When working on a battery pack, the charger should be disconnected from the
battery pack. The controller circuit is also disconnected from the battery
pack, because in many controllers, the negative may go through the control
and right to the motor, which may have a conductance path to the chassis by
brush dust if you are using DC motors.
Make sure that the most positive end of the battery terminal is the furthest
from the most negative end.
When you run many short rolls of batteries, it is best not to nave more than
72 volts between each roll.
If the batteries are super clean, you can actually touch any battery
terminal, but make sure your other hand is behind you or in you pocket.
Lay a rubber insulation blanket over the batteries and only exposing the one
you are working on.
Lay a rubber type of fender protection mats over any expose metal parts of
the vehicle.
Have one set of battery tools that have a insulated handle by heat shrinking
one end of a box, open end, ratchet type or adjustable type wrenches.
A torque wrench that is normally in the one inch pound range, I first adjust
it for the specifications it calls for and than slip over the handles a foam
pipe insulation, the heavy duty type with glue edge that is use for air
condition work.
Then lastly you could have the vinyl square tiles that are use for garages,
for the EV to set on while you work on it for maximum safety.
Install a on board chassis mount GFI circuit breaker that is in the circuit
between your input plug and a on board charger. This way, no matter what
receptacle you plug into it will be GFI protective.
Do not wear any watches, rings and any metal while working on batteries.
Wear clothes that are 100 percent cotton.
Do not work on the batteries just after they been charge, wait about 24
hours.
The charger should not be in the same compartment as the batteries or any
thing that may produce a arc.
Before the charger can start up, a totally enclosed exhaust fan exhaust a
totally enclose battery box or area, which at the same time bring in fresh
air. For maximum safety this will trip a pressure switch and a DC contactor
to connect the charger to the battery or you could use a AC contactor to
provide power to the charger.
If the battery exhaust fans shut down for some reason, than the charger will
shut down.
A means of disconnecting the ignition circuit to start up the controller
while the AC power connector is plug in. A micro switch operated a small
contactor and/or use a extra power pole on the incoming AC contactor that is
normally close while the contactor is close when the AC power connector is
plug in.
This ignition circuit interlock will prevent you from driving off with AC
plug connected.
If charging in a enclose garage or room, crack open the garage door a bit,
or install a exhaust hose from the fan out pipe. Mine is a 2-inch pvc that
comes out the bottom of the EV like a exhaust pipe and when its gets down to
below zero, I run a exhaust hose through a port in the door like service
stations do.
Also it is best to install a lover grill whole house fan in the ceiling if
you do a lot of charging in a in closed space.
No open flames units in the same space that the EV is being charge.
Laatly, read and study the National Electric Code NEC Article 625 -
Electric Vehicle Charging Systems which tells you want type, size and length
of AC components to use for a EV.
Roland
----- Original Message -----
From: "Tehben Dean" <[email protected]>
To: "EV mail list" <[email protected]>
Sent: Sunday, September 09, 2007 4:31 PM
Subject: [EVDL] High voltage battery pack safety
> I was wondering if someone could talk about safety concerns when
> working with EV battery packs, or point me to a good reference?
>
> Like if you touch a hot circuit in a building you will get seriously
> shocked because it is grounded. But in an EV the pack is not grounded
> so there is only concern if you touch both the + and - sides of the
> circuit.. right?
>
> Anyway, before I actually start wiring up my batt's I would like to
> read up on safety.
>
> Thanks,
> --
> Tehben
> '90 Toyota 4x4 Pickup
> 'hElix EV'
> Website: www.helixev.com
> evalbum: http://www.austinev.org/evalbum/1225
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
battery pack. The controller circuit is also disconnected from the battery
pack, because in many controllers, the negative may go through the control
and right to the motor, which may have a conductance path to the chassis by
brush dust if you are using DC motors.
Make sure that the most positive end of the battery terminal is the furthest
from the most negative end.
When you run many short rolls of batteries, it is best not to nave more than
72 volts between each roll.
If the batteries are super clean, you can actually touch any battery
terminal, but make sure your other hand is behind you or in you pocket.
Lay a rubber insulation blanket over the batteries and only exposing the one
you are working on.
Lay a rubber type of fender protection mats over any expose metal parts of
the vehicle.
Have one set of battery tools that have a insulated handle by heat shrinking
one end of a box, open end, ratchet type or adjustable type wrenches.
A torque wrench that is normally in the one inch pound range, I first adjust
it for the specifications it calls for and than slip over the handles a foam
pipe insulation, the heavy duty type with glue edge that is use for air
condition work.
Then lastly you could have the vinyl square tiles that are use for garages,
for the EV to set on while you work on it for maximum safety.
Install a on board chassis mount GFI circuit breaker that is in the circuit
between your input plug and a on board charger. This way, no matter what
receptacle you plug into it will be GFI protective.
Do not wear any watches, rings and any metal while working on batteries.
Wear clothes that are 100 percent cotton.
Do not work on the batteries just after they been charge, wait about 24
hours.
The charger should not be in the same compartment as the batteries or any
thing that may produce a arc.
Before the charger can start up, a totally enclosed exhaust fan exhaust a
totally enclose battery box or area, which at the same time bring in fresh
air. For maximum safety this will trip a pressure switch and a DC contactor
to connect the charger to the battery or you could use a AC contactor to
provide power to the charger.
If the battery exhaust fans shut down for some reason, than the charger will
shut down.
A means of disconnecting the ignition circuit to start up the controller
while the AC power connector is plug in. A micro switch operated a small
contactor and/or use a extra power pole on the incoming AC contactor that is
normally close while the contactor is close when the AC power connector is
plug in.
This ignition circuit interlock will prevent you from driving off with AC
plug connected.
If charging in a enclose garage or room, crack open the garage door a bit,
or install a exhaust hose from the fan out pipe. Mine is a 2-inch pvc that
comes out the bottom of the EV like a exhaust pipe and when its gets down to
below zero, I run a exhaust hose through a port in the door like service
stations do.
Also it is best to install a lover grill whole house fan in the ceiling if
you do a lot of charging in a in closed space.
No open flames units in the same space that the EV is being charge.
Laatly, read and study the National Electric Code NEC Article 625 -
Electric Vehicle Charging Systems which tells you want type, size and length
of AC components to use for a EV.
Roland
----- Original Message -----
From: "Tehben Dean" <[email protected]>
To: "EV mail list" <[email protected]>
Sent: Sunday, September 09, 2007 4:31 PM
Subject: [EVDL] High voltage battery pack safety
> I was wondering if someone could talk about safety concerns when
> working with EV battery packs, or point me to a good reference?
>
> Like if you touch a hot circuit in a building you will get seriously
> shocked because it is grounded. But in an EV the pack is not grounded
> so there is only concern if you touch both the + and - sides of the
> circuit.. right?
>
> Anyway, before I actually start wiring up my batt's I would like to
> read up on safety.
>
> Thanks,
> --
> Tehben
> '90 Toyota 4x4 Pickup
> 'hElix EV'
> Website: www.helixev.com
> evalbum: http://www.austinev.org/evalbum/1225
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
