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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

An Introduction toEV Wiring

By Charlton Jones

Gateway EV

Washington, MO

basic low voltage functions
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
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

slide4

SPST Cube Relay

87

30 to 87 is NORMALLY OPEN

85

86

Actuating coil is between

85 and 86

30

slide5

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

double pole double throw relay
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)

charger interlock relay
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

charger interlock relay1
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

charger interlock relay2
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

keyswitch relay
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

keyswitch relay1
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

neutral safety relay
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

neutral safety relay1
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

the low voltage components
The Low Voltage Components

Neutral

Safety

Relay

Keyswitch

Relay

Charger

Interlock

5 Fuse Panel

DC/DC

12 volt AUX BATTERY

3 dpdt relays
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
slide17
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
plan and be neat
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