55 S. Vineyard Avenue Ontario, CA 976 (909) 93-973 WIRING SCHEMATICS FOR SOFTWARE VERSIONS 5.3 AND HIGHER FOR CURTIS 39 CONTROLLER ON-ROAD VEHICLE CONVERSION FOR SINGLE AND WITH DUAL MOTOR APPLICATIONS REN: C Date 4//4 Page
NOTICE: This drawing is the property of Hi Performance Electric Vehicle Systems Inc., and/or its subsidiaries and affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear Pre-Charge Relay (NOTE*) Main Contactor (NOTE *) A +A -A 3 4 5 6 7 8 9 0 3 4 5 6 7 8 9 0 3 4 5 6 7 8 9 30 3 3 33 OEM WIRING 0 BLUE 8 AWG TACHOMETER DRIVER. ORANGE / BLACK8 AWG ORANGE / BLACK8 AWG BRAKE LIGHT SWITCH ORANGE/ RED 8 AWG WHITE / BLUE 8 AWG OEM WIRING PRECHARGE ORANGE 8 AWG BLUE 8 AWG OEM WIRING SEE BRAKE SCHEMATICS OPTIONAL BRAKE SWITCH INPUT (NOTE *0) LOCK BROWN 8 AWG OPTIONAL CLUTCH / SWITCH (NOTE *6) IGNITION KEY SWITCH GREEN 8 AWG N.C. PEDAL INTERLOCK (SEE THROTTLE SCHEMATICS) CLUTCH/ SHIFT SWITCH BROWN 8 AWG MAIN CONTACTOR COIL ORANGE/ WHITE 8 AWG I/O GROUND BLACK 8 AWG MOTOR TEMP BLUE AWG PEDAL INTERLOCK GREEN 8 AWG MENU BUTTON WHITE/ RED 8 AWG START BUTTON INPUT WHITE/ BLUE 8 AWG ECONOMY MODE PURPLE 8 AWG WHITE/ RED 8 AWG BLUE/ WHITE 8 AWG WHITE/ BLACK 8 AWG LABEL # 4 POT HIGH BLACK/ WHITE 8 AWG LABEL # 5 POT WIPER YELLOW/ WHITE 8 AWG YELLOW/ RED 8 AWG PURPLE/ WHITE 8 AWG MALE 3/6 QD FEMALE 3/6 QD SEE BRAKE SCHEMATICS MALE 3/6 QD LABEL # 7 MALE 3/6 QD FEMALE 3/6 QD FEMALE /4 QD MALE /4 QD BLACK8 AWG FOWARD WHITE 8 AWG CAN HIGH ORANGE 0 AWG WHITE 8 AWG FWD YELLOW 8 AWG REV RED/ BLUE 8 AWG 5V POWER CNTRL RED / WHITE 8 AWG RED/BLUE 8 AWG LABEL # 7 FEMALE 3/6 QD BLACK AWG S MULTIPLE CONDUCTOR CABLE GREEN AWG 5 WHITE AWG 6 DISPLAY R5 DEUTSCH DTM-06-S MAIN BATTERY PACK (NOTE *4) A ENCODER PHASE A WHITE AWG ENCODER PHASE B GREEN AWG GREY 0 AWG S R4 DEUTSCH DT-06-6S SCHEMATIC FOR SINGLE MOTOR OR PRIMARY MOTOR IN A DUAL MOTOR CONFIGURATION-39 CONTROLLER MULTIPLE CONDUCTOR CABLE 3 4 5 FOR SINGLE MOTOR CAR CONVERSION, CONNECT TO MOTOR ENCODER HARNESS (*8) Allows the use of ECONO Mode Parameters. See Programming Instructions. (*9) Forward is CLOCKWISE motor rotation from Encoder end view. Depending on Transmission configuration, use either wire to obtain desired rotation. Use a FWD & REV Switch in direct drive applications. - B FEMALE /4 QD LABEL # 6 35 PIN CONNECTOR (SEE R) RED AWG CAN LOW BLACK AWG BLACK8 AWG BLUE AWG YELLOW 8 AWG CAN TERMINATION 500 A + GREN AWG REVERSE (*7) Gives access to Drive System information. Required to access Programming and Diagnostic modes. See Programming Instructions. R3 MOLEX MINI FIT JR 39-0-080 OPTIONAL CAN BUS S3 RX SERIAL 8 RED AWG GREEN AWG WHITE AWG (*6) Install the Optional Clutch/ Shift Switch so that is ON when the clutch pedal is pressed. When the clutch pedal is pressed, the Regen setting is changed to Shift Neutral Braking Parameter to prevent the motor from stalling during gear shifting. In a clutchless system, this allows you to set the coast down rate of the motor so that the gears align properly See Instructions on SHIFT-NEUTRAL BRAKING PARAMETERS. SEE THROTTLE SCHEMATICS PURPLE/ WHITE 8 AWG SEE BRAKE SCHEMATICS TX SERIAL (*5) Start switch option is required if Idle or Creep Torque are ENABLED. See Programming Instructions. A start switch CAN be used without using IDLE. See programming instructions for information. FWD/ REV SWITCH (NOTE*9) V POWER CNTRL V BLACK/ WHITE 8 AWG CAN TERMINATION (*4) A Battery Management System (BMS) is strongly recommended if Lithium Ion batteries are used. Possible source of a BMS is Ewert Energy System s ORION BMS (www.orionbms.com) OPTIONAL ECONOMY SWITCH (NOTE*8) YELLOW/ WHITE 8 AWG LABEL # 8 START ON MENU BUTTON (NOTE *7) PURPLE 8 AWG BRAKE SWITCH INPUT BRAKE POT WIPER (*3) Tachometers that are designed to work off of an ignition coil may not function in this application. Some Tachometers may need a pull up resistor of 4.7K Ω ACC COIL RETURN POT LOW Optional Start Switch (Note*5) Pull up Resistor (Note *3) (*) Use supplied Pre-Charge Resistor and Relay (Tyco Electronics Part # T9APD5-). For Coil connection, connect to small terminals. TACHOMETER KSI WHITE AWG 35 SEE BRAKE SCHEMATICS ORANGE AWG 34 6 MOTOR ENCODER (*) Use supplied Contactor. NO Resistor (NOTE *) R AMP #77664- COM B NOTES: 6 W MOTOR V U B+ CAD TYPE 39 CONTROLLER UNIT NONE B- W V U DRW SIZE A DRAWING TITTLE DATE 4//3 SUPPLIER PART SCALE none Page APPLICABLE SOFTWARE Version 5.3 00-AUTO39-PRI 39 CONTROLLER ON-ROAD VEHICLE CONVERSION / PRIMARY DUAL MOTOR SCHEMATICS HW-00AUTO39-HPG SHEET OF REN C
NOTICE: This drawing is the property of Hi Performance Electric Vehicle Systems Inc., and/or its subsidiaries and affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear on any complete or partial reproduction of this drawing. DUAL MOTOR 39 CONTROLLER SECONDARY MOTOR SCHEMATICS MAIN CONTACTOR (NOTE *) A +A -A +A B Resistor (NOTE *) R AMP #77664-3 4 5 6 7 8 9 0 3 4 5 6 7 8 9 0 3 KSI (*) Use supplied Pre-Charge Resistor and Relay (Tyco Electronics Part # T9APD5-). For Coil connection, connect to small terminals. Pre-Charge Relay (NOTE*) PRECHARGE ORANGE 8 AWG MAIN CONTACTOR COIL ORANGE/ WHITE 8 AWG I/O GROUND BLACK/ BLUE8 AWG MOTOR TEMP BLUE AWG MENU BUTTON (NOTE*3) R3 MOLEX MINI FIT JR 39-0-080 MENU BUTTON WHITE/ RED 8 AWG BLACK AWG COIL RETURN 8 9 30 3 3 33 34 35 8 RED AWG 5 WHITE AWG BLUE/ WHITE 8 AWG 6 GREEN AWG DISPLAY MULTIPLE CONDUCTOR CABLE S P6 DEUTSCH DTM-04-P CAN TERMINATION BLACK8 AWG ORANGE 0 AWG R5 DEUTSCH DTM-06-S B CONNECT TO PRIMARY HARNESS AT CAN BUS CONNECTOR S4 WHITE AWG RX SERIAL GREEN AWG RED AWG BLACK AWG S5 ENCODER PHASE A WHITE AWG ENCODER PHASE B GREEN AWG WHITE AWG GREN AWG MULTIPLE CONDUCTOR CABLE S6 CAN TERMINATION BLACK8 AWG CAN LOW GRAY 0 AWG MAIN BATTERY PACK S3 RED/ BLUE 8 AWG TX SERIAL - S V POWER CNTRL 500 A + CAN HIGH A ORANGE AWG BLUE AWG S7 BROWN AWG YELLOW AWG S8 P7 DEUTSCH DTM-04-4P 3 4 CONNECT TO DUAL MOTOR ENCODER HARNESS W MOTOR V U 3 4 R8 DEUTSCH DTM-06-4S CAD TYPE BLACK AWG MULTIPLE CONDUCTOR CABLE WHITE AWG GREN AWG ORANGE AWG BLUE AWG UNIT NONE 3 4 CONNECT TO PRIMARY CONTROLLER HARNESS AT ENCODER CONNECTOR 5 6 P4 DEUTSCH DT-04-6P Page 3 B+ S9 RED AWG B- 39 W SECONDARY V U CONTROLLER MOTOR ENCODER 7 (*3) Gives access to Drive System information. Required to access Programming and Diagnostic modes. See Programming Instructions. CONNECT TO PRIMARY HARNESS AT BLUE KSI WIRE. BLUE 8 AWG 35 PIN CONNECTOR (SEE R) 6 (*) Use supplied Contactor. -A 4 5 NOTES: DRW SIZE A APPLICABLE SOFTWARE DRAWING TITTLE DATE 4//3 SUPPLIER PART SCALE : Version 5.3 00-AUTO39-SEC 39 CONTROLLER SECONDARY DUAL MOTOR SCHEMATICS HW-00AUTO-HPG SHEET OF REN C
THROTTLE CONFIGURATION Depending on the type of throttle used for the application, the different types of throttle configurations are listed in the table below. Electrical schematics are also included within the following pages. THROTTLE CONFIGURATION TYPE ELECTRONIC without SWITCH TYPE WIRE with SWITCH 0-5k Ω TYPE 3 WIRE with SWITCH 0-5k Ω TYPE 3 CURTIS PB8 THROTTLE ASSEMBLY TYPE 3 Page 4
