Electrical - Build 1 - Battery Box

u2s11-13 Lithium Battery Box Install 02-03-20.pdf

9/16/24

Inventory was taken for the first day

all parts were accounted for
Our parts for the control box stops at the 3/8-16x3/4" bots to mount Battery Box to lower bumper.

We raised the box onto two wood boxes
We installed the j1772 Socket(the cars' charging port).
- First putting the wires in, then putting the cover on.
Installed the pack rail with two 1/4-20x3/4” bolts
Installed the black J1772 relay
Lastly began installing the AC Relay.

The AC relay was fully attached
The Shunt was attached( with two 10-24x3/4” machine screws, washers and Nylock nuts.)
Connected the wires from the J1772 socket to the middle block on the pack rail.
- a. Brown – 96
- b. Orange – 95
- c. Black – 94
- d. White – 92
- e. Green – 90
There are two wires for the shunt, one is longer
Blue and white wires for the shunt. Connected two wires to the pack rail terminal blocks.

Today the wires were added to Relays.
- Red - 42
- Green - 65
Attached Ground and red wire to AC relay and pack rail
connected the red wire labelled 100 to the pack rail terminal, will be going to B+ on the lithium battery pack after it’s completely installed and wired.
There are two green wires labelled 89. This will be the BMS ground.
- Shorter wire was connected, however the second wire is missing.

Connected the green relay wires.
- shorter wire to 89 right side and screwed into relay pack bolt.
- longer wire found and tightened to left side.
added the black and white striped wire to the J1772, on the post on the left underside of the relay.
Connected the Orion BMS Main I/O Harness to relay pack.
- The red and wire striped wire and attach it to the AC relay post marked “0”. This is the safety relay that shuts off the BMS if it gets too hot.
- Instead of the Grey and brown wires, red and black wires were attached to 20(red) and 21.(black)
Established where the 96V Pack Charger, Charger/BMS Mounting Bracket, and Orion BMS 2.0 will be.

First the Posts were screwed in to prepare for attaching the Battery Management System.(BMS)
- The BMS charger would have covered it.
The BMS charger was attached to the BMS Stand.
The BMS was attached after the charger and also to the stand. Finally connecting with the previously attached Posts
- Both BMS systems used 7/16 wrench
The BMS stand was screwed in using a 1/2 Wrench
Attached the white BMS harness connector. Connect all the wires
Located the three wires coming from the bottom of the charger. Attach the relay connector to AC relay number 2.
- Attached the two remaining wires (ferrules numbered 90 and 92) to the AC brick on the pack rail.
- Attached the last red and black wires (red 20, Black 21)

Added and screwed in wire holder
- however the bolt size is wrong and will need to be replaced
The Green BMS has been attached to ground on the BMS
The Relay connecter has been attached to AC relay #2

Discovered Missing pages from Book
Black shunt wire was screwed into Right Shunt bolt
Shunt Lithium Cable added to left Shunt Bolt
Contactor with hardware found and attached with 3/8th bolts
- Contactor Fuse with 7/16 attached
- Lithium Cable Wire attached to contactor fuse
Contactor later removed in order to make room for future battery placement.

Attached the wires from control panel to pack rail
Connected the other end marked Cell 1 minus to the 1- terminal on the battery pack.
Connected the other end of this cable marked Cell 32+ to the 20+ cell (B+) on the battery pack.
Connected the other end of this cable marked Cell 16+ to the battery pack, terminal marked 20
Connected the Cell 17 cable connects to rear left terminal marked 1-

The last lithium wire was put in
charging attempted however the console and the low voltage box did not have their fuses in and it did not work.

Group photo in front of car

Battery Balancing