High voltage cables are a safety critical portion of any electric vehicle drivetrain and after completing any high voltage cabling or system you should go through a complete check process on every cable you produce.
Polarity Check #
On two-port connectors used in the Atom Drive System, all connectors are setup such that Pin A should be positive and Pin B should be negative. You should confirm this on both sides of the cable such that A goes to A and B goes to B. Polarity for single-wire cables does not apply at the cable level, but it will be important when you go to plug those in.
Shielding Check #
Perhaps the most common mistake when making high voltage cables, it is important to ensure that your cable shielding does not come into contact with your conductor. If this were to happen, you would be connecting your high voltage to the vehicle ground through the shielding. Even a single frayed wire can create an isolation fault with the vehicle. Thankfully, this issue is easy to check before connecting to the vehicle! The method for checking this depends on the connector as every connector grounds this shielding slightly differently.
- Amphenol Powerlok Connectors: Using a multimeter set to resistance measurement mode, check the resistance between the conductor pins and the metal housing of the connector. For two-pin connectors make sure to check both conductors. The multimeter should indicate open loop.
- For TE HVA280 Connectors: Using a multimeter set to resistance measurement mode, check the resistance between the conductor pins and the small metal shield contacts on the inside of the connector. These are seen just above and below the middle HVIL contact pins. The multimeter should indicate open loop.