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Electrical - Build 2 - Low Voltage
Electrical - Build 2 - Low Voltage
Nathaniel May, Brady Weimert and José Barco (left to right)
How to Identify and Read Wires
How to Identify and Read Wires
All wires are labeled on both ends. There are three main types of wire terminations in use: Rail Ferrules for connecting wires to the DIN-rail blocks, Spade Terminations for wire to wire and wire to relay connections, and Ring Terminations for attaching wires to a stud or bolt. The DIN-rail is numbered and color coded to match the wires. Rails are also set up to have the same number on either side of a terminal block to make wire to wire connections clear. All relays have 12 volt DC coils(85,86) with a normally open(87), normally closed(87a), and common(30) spade connections. Each relay is further identified with a sticker for ease of connection and troubleshooting. An example of each connection type is show below:
The place where the wire connector connects is written on the end, with an acronym for the area, and where on that system the wire connects. For example, RLVP.87, goes on the Low Voltage Rail (RLVP), in terminal 87.
This is a spade connector, which is not screwed into a terminal, but instead fits over a male connector, and makes contact on metal to metal connection, again without the need for screws.
This is a standard wire, which connects to either a DIN rail, or the regular rail, and is connected either by a screw if it is just in a standard terminal, or if it is in a DIN terminal, it is held in place by pressure from the terminal pushing on it.
Low Voltage Power Rail (RLVP) and The Cycle Analyst Rail (9/17/24)
Low Voltage Power Rail (RLVP) and The Cycle Analyst Rail (9/17/24)
The Low Voltage Panel Rail is installed along the
forward edge on top of the panel.
The Cycle Analyst Rail is installed down and right of
the panel center, across from the RLVP numbers 71 through 77.
RLVP Install
Using a 7/16" socket and wrench, the RLVP was fastened to the panel using two 1/4"-20 x 3/4" bolts, a flat washer, and nylon insert locknuts.
The RCAN, or cycle analyst rail, was installed using two 1/4"-20 x 3/4" bolts, flat washers, and nylon insert locknuts.
Completed with RCAN and RLVP mounted to the panel
The RLVP and RCAN are used as the primary wiring hub for the front section of the vehicle. All low voltage connections from the battery box, control box, and dashboard all connect somewhere throughout the RLVP, or Low Voltage Panel Rail. The panel also holds all the 12 volt relays that will be shown in the sections below, which are responsible for the logic needed to turn on the vehicle, power the high beams, activate the pack contactor, and prevent driving away while charging. The RCAN handles the higher voltage connections from the battery box to the cycle analyst that is mounted to the dashboard.
Flasher Mount Bracket and Flasher Unit
The Flasher unit mounts to a bracket on the low
voltage panel. The bracket is located to the left of the
RCAN, orientated so the gap is open towards the RLVP.
Firstly, the bracket has to be mounted using a 7/16" socket and wrench to fasten it to the panel
Secondly, the flasher unit is clipped into the flasher bracket with some light pressure
Lastly, the wires for the unit are connected to the main rail.
from the flasher harness to the RLVP, numbers 74, 75,
81 and fuse block ‘V’.
The Flasher Unit, also called the Turn Signal Unit, interfaces with the RLVP to turn on and distribute flasher signals to the turn signal lights on the front and back of the vehicle.
Alarm Buzzer
A phillips head screwdriver and a 3/8" wrench were used to fasten the alarm buzzer into the panel
Top view after installation and wire connections
The black wire connects to
RLVP #87, and the red will connect to the Alarm Relay
The Alarm Buzzer sounds when the vehicle is switched into reverse, and is also used to signal a low voltage fault.
Relays
Relays
Alarm Relay
Using a 3/8" wrench and a Phillips head screwdriver, the alarm relay was mounted to the panel
Alarm Relay
This is a view of the Alarm Relay after being wired, and highlighted for clarity
Plugged in wires: Pin 86, Blue wire to RLVP #88
Pin 85, White wire to RLVP ‘I’
Pin 87, White wire to Alarm Relay Pin 85
Pin 30, Red wire to Alarm Buzzer
Pin 87a, Red wire to Low Volt Relay Pin 87a (FYI, the wires that travel the longest distance are the lowest/under everything else).
The Alarm Relay controls the activation of the Alarm Buzzer when the FNR (Forward-Neutral-Reverse) switch is toggled to reverse.
