Integrating the existing wiring with the EV Systems Controls

Now that we have the wiring diagrams sorted and the startup sequence identified, we can start integrating them into the bike.

Firstly, we need to change the bike's kill switch and start button wiring from a parallel to a series circuit.

Currently, the 12 volts feed into both switches and out from each switch when activated. For our new circuit, I need the 12 volts to pass through the Kill Switch first, then once activated, pass to the Start Button as drawn below.

This is easy to correct, and we don't need to re-solder the wires in the switch or cut anything. All we need to do is swap over 2 wires in the connection plugs for the switches as shown below.

Now what was the 12-volt supply is now the first output for Contactor Number 1.

In this video, I will explain the drawing for the control circuit and how it will work on the bike. I think this is version 3 or 4.

It has been necessary to make some small changes to the drawing as we learn more about how the EV wiring operates and the sequence for the startup process.

This is the final draft as I found that the Inertia Switch only has 2 wires, so I have placed the Engine Fault light across the Inertia Switch contacts. As the engine fault indicator is just an LED, it will not affect the operation of the circuit if the Inertia Switch is activated.

When testing the Inertia Switch, I found that the switch is in the normally open position when set. I prefer to have any safety circuit wired in a fail-safe configuration, so I was able to change over the wires in the terminal plug of the switch, and now it trips from a closed to an open circuit when activated.

While sorting out the wiring, the additional kill switch arrived for the Motor Controller shutdown relay. In this part of the circuit, the contacts in the relay will replace the Kill Switch that came with the Motor Controller, and the relay coil will be activated via the new switch and the Inertia Switch to safely shut down the Motor Controller in case of an emergency.

Now we need to get the remainder of the control wiring into the bike so that it is ready for the Battery Box to be constructed and fitted into the bike's frame.