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AIR Circuitry

JLCPCB Sponsored AIR Circuitry PCB Project with Penn Electric Racing

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This board (sponsored by JLCPCB) will be used to protect our battery pack and high voltage contacts.

The AIRs, or Accumulator Isolation Relays, are large relays used to separate the battery  pack from the rest of the car. This is done for safety reasons, since our battery pack outputs 450V, which can be dangerous. One of the safety systems used by our battery pack is the AIR Circuitry. This board consists of a series of diodes and capacitors that allow the AIRs to stay open for up to 92ms after power is disconnected from the AIRs. It is very dangerous to cut off power to the AIRs abruptly, since this can cause the relays to “weld” together. Thus, this board protects the AIRs and is a critical safety feature of our car.

  • Key Components: 
    • EV200HAANA

EV200HAANA: The smallest, lightest weight, lowest cost sealed contactor in the industry with its current rating (500+A carry, 2000A interrupt at 320VDC). On our car, we use two of these as our positive and negative Accumulator Isolation Relays. 

Features:

  • Hermetically sealed – intrinsically safe, operates in explosive/harsh environments with no oxidation or contamination of coils or contacts, including long periods of nonoperation.
  • 1.7W hold power @ 12VDC
  • Auxiliary contact for easy monitoring of power contact position. 

Adobe Portable Document Format - 314.46 kB - 10/15/2022 at 21:37

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Comma-Separated Values - 786.00 bytes - 10/09/2021 at 15:43

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Adobe Portable Document Format - 304.73 kB - 10/09/2021 at 15:43

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  • 1
    Ordering the PCBs

    Now, with our PCB design in hand, it's time to order the PCBs and Assembly. For this step, head to JLCPCB.com, and click on QUOTE NOW.

    JLCPCB has sponsored our project. JLCPCB (ShenzhenJLC Electronics Co., Ltd.), is the world's largest PCB prototype company and the leading high-tech manufacturer specializing in quick PCB prototypes and small volume PCB production. You can order PCB and SMT Assembly starting at just $2 for 5 PCBs. You can read more about them on our website here: https://www.pennelectricracing.com/s/JLCPCB-Sponsorship-Document.docx

  • 2
    Add Your Gerber File

    After exporting your gerber and drill files from Altium (see Files section for instructions), compress them and upload your zip file to JLC's website.

  • 3
    Confirm Options

    Here, you can see we successfully uploaded our zip file. We are then able to review our board using the Gerber Viewer function to ensure that both the Top and Bottom layers look good.

View all 4 instructions

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