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Old 06-27-2014, 01:04 AM   #6574 (permalink)
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Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
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Originally Posted by jedsmd View Post
And it has arrived!!!

There are lots of wires hanging out the low power end, so I'm trying to identify them:

Mediam gauge twisted pair red/black - - 12vdc
light gauge twisted pair red/black - - idiot light
light gauge twisted pair red/green no connectors -- ??????
light gauge twisted pair green/green no connectors -- ??????
5 conductor ribbon -- Pickit 3
serial port -- Flores' web device
light gauge twisted blue/white -- ??????
light gauge twisted blue/white -- ??????

The power stuff looks pretty straight forward.
This is only for jedsmd, as I ran out of some of those colored wires:
Wiring for 1000amp controller:

Rightmost blue & white twisted pair (J6):
J6 blue wire is main contactor ground wire. Don't connect the contactor ground wire to anything other than J6 blue wire.
J6 white wire is main contactor coil +24v. Yes, 24v. If you currently use a 12v coil, I'd just not bother with J5 and J6.

J5 (next twisted pair over to the left from J6. Blue and white again):
J5 is for turning on the precharge relay, which is NOT a part of the controller. J5 blue connects to the precharge relay ground.
J5 white connects to the precharge relay +24v.

Note: If you don't want to be bothered with J5 and J6, just don't connect them, but you should still take care of precharge and closing the contactor yourself.

The next twisted pair (black and blue) to the left, J4, is the +24v auxiliary supply input. It comes from the DC-DC that's inside the controller, mounted
to the top of the enclosure. Blue is 24v, and black is ground.

J3 is valet Mode. The pin on the left needs to be connected to ground (possibly through an on/off toggle switch).
The pin on the right need to be connected to the car's auxiliary +12v supply. You could put the on/off switch on either line.

The next connection over is Temperature. That's already connected to a thermistor inside the controller.

Throttle (connected on the bottom) is the next connection to the left after Temperature. 2 wire. No polarity.

The black and red twisted pair sticking out (18 gauge wire) is where you connect the 12v auxiliary supply.

The ribbon cable is for programming the microcontroller with the pickit 2 or 3. It plugs into the PICKIT as follows:

black - PIN 1, which is MCLR (indicated with an arrow on the pickit 3)
white - PIN 2, which is Vdd Target
gray - PIN 3, which is Vss (ground)
purple - PIN 4, which is PGD
blue - PIN 5, which is PGC
kits and boards
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