Lafayette College | Electrical and Computer Engineering

Dynamometer Interconnectivity DocumentECE 492 Spring 2017

Prepared By: Richard Diego

Overview

The purpose of this document is to provide wiring and interconnect information about the Dynamometer subsystem and all its components for the Lafayette Formula Electric Vehicle as of spring 2017.

For information about the dynamometer, see the User Manual and Maintenance Manual, both of which can be accessed here: https://sites.lafayette.edu/ece492-sp17/subsystems/dyno/

Dyno System Overview

Figure 1. Motor Controller/Dyno System Overview

Motor and Motor Controller Connection Points

Figure 2. Motor and Motor Controller Connection Points

Top Level Dyno Wiring Diagram

Figure 3: Overall Schematic of the Top Level of the Dyno / Overall Car System

Overall- what needs to be connected is the two Powerlock Connections from the either TSV or the Dyno Power Supply to the motor controller which in turn powers the motor. GLV contains VSCADA which connects to the rest of the system through a CANBus connection through DT connectors on the CANBus cables. GLV also has its own power supply which powers the GLV Safety

Loop which connects to all of the subsystems – including TSV, TSI and VSCADA through DT connectors on the safety loop cables. The 35-pin connection off of the motor controller connects to the motor and TSI so that TSI can control the motor controller and motor. In the configuration in which TSI is disconnected – the Huff Box can also control the motor controller to allow you to run tests while bypassing the TSI connections.

DATE

DRAWN BY

CHECKED BY

APPROVED BY ECE

APPROVED BY ME

LAFAYETTELafayette College

Easton, Pa

ECE Department

TITLE

SIZE

COURSE

DWG NO ASSIGNMENT

SHEET

REV

F TOP LEVEL SENIOR DESIGN II 1.2

1 OF 1

LFEV CAR ELECTRICAL SYSTEM DIAGRAM

TOP LEVEL

Greg Flynn

2017 - 04 – 26

W6-?

W6-?

W6-?

W6-?

W24-?

BRBLSW3P112/2 CableDT06-2S

P112/3 Cable

W1 P2

P116/4 CableDT06-4S

W6 P2Safety Loop

GLV Power

DT06-4S

Color SignalPin

1234

WHTBRNREDBLK

12

GRNBLK

12

GRNBLK

24VDC +LV RTN

SL1SL2AIRs+AIRs-

W112/0 Battery Cable

Tractive System HV

P2NLDFT-E-GN-L-S120-M40A

Color SignalPin

1 RED TSV HV

Color SignalPin

Tractive System HV

2/0 Battery Cable

3/8 RingConn.

3/8 RingConn.

1 RED TSV HV3/8 RingConn.

1 RED TSV HV P1W132/0 Battery Cable

Tractive System HV

NLDFT-N-BL-L-S120-M40A

P1

16/8 & 2x16/1

16/12 Cable

Color SignalPin

12345678

Brake LightBrake Light RTNTSAL LeftTSAL Left RTNTSAL RightTSAL Right RTNRTDSRTDS RTN

1 P2W20 HDMI

Control System

Color SignalPinColor SignalPin

W2416/12 Cable

Control System

123456789101112

PNKBLKBLUORGWHTGRNWHT/BLKPNK/BLKGRN/BLKORG/BLKBLU/BLKBLK/WHT

Select buttonScroll buttonCruise buttonBRBBRB RTNCPRCPR RTNGLV Present LEDSL LEDFault LEDAIRs LEDGLV RTN

4 x 16/2 Cable

123456789

101112

PNKBLKBLUORGWHTGRNWHT/BLKPNK/BLKGRN/BLKORG/BLKBLU/BLKBLK/WHT

Brake 24VDC +Brake 24VDC +Brake PressureBrake Over-TravelAPPS 1 10VDC+APPS 1 SignalAPPS 1 RTNAPPS 2 5VDC +APPS 2 SignalRTN GLVSpareSpare

8/32 RingConn.

