High Voltage Wiring Diagram

It's getting dark earlier these days, so no time before / after work for actual metal fabrication. So, I spent some time creating the high-voltage wiring diagram. You can get the PDF here.


The parts list is as follows:

• AC55 AC55 3-phase AC motor from Azure Dynamics
• DMOC DMOC445 AC controller from Azure Dynamics
• DC-DC DCDC 750 BC12 DC to DC (200-400V; for use with 12V aux battery) from Azure
• Htr 2x 400V, 1000W ceramic heaters from Mor Electric
• Ctctr Tyco Kilovac 500A 320V LEV200 Contactor (overkill...)
• 400A 2x Ferraz-Shawmut A50QS400-4 500VDC 400A fuses from evsource
• 30A Littelfuse KLKD030 600VDC 30A fuse from onlinecomponents
• 1.5A Littelfuse KLKD01.5 600VDC 1.5A fuse from onlinecomponents
• 50 mV Westach 237-150 150A 50mV shunt from westach.com
• V Westach 2C5-84 200-400VDC voltmeter from westach.com
• A Westach 2C6-14 -150-0-+150A DC ammeter from westach.com
• Charger Manzanita Micro PFC-20 110-240V 20A battery charger
• 12V, 96V... Battery packs built from 12V Concorde Chairman AGM-1280T batteries

High-current wiring is 4/0 gauge welding cable
Medium-current wiring (charger, DC-DC converter) is 10 AWG primary wire
All other wiring is 16 AWG primary wire

High-current connectors are Cam-Lok400A 600VDC connectors from lightsonretail - NOT INTENDED FOR DISCONNECTING WITH LOAD APPLIED

Medium-current connectors are either Anderson SB-50 (charger) or Yazaki 2-pin (P/N 7222-4220-30) (DC-DC converter)