Here is a diagram of wiring changes to my previous Schematic needed for installing the Zapi H3 controller. The extra complexity comes in as a result of adding regenerative braking to a series wound motor. Specifically the three relays between the controller and motor are "extra" parts required to perform the switching. These are the same contactors I showed photos of in step 13, BFR is the single contactor and BTA/BTI are the big dual reversing contactor.
I've also added an inertia switch to the diagram. This is a safety cutoff switch that engages during impact, shutting off the power. The light blue, central rectangle is the Zapi and I've drawn in only those connectors that are applicable to the schematic. The potbox is, of course, hooked to the car's normal gas (volts?) pedal and the extra switch below it is hooked up to the brake and signals the Zapi to start regenerative braking.
There are essentially three phases of regenerative braking and I'll try to explain each
In fact there's a bunch of stuff about the Zapi I'm not explaining here, most of it
because I don't understand it! The Zapi H3 comes with a nice big instruction manual
full of charts, graphs, and specifications. It also has nice wiring diagrams for
hooking up your EV, along with another machine you might use a Zapi in: a fork lift!
That's right, most of the controllers used in EVs come from companies that have made
and are probably still making lots of controllers for golf carts, fork lifts, and
other manufacturing equipment. Next time you go to a big warehouse store take a
closer look and listen to the forklifts driving up and down the isles. Also notice
that the store isn't full of exhaust fumes.
Next: Battery Wiring
© Copyright 1995-2002 Jerry Halstead