An Introduction to EV Wiring

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

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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

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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

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Traction Pack Voltage Wiring