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE //03 Pin #7* BLACK / BLUE (BLACK IN 39 CTRL) GROUND TYPE ELECTRONIC THROTTLE** Pin #6* YELLOW / WHITE SIGNAL ELECTRONIC THROTTLE For 5V: Pin #6* For V: Pin #5* PURPLE / WHITE +5V or +V * Typical connection, verify correct voltage and connection in throttle documents or instructions. Not all Electronic Throttles supported ** When an electronic throttle is used, the GREEN wire from the pedal interlock does not need to be connected. CAD TYPE UNIT NONE DRW SIZE A DATE //3 SUPPLIER PART SCALE NONE APPLICABLE SOFTWARE DRAWING TITTLE 00-THROTTLE-00 ELECTRONIC THROTTLE SHEET 4 OF 4 REN B Page 5
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE //03 Pin #6 YELLOW / WHITE WIPER WIRE TYPE THROTTLE Pin #8 PURPLE / WHITE POT LOW Pin #5 RED/ BLUE COM NORMALLY CLOSED INTERLOCK SWITCH** NC Pin #9 GREEN ** When the accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position (switch not activated) thus completing the circuit since its green wire is connected to the normally closed (NC) connection. CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING DESIGN CHECKED DETAIL SAFETY TITTLE SCALE DATE REN A NONE //3 SHEET OF 3 00-THROTTLE-00 WIRE TYPE THROTTLE DRW SIZE A Page 6
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE //03 Pin #5 BLACK / WHITE POT HIGH Pin #6 YELLOW / WHITE WIPER 3 WIRE TYPE 3 THROTTLE Pin #8 PURPLE / WHITE POT LOW Pin #5 RED/ BLUE COM NORMALLY CLOSED INTERLOCK SWITCH** NC Pin #9 GREEN ** When the accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position (switch not activated) thus completing the circuit since its green wire is connected to the normally closed (NC) connection. CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING DESIGN CHECKED DETAIL SAFETY TITTLE SCALE DATE REN A NONE //3 SHEET OF 3 00-THROTTLE-00 3 WIRE TYPE 3 THROTTLE DRW SIZE A Page 7
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE /7/03 Pin #5 BLACK / WHITE POT HIGH THROTTLE ASSEMBLY RED Pin #6 YELLOW / WHITE BLACK WIPER CURTIS PB8 THROTTLE ASSEMBLY Pin #8 PURPLE / WHITE POT LOW WHITE Pin #5 RED/ BLUE COM NORMALLY CLOSED INTERLOCK SWITCH** NC Pin #9 GREEN ** When the accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position (switch not activated) thus completing the circuit since its green wire is connected to the normally closed (NC) connection. CAD TYPE APPLICABLE SOFTWARE UNIT DRAWING NONE DRW SIZE TITTLE A DATE //3 00-THROTTLE-00 CURTIS PB8 THROTTLE ASSEMBLY SUPPLIER PART SCALE NONE SHEET 3 OF 4 REN A Page 8
PEDAL INTERLOCK CONNECTION The pedal interlock connection is required for both and 3 wire throttle pot assemblies. The Green wire is connected to the Normally Closed tab. The red/blue wire is connected to the common tab. See picture below. NOTE: when the accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position (switch not activated) thus completing the circuit since its green wire is connected to the normally closed (NC) connection. Page9
BRAKE INPUT CONFIGURATION Depending on the type of brake input used for the application, the different types of brake input configurations are listed in the table below. Electrical schematics are also included within the following pages. BRAKE INPUT CONFIGURATION TYPE NO BRAKE INPUT USED TYPE 0 PRESSURE TRANSDUCER/ ELECTRONIC 0-5V INPUT TYPE WIRE 0-5k Ω POT TYPE SWITCH TYPE 3 Page0