High Beam Relay (9/18/24)
The High Beam Relay controls activation of the
secondary center light as well as an increase in power
to the right and left run lights.
Use a #10-24 x 3/4” machine screw and nylon insert locknut, with a #2 Phillips Head Screwdriver
Bolted in relay
Finished: Pin 30, White wire to RLVP #69
Pin 85, Brown wire to RLVP #68
Pin 86, Black wire to RLVP #83
Pin 87, Yellow wire to RLVP ‘J’
Pack Relay
The Pack Relay controls power to the pack
contactor and peripherals.
#10-24 x 3/4” machine screw and nylon insert locknut to attach the relay to the panel
Completed: Pin 85, Green wire to RLVP ‘G’,
Blue wire to Charge Relay Pin 87
Pin 86, Black wire to RLVP #79
Pin 87, Orange wire to RLVP ‘X’
Pin 30, Orange wire to RLVP #39
Key Relay
The Key Relay controls the source power to the Key-
On Fuse Block on the RLVP and is activated by the Key Switch.
Fastening the key relay to the LV panel with a #10-24 x 3/4" machine screw and a nylon insert locknut.
Connecting the wires from the Key Relay to the RLVP with a small flat head screwdriver
Top view after the Key Relay is fully connected.
Charge Relay
The Charge Relay powers a small amount of pack
peripherals when the vehicle is plugged in.
Installing the wires from the charge relay
Completed: Pin 30, Purple wire to RLVP ‘W’
Pin 87, Blue wire to Pack Relay 85,
Blue wire to RLVP #41
Pin 85, Red wire from Battery Box
Pin 86, Black wire from Battery Box(or RLVP-ASR72)
Brake Sensor Wires
Brake Sensor Wires
The Brake sensor wires will connect to the brake sender units on the master cylinders when the panel is installed in the vehicle. The purple lead is for the front brake unit, connected to the always on power supply so the brake lights work even when the vehicle is off. The orange lead is connected to the rear brake unit and is powered by the Key-On fuse block. The rear brake unit also connects to the orange light on the dash, to signal the driver the rear brake is active when used as a parking brake.
Front Brake Source, Purple wire to RLVP ‘S’
Front Brake Return, Gray wire to RLVP #77
Rear Brake Source, Orange wire to RLVP ‘H’
Rear Brake Return, Gray wire to RLVP # 41,
Gray wire to RLVP #76
H9X1: THROTTLE RELAY
Attaching the H9X1: THROTTLE RELAY to the plate using a #10-24 x 3/4” machine screw and nylon insert locknut. This is activated when the BMS detects a cell voltage below the threshold.
Connecting the H9X1: THROTTLE RELAY wires to the Low Voltage Panel Rail.
Pin 85, White wire to RLVP #47, Low Volt Relay Pin 85
Pin 86, White wire from Battery Box
Pin 87, Green wire to RLVP #55
Pin 30, Blue wire to RLVP #56
Others wires that we needed to connect to Low Voltage Panel Rail.
Here is when we are finishing all those relay and wires to Low Voltage Panel Rail.
COMPLETED LOW VOLTAGE PANEL
Dashboard Assembly (9/23-24/24)
Dashboard Assembly (9/23-24/24)
OVERVIEW
The Dashboard is the primary interface between the driver and the vehicle. It connects directly to the Low Voltage Panel Rail where signals are distributed throughout the vehicle. The order of assembly presented here is a suggestion and designed primarily for ease of assembly flow. The components and wiring can be installed in any order without issue. Dashboard components from left to right: High beam switch, red on-off toggle. Charge mode indicator, blue light. Error indicator, red light. Cycle analyst computer. Vehicle ready indicator, green light, Parking brake indicator, orange light. Emergency 12 volt shut off, big red button. State of auxiliary battery, 12 volt meter. Forward-Neutral-Reverse(FNR) switch, on-off-on toggle switch with red safety cover. Vehicle on control, key switch.
BIG RED BUTTON: EMERGENCY SHUT OFF SWITCH (9/23/24)
The emergency shut off disables all 12 volt systems in the vehicle. This includes the deactivating the pack contactor, shutting down all high voltage circuits as well.
Fastening the Emergency Stop switch to the dashboard
Screwing in the button into the emergency stop
Completed emergency stop button
12 VOLT METER (12VMTR)
The 12 Volt Meter is installed from the front of the panel, to the right of the Big Red Button. This meter monitors the voltage within the vehicle and shows any fluctuation in voltage.
