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
► Disconnect
both voltages from DC/DC converter
when charging or with ign off
► Turn on ventilation fans and turn off controller
when charging
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
SPST Cube Relay
87
30 to 87 is NORMALLY OPEN
85
86
Actuating coil is between
85 and 86
30
SPDT Cube Relay
87
30 to 87a is NORMALLY CLOSED
30 to 87 is NORMALLY OPEN
86
87a
Actuating coil is between
85 and 86
30
85
Double Pole Double Throw Relay
1, 4, and 7
make up
the left switch
1
3
4
6
7
3, 6, and 9
make up
the right switch
A
9
B
7 to 4 and 9 to 6
Are NORMALLY OPEN
7 to 1 and 9 to 3
Are NORMALLY CLOSED
Actuating coil between
A and B at 12VDC or 120 VAC
Tyco KUHP-11e51-volts
(e is either A for AC or D for DC)
CHARGER INTERLOCK RELAY
1
3
4
6
7
9
9 to 3
Are NORMALLY CLOSED
A
B
No voltage at A and B
Tyco KUHP-11A51-120
CHARGER INTERLOCK RELAY
12 volts out to fuse #1
to operate vehicle
1
3
4
6
7
9
Apply ignition switch
12 volts at 9
A
B
No voltage at A and B
which is connected to plug
(Ignition voltage will be cut off if charger is plugged in to 120VAC)
Tyco KUHP-11A51-120
CHARGER INTERLOCK RELAY
Power out to
Vent fans
via fuse #2
12 volts
Applied at 7
12 volts cut to fuse #1
Vehicle won’t operate
1
3
4
6
7
9
Apply ignition switch
12 volts at 9
A
B
120 VAC at A and B
Which is connected to plug
Optional: signal to disable controller
(Ignition voltage cut off if charger is plugged in to 120VAC.
Ventilation fans are turned on.)
Tyco KUHP-11A51-120
KEYSWITCH RELAY
1
3
4
6
7
9
A
B
7 to 4 and 9 to 6
Are NORMALLY OPEN
7 to 1 and 9 to 3
Are NORMALLY CLOSED
Actuating coil between
A and B at 12 VDC
Tyco KUHP-11D51-12
KEYSWITCH RELAY
Sends 12v to CI pin 7
For fans when ign off
1
3
4
4 and 7
Connect DC/DC
to 144v pack, 7
Fuses 4 & 5
6
9
12v from aux battery
12 v from CI A
and fuse #1
powers coil
B
B is chassis ground
To fuse #3 connecting DC/DC
(and optional vacuum pump)
Tyco KUHP-11D51-12
NEUTRAL SAFETY RELAY
1
3
4
6
7
9
A
B
7 to 4 and 9 to 6
Are NORMALLY OPEN
7 to 1 and 9 to 3
Are NORMALLY CLOSED
Actuating coil between
A and B
Tyco KUHP-11D51-12
NEUTRAL SAFETY RELAY
1
3
Ign switch
(fuse 1)
4
And N/O
PotBox micro
7
7 and A connected
Together and to
N/O PotBox micro A
6
9
B
(This is a LATCHING
Circuit that only actuated
When ign on and foot
is off accel pedal and
PotBox micro is closed)
Terminals 6 and 9 close
to power controller
B is chassis ground
Tyco KUHP-11D51-12
The Low Voltage Components
Charger
Interlock
Keyswitch
Relay
Neutral
Safety
Relay
5 Fuse Panel
12 volt AUX BATTERY
DC/DC
3 DPDT Relays
► Disconnect
► Disconnect
► Supply 12v
► Turn
DC/DC from Traction Pack
DC/DC from Aux Battery
to vent fans
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
Wire
► Use
10 gauge wire on 12v power circuit to
DC/DC converter, fuse position #3
► Use
► Use
30 amp fuse in position #3
14 or 16 gauge wire and 10 amp 250v
fuses elsewhere
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
Traction Pack Voltage Wiring