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Wiring
Controller Min. Wire AWG
Standard Duty
Min. Wire AWG
Heavy Duty
300A OEM -6 AWG 4 AWG
400A 4 AWG 4 AWG
500A 2 AWG 1/0 AWG
600A 1/0 AWG 2/0 AWG
Power Wiring
When running wiring for the vehicle care must be taken for proper
wire routing. Power wiring should be of proper sizing and ran as
low in the framework of the vehicle as practical. Lengths of power
wire runs need to be kept short and pairs of wires from common
circuits should be grouped together to reduce EMC emissions.
Secure all power wiring to the vehicle framework.
Signal Wiring
Signal wires should be keep as short as practical. Care should
be taken to protect the wires sharp edges and rubbing. Consider
the use of split loom or braided wire sheathing. Fasten bundles
securely to framework. Do not route the signal wires together
in the same bundle with power wires. All safety interlocks
(KSI, Footswitch, etc) need to be mechanical switches or
electromechanical relay.
Wiring and battery health in an electric vehicle are very important
and overlooked during performance upgrades. Wiring size
is important for safety and proper operation of the vehicle.
Undersized wires will affect the performance of controllers and can
overheat. Wires should be crimped with proper sized terminals and
tools to provide a clean low resistance connection.
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