EV.6.5 Voltage Separation

EV.6.5.1 Separation of Tractive System and GLV System:

a. The entire Tractive System and GLV System must be completely galvanically separated.

b. The border between Tractive and GLV System is the galvanic isolation between both systems. Therefore, some components, such as the Motor Controller, may be part of both systems.

This is why the previous team didn't pass electrical tech! - Hunter Horan

EV.6.5.2 There must be no connection between the Chassis of the vehicle (or any other conductive surface that might be inadvertently touched by a person), and any part of any Tractive System circuits.

The body panels are painted. Don't be stupid

EV.6.5.3 Tractive System and GLV circuits must not run through the same conduit or connector, except as allowed in EV.7.8.4

EV.6.5.4 GLV Systems other than the AIRs EV.5.4, parts of the Precharge and Discharge Circuits EV.5.6, HV DC/DC converters, the AMS EV.7.3, the IMD EV.7.6, parts of the TSAL EV.5.9.1 the Energy Meter EV.3.1 and cooling fans must not be inside the Accumulator Container.

EV.6.5.5 Where both Tractive System and GLV are included inside an enclosure, they must meet one of the two:

a. Be separated by insulating barriers (in addition to the insulation on the wire) made of moisture resistant, UL recognized or equivalent insulating materials rated for 90° C or higher (such as Nomex based electrical insulation)

b. Maintain the following spacing through air, or over a surface (similar to those defined in UL1741):

U < 100 V DC 10 mm

100 V DC < U < 200 V DC 20 mm

U > 200 V DC 30 mm

"This is why the previous team didn't pass electrical tech! - Hunter Horan

They had GLV wires inter woven between tractive system wire. You can even have air gaps or nomex."

EV.6.5.6 Spacing must be clearly defined. Components and cables capable of movement must be positively restrained to maintain spacing.

Spacing between high voltage/low voltage per say must be clearly labeled and defined yyou cant have a bunch of freefloating HV/LV wires intertwined between each other like in the attic.

EV.6.5.7 If Tractive System and GLV are on the same circuit board:

a. They must be on separate, clearly defined and clearly marked areas of the board

b. Required spacing related to the spacing between traces / board areas are as follows:

Voltage Over Surface Thru Air (cut in board) Under Conformal Coating

0-50 V DC 1.6 mm 1.6 mm 1 mm

50-150 V DC 6.4 mm 3.2 mm 2 mm

150-300 V DC 9.5 mm 6.4 mm 3 mm

300-600 V DC 12.7 mm 9.5 mm 4 mm

"This is essentially say the same thing as having two HV non insulated wires next to each other vs having two insulated hv wires next to each other. This is why the conformal coating is so realaxed. Notice the 3mm air gap was used to separate HV/LV on the TSAL. Gustavo mention he could have used the conformal coating instead to make the board much smaller.

Over surface means non-installed traces on PCP you could essentially short 60V to ground just with you finger on PCB"

EV.6.5.8 Teams must be prepared to show spacing on team built equipment

For inaccessible circuitry, spare boards or appropriate photographs must be available for inspection.

EV.6.5.9 All connections to external devices such as laptops from a Tractive System component must include galvanic isolation.

Can/Bus you can prove that the BMS issolates LV communicattion for tracttive system high voltage.

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