Pre-Charger (PC)

The goal of the REV2 Pre-Charge system is to protect the motor controller from the in-rush current during the initial ignition of the bike. With a sudden large difference in voltage coming from the battery pack to the motor controller the risk of this in-rush current causing heating issues becomes a main concern. The Pre-Charge on its most basic level acts as a large resistor to restrict the amount of in-rush current to the motor controller to reduce high voltage power from entering, which then charges the internal capacitors of the motor controller. These charged capacitors lessen the energy difference between the battery pack and motor controller, which reduces the chance of inrush current.

This system makes use of two separate circuits; a 12V low voltage control circuit, and a 400V high voltage main power control. Once an ignition signal is received the Pre-Charge system begins receiving the 400V high voltage from the battery pack, eventually the motor controller will send a signal to the pre-charge to begin entering the 12V low voltage control-circuit. The low voltage circuit is responsible for controlling the timing of signals coming from the REV2 handlebar. The high voltage power side is controlled by one signal coming from the motor controller, which is dependent on the low voltage side working as intended. In addition to this functionality the Pre-Charge system also receives inputs from other devices and outputs them to their corresponding systems.