Tractive System Activation Light 2024

The Tractive System Active Light (TSAL) circuit is a device that indicates a dangerous voltage is present in the Tractive System – the system of components including motor drivers and motors. It gets activated once the shutdown circuit closes the AIR(accumulator isolation relays), connecting the TS to the 80V power supply. As soon as the voltage reaches 60V, it indicates that the TS is in active state. This circuit is mainly based on the 555 timer set in astable mode which generates a 3Hz signal.The TSAL circuit is always powered when the LVS is switched on and remains powered after the LVS is switched off.

Step 1: Parts of Circuit

The circuit consists of two LEDS, red and green, which have a different working mechanisms under different conditions.

As per the section EV4.10.2 of the rulebook, the red LED must illuminate when the container voltage exceeds 60V. Under normal conditions(i.e when the signal from the HV-IND is below 60V)the relay ‘R1’ is switched on and the LED labelled RED is turned off since the output signal of the 555 timer is connected to the normally closed pin of the relay ‘R1’ and the red LED is connected to the normally open pin of the relay. Once the voltage exceeds 60V, the HV-IND circuit is powered through, which in turn breaks the path of the signal from the HV-IND to the TSAL circuit. Simultaneously, the relay ‘R1’ switches back to its normal position and as a result, the RED LED starts blinking.

Similarly, the green light must illuminate when the container hasn’t exceeded 60V.Generally, the connectors HV IND G+ AD HV IND G- are shorted through a relay in the HV-IND circuit. This causes the LED labelled GREEN to turn on. However, as the voltage exceeds 60V, the relay ‘R3’ switches off and returns back to its original position. This results in the green LED being turned off.

Step 2: Reference

The TSAL itself must:

• Be red in colour and flash continuously with a frequency between 2Hz and 5Hz if and only if the TS is active.

• Be green in colour and continuously illuminated if and only if the TS is deactivated.

• Be powered from an independent power supply.

• Always be powered when the LVS is switched on and remain powered for at least 15 minutes after the LVS is switched off. It is permissible for the team to deactivate the TSAL when the LVS is switched off and the TS is confirmed to be deactivated. The driver must not be able to deactivate the TSAL

• Comply with all requirements but must not be deactivated by opening the LVMS.

The TS is active when ANY of the following conditions are true:

• An accumulator isolation relay is closed.

• The pre-charge relay is closed.

• The voltage outside the accumulator container(s) exceeds 60VDC or 25VAC Root Mean Square (RMS).

The TS is deactivated when ALL of the following conditions are true:

• All accumulator isolation relays are opened.

• The pre-charge relay is opened.

• The voltage outside the accumulator container(s) does not exceed 60VDC or 25VAC RMS.

Step 3: Ordering the PCBs

Now we have got the PCB design and it’s time to order the PCBs. For that, you just have to go to https://jlcpcb.com/HAR, and click on the “Order now” button. JLCPCB has sponsored this project. JLCPCB (ShenzhenJLC Electronics Co., Ltd.), is the largest PCB prototype enterprise in China and a high-tech manufacturer specializing in quick PCB prototype and small-batch PCB production. You can order a minimum of 5 PCBs for just $4.

To get the PCB manufactured, upload the Gerber file you downloaded in the last step. Upload the zip file or you can also drag and drop the Gerber files.

After uploading the zip file, you’ll see a success message at the bottom if the file is successfully uploaded. You can review the PCB in the Gerber viewer to make sure everything is good. You can view both the top and bottom of the PCB.

After making sure our PCB looks good, we can now place the order at a reasonable price. You can order 5 PCBs for just $4 but if it’s your first order then you can get 5 PCBs for $2. To place the order, click on the “SAVE TO CART” button and then proceed to payment.

My PCBs took 3 days to get manufactured and arrived within a week using the SF express delivery option. PCBs were well packed and the quality was really good.