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE /9/03 Pin #7 BLACK/ BLUE (BLACK 0N 39 CNTRL) GROUND Pin #7 YELLOW / RED SIGNAL PRESSURE TRANSDUCER TYPE PRESSURE TRANSDUCER Pin #5 RED/ BLUE +V ** Typical Pressure Transducer Ratings 8-30 Volt Input -5 Volt Output 500 PSI CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING DESIGN DETAIL TITTLE CHECKED SAFETY 00-BRAKE PRESSURE TRANSDUCER DRW SIZE A SCALE DATE REN A NONE /9/3 SHEET OF Page
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE /9/03 Pin #7 YELLOW / RED WIPER TYPE WIRE BRAKE POT Pin #8 PURPLE / WHITE POT LOW CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING DESIGN CHECKED DETAIL SAFETY TITTLE SCALE DATE REN A NONE /9/3 SHEET OF 00-BRAKE WIRE BRAKE POT DRW SIZE A Page
OPTIONAL ACTIVE BRAKE LIGHT CONFIGURATIONS These optional active brake light configurations are used to activate the brake lights during regenerative braking or when the vehicle brakes are being applied. Based on the brake type configuration that is being used in the application use one of the following wiring configurations. Page 3
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE /9/03 ACTIVE BRAKE LIGHT CONFIGURATION OPTION FOR BRAKE TYPE 0, OR CONFIGURATIONS TO BRAKE LIGHT BRAKE LIGHT SWITCH (pin #3) ORANGE / RED 85 87 OEM BRAKE SWITCH 86 30 COIL RETURN (pin #3) BLUE / WHITE +V ** This option turns the brake lights ON during REGEN. Brake TYPE 0 does not allow for BOOSTED BRAKE while pressing the brake pedal. Brake TYPE & uses a variable input for BOOSTED REGEN. CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING DESIGN CHECKED DETAIL SAFETY TITTLE SCALE DATE REN A NONE /5/3 SHEET 3 OF 4 00-BRAKE OPTION BRAKE LIGHT SWITCH DRW SIZE A Page 4
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE /9/03 ACTIVE BRAKE LIGHT CONFIGURATION OPTION FOR BRAKE TYPE 3 39 CONTROLLER TO BRAKE LIGHT +V BRAKE LIGHT SWITCH (pin #3) ORANGE / RED 85 87 OEM BRAKE SWITCH 86 30 COIL RETURN (pin #3) BLUE / WHITE +V BRAKE SWITCH INPUT (pin #4) WHITE/ BLACK LABEL # 4 MALE 3/6 QD FEMALE 3/6 QD YELLOW / RED ** This option will turn ON the brake lights when either of two conditions are satisfied:. The users foot is OFF of the accelerator pedal and REGEN is active.. Brake pressure is applied and the OEM brake switch is active. CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING 00-BRAKE DESIGN DETAIL TITTLE OPTION CHECKED SAFETY BRAKE LIGHT SWITCH 39 CONTROLLER SCALE DATE REN A NONE /5/3 SHEET 3 OF 4 DRW SIZE A Page 5
affiliates (individually and collectively ), and contains highly proprietary, confidential, and trade secret information of. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by (b) to return this drawing upon request. This notice shall appear RENS A INITIAL RELEASE /9/03 BRAKE SWITCH INPUT LIGHT CONFIGURATION OPTION 3 FOR BRAKE TYPE 3 CONFIGURATION 39 CONTROLLER TO BRAKE LIGHT BRAKE SWITCH INPUT (pin #4) WHITE/ BLACK LABEL # 4 MALE 3/6 QD FEMALE 3/6 QD YELLOW / RED SIGNAL +V BRAKE SWITCH ** This option will provide single level BOOSTED REGEN when brake pedal pressure is applied. ** Brake lights will not turn on during ACCELERATOR PEDAL UP/ REGEN. CAD TYPE CAD LOC. CAD FILE OPER. NO. UNIT DRAWING 00-BRAKE DESIGN DETAIL TITTLE OPTION 3 CHECKED SAFETY BRAKE SWITCH INPUT 39 CONTROLLER SCALE DATE REN A NONE /9/3 SHEET 4 OF 4 DRW SIZE A Page 6