Monday, June 9, 2014

3.3.1 Design

All electrical cables that carry greater than 30 VAC or 60 VDC should be considered high-voltage cables and should be permanently identified with orange covering material, and be located to preclude casual contact by vehicle operators and maintenance personnel. No high voltage cables should be routed through the passenger compartment.





Any part or connector energized with high voltage during normal operations should be located behind a cover or in an enclosure labeled with the hazardous voltage symbol. See Figure 18. Removal of the cover should require removal of special fasteners and/or should trigger an interlock system that de-energizes the high-voltage components. If the cover or enclosure is made of conductive material, it should be grounded to the vehicle chassis.

The electrical system should include an automatic disconnect function that isolates both poles of any high-voltage source (fuel cell stack and/or high voltage battery pack) from other system components.

The connectors used should be “fail safe” so that they will open if the control signal is lost due to a system fault. This automatic disconnect function should be triggered by the following:

• Turning off the main switch
• By automatic system shutdown (due to a hydrogen sensor detecting a leak, or other system fault that shuts off the hydrogen fuel supply)


All high-voltage components should be designed with adequate electrical isolation to prevent “current leakage” between them and other electrical components or the chassis. The vehicle control system should include a ground fault monitoring system that can detect leakage current and set a warning light and/or take other action (up to automatic system shutdown) when a current above a set threshold is detected.

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