Inspecting the 12V meter
After the meter has been fastened to the dashboard
Front View of the mounted 12V meter
KEY SWITCH
Wiring the key switch and fastening it to the dashboard
The Key Switch is the ignition for the vehicle, and connects to the Key Relay.
FORWARD-NEUTRAL-REVERSE SWITCH (FNR)
The Forward-Neutral-Reverse Switch (FNR) controls motor direction. It is a double pole double throw toggle switch. The terminals are labeled on the bottom of the switch.
Mounted and wired FNR switch from the back of the dashboard
View of the FNR switch from the front of the dashboard
HIGH BEAM SWITCH (HBS)
Used to turn the high beams on/off, powered by the high beam relay. Has three wires, supply, load, and ground.
Mounting and connecting the HBS wires
Front View of the completed HBS switch
CYCLE ANALYST (9/24/24)
Feeding wires from the cycle analyst through the dashboard
Fastening Cycle Analyst mount to the Dashboard
Fastening Cycle Analyst to the Cycle Analyst Mount
Mounted Cycle Analyst, Kill Switch, 12V meter, FNR switch, and key switch.
DASH INDICATOR LIGHTS
The Dash Lights give an indication as to the current state of the vehicle. The green light designates the vehicle is on and ready to drive. The orange light indicates the parking brake is on. The blue light indicates the vehicle is in charge mode. The red light indicates a the inertia switch has been tripped or that there is a fault with the battery management system. All leads terminate on the Low Voltage Panel Rail, except the red light source, which connects to the Inertia Switch.
Fastening the Dash Lights to the Dashboard
Mounted dash lights from the back
Mounted Cycle Analyst and dashboard lights
THE COMPLETED DASHBOARD ASSEMBLY
Mounting of Dashboard and Low Voltage Panel
Mounting of Dashboard and Low Voltage Panel
Mounting the Dashboard (9/25/24)
Mounting the Dashboard (9/25/24)
u2s7 Dashboard and Turn Signal Installation.pdfThe dashboard is installed on top of the two 1/2”-13 nuts securing the steering plate, as well as two 1/4”-20 isolation mounts mounted on the center and rightmost tabs on the dash cross tube. Take care to not pinch any wires between the dashboard and the steering plate.
Putting the dash in place and bolting using a 5/16" wrench and two 1/4”-20 acorn cap nuts
Diagram of where the mounting spots are
Bolting down the dash using a 3/4” Wrench and two 1/2”-13 acorn cap nuts
Fully mounted dash
(Side note: this is supposed to be mounted after the Low Voltage Panel, but we accidently did this first)
Turn Signal Assembly (9/25-26/24)
Turn Signal Assembly (9/25-26/24)
Turn signal before being mounted. The orange plunger is for the hazard lights.
Mounting the turn signal to the steering column
Fully Mounted Turn Signal
Mounting Low Voltage Panel (9/25-26/24)
Mounting Low Voltage Panel (9/25-26/24)
u2s8 Low Voltage Panel Installation.pdfPlace the low voltage panel on top of the master cylinder reservoirs. Do not bolt the panel to the vehicle at this time. Being able to move the panel while connecting the dash wires makes the process easier.
The low voltage conduit feeds up from
underneath the low voltage panel through a
3/4” hole and uses a ring nut to hold it into
place. Be sure to remove the ring before
feeding the wires through the panel.
Fully pulled thru conduit wires
Bolting down the panel using a 7/16" wrench and two 1/4”-20 x 3/4” Hex Bolt
Connecting Conduit & Dashboard Wires
Connecting Conduit & Dashboard Wires
his step included the connection of wires both from the conduit from the control box and the dashboard wires. Some other wires worth mentioning are the wires going to the brakes. The red light wire connects to the inertia switch on the steering column.
Connecting the Rear brake wire to the brake relay on the dash
Plugging the conduit to the low voltage power rail. Begin with the red and black 10AWG wires going to #45 and #78. They are the most difficult to maneuver through the panel. Following that, start connecting the shorter wires to the rail and work through to the longer wires.
Brake connections
Connecting wires to the Low Voltage Power Rail
Test stuff
Test stuff
Test for understanding questions: Enter Game PIN - Kahoot!
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