Electric Vehicle Management System v1.1: User Manual
Contents
1. The status LED may display the following e Blue blinking Vehicle idle sleep Blue Charging enabled Green flashing Precharging Green Drive enabled Red BMS error Red flashing Precharge error Green red flashing BMS shut down drive Blue red flashing BMS shut down charger The buzzer will sound continuously on BMS error or intermittently on precharge error pug Zero Emission Vehicles Australia http ww zeva com au 4 Recommended Wiring Diagram Splice into B either Enable or 5V line BMS Signal Wiring E 4 X Oo o z o d pu p E o 2 L3 Pot Box G x E n TOI e a 2 qe p o CTO 2 j c CC E BMS Modules LL OT eis Output ve m E A1 za Output ve Chassis Traction Circuit Wiring Ground Charger Inertia Emergency Switch Stop Button s AC Input ct 3 Fuse E z 12V Wiring 61 D E P Ae 2007 1 1 C INC 3 E i L 12VDC PrechA Auxilliary Ground PehBE r ft ii di qT 3 A A 3 M 3 323 Battery i 4 2v Key In Drive I Chg Sense Enable tam i C BMS In Charge i ug i A Status R Enable I 3 Status G Main Ctr m Status B Ground Chassis i O Buzzer Aux Ctr Ground 1 Charge Ground Ground 1 Door I buzzer in dash AAA x Input ve Chassis Ground Input ve DC DC Output ve Conv To other 12V accessories Output ve e g vacuum pump PS pum2. 5 Description of I O Terminals e 12V A permanent 12V supply 9 16V range in series with any emergency stop switches to ensure 12VDC PrechA everything downstream from the EVMS charge and drive Ground Prech B systems switch off immediately in an emergency aay In Drive e Ground Connect this to chassis ground in your vehicle TU NEM BMS In Charge not traction circuit negative e Key In Should see 12V when they key is turned on ground or floating otherwise e Chg Sense This terminal should be pulled to ground whenever you wish to charge Typically achieved with either a normally open switch on your charge door or an AC relay that closes when charge lead is plugged in e BMS In This terminal should be pulled to ground whenever there is no error reported from the BMS modules If using a one wire BMS system connect one end to ground and the other end to this terminal e Status RGB Outputs for Red Green and Blue pins on the multicolour status LED should be installed in the vehicle cabin e Buzzer Connect this to the positive terminal on the included piezo buzzer should be installed in the vehicle cabin e Ground May be used as the ground connection for both the status LED and buzzer e Prech A amp B Connect these to either side of your main contactor These The polarity is important A should be on the battery side B should be on the controller side Drive Enable Connections to the drive enable relay which w
3. ill close when the vehicle is allowed to drive Best used to switch in either the controller enable or throttle signal to controller e Charge Enable Connections to the charge enable relay which will close when the vehicle may be charged These internal relays rated to 10A current at either 250VAC or 28VDC They are not suitable for switching typical traction pack DC voltages or high charge currents Unless using a low current charger in most cases you will need to use the internal relay to switch an external power relay to control AC power to the charger e Main Ctr This terminal goes to the positive connection on your main contactor e Ground May be used for the negative connection on your main contactor e Aux Ctr This terminal goes to the positive connection on your auxillary contactor s e Ground May be used for the negative connection on your auxillary contactor s Status R Enable Status G Main Ctr Status B Ground Buzzer Aux Ctr Ground Ground 6 BriefSpecifications V 0 0 0 0 0 0 e Power supply 9 16VDC 20mA idle 5A max e Suitable for traction packs 12 160VDC e Dimensions 150x100x50mm e Casing Fully enclosed die cast aluminium weatherproof to IP65 e Internally fused reverse voltage and over voltage protected The ZEVA Fuel Gauge Driver is proudly designed and manufactured in Australia Zero Emission Vehicles Australia http ww zeva com au ZEVA HO Electric Vehicle Management System
4. p Zero Emission Vehicles Australia http ww zeva com au
5. v1 1 User Manual 1 Introduction Developed to address the need to build safer neater EV conversions the ZEVA Electric Vehicle Management system combines several common functions required by EVs into one device e Battery Management System BMS Master Unit Monitors your BMS cell modules and takes action to protect your battery pack e Staged Precharging Most motor controllers require a precharge soft start system to slowly charge up their internal capacitors before they are enabled e Contactor control Many EVs run multiple contactors for redundant safety This device manages auxillary contactors which must be engaged when either driving or charging e Charge drive interlock Ensures that the vehicle cannot be driven while plugged in e Status light and buzzer A multicolour LED indicates the vehicle status and a buzzer gives audible warning of any errors detected 2 Installation The EVMS should be mounted securely to the vehicle using screws through the four 5mm holes on the case flanges There are 20 I O terminals to connect for full functionality A recommended wiring diagram is overleaf The use of forked crimp terminals is recommended for the most reliable connections to the EVs Wire gauge used for most connections should be around 18 20 AWG to ensure reasonable mechanical strength Small multicore cable is acceptable for the LED and buzzer wiring harness 3 Status LED and Buzzer Status LED Pins
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