CrimpConn. P1

22/6 CableEncoder/Temp. P2

123456

REDBLKGRNWHTBLUBRN

5V +GNDEncoder BEncoder AGNDMotor Temp.

267

323178

5V +GNDEncoder BEncoder AGNDMotor Temp

35-PinMotor Cont.Conn.

DT06-6S

W26

ITT CanonLine Source

ITT CanonLine Drain

ITT CanonLine Source

ITT CanonLine Drain

123456789101112

PNKBLKBLUORGBRNGRNWHTPNK/BLKWHT/BLKBRNYELGRN

Throttle 5VThrottleThrottle RTNFWD SignalKSIGIGAVAC CoilCoil ReturnREV SignalI/O Gnd+12VCAN HCAN L

P1 W2516/8 Cable

Control System

12345678

BLKPNKBLUORGWHTGRNPNK/BLKWHT/BLK

LV GNDIMD Fault LED+5LV (Spare)From Drive ButtonDrive LEDHV Present LEDCruise LEDHVPL_RTN

CrimpConn.

DT06-2S

DT06-8S

Misc.Conn.

W12

WHTBLKWHTBLKWHTBLKWHTBLK

REDBLKGRNWHTBLUBRN

Color SignalPin

1234

WHTBRNREDBLK

12

GRNBLK

12

GRNBLK

24VDC +LV RTN

SL1SL2AIRs+AIRs-

Color SignalPin

1 RED TSV HV

1 RED TSV HV

Color SignalPin

1 RED TSV HV

Color SignalPin

12345678

Brake LightBrake Light RTNTSAL LeftTSAL Left RTNTSAL RightTSAL Right RTNRTDSRTDS RTN

1

123456789101112

PNKBLKBLUORGWHTGRNWHT/BLKPNK/BLKGRN/BLKORG/BLKBLU/BLKBLK/WHT

Select buttonScroll buttonCruise buttonBRBBRB RTNCPRCPR RTNGLV Present LEDSL LEDFault LEDAIRs LEDGLV RTN

151618221613337252335

PNKBLKBLUORGBRNGRNWHTPNK/BLKWHT/BLKBRNYELGRN

Throttle 5VThrottleThrottle RTNFWD SignalKSIGIGAVAC CoilCoil ReturnREV SignalI/O Gnd+12VCAN HCAN L

WHTBLKWHTBLKWHTBLKWHTBLK

DT06-2S

Control System

Control System

12345678

BLKPNKBLUORGWHTGRNPNK/BLKWHT/BLK

LV GNDIMD Fault LED+5LV (Spare)From Drive ButtonDrive LEDHV Present LEDCruise LEDHVPL_RTN

W13-?

BRBLSBRBLS RTN

BRBLSBRBLS RTN

P1 16/1 CableDT06-4S

W7 Safety Loop1234

Jumper wire between pins 1&2AIRs+AIRs-

PACK 1

LCD Display

TS-

ChargePort

USB

A4

TS+J1

6-Pin

P1

J24-Pin

P1

J44-Pin

P2

J36-Pin

P2

J16-Pin

P1

J24-Pin

P1

J44-Pin

P2

J36-Pin

P2

PACK 2

LCD Display

TS-

ChargePort

A5

TS+

USB

PACK 3

LCD Display

TS-

ChargePort

A6

TS+

USB

J16-Pin

P1

J24-Pin

P1

J36-Pin

P2

J44-Pin

P2

PACK 4

LCD Display

TS-

ChargePort

A7

TS+

USB

J16-Pin

W32

J24-Pin

W7

J44-Pin

P2

J36-Pin

P2

LEFT SIDE

E-STOP

BRAKE PRESSURE

BRAKEOVER-TRAVEL

APPS #1 APPS #2

FOOT PEDALS

P1 P2

TSV power supply enable

12

BLKWHT

ENBRTN

W1816/2

2619

BLKWHT

ENBRTN

J51-Pin

A4-P1

A5-P1

P1

J51-Pin

P2

J51-Pin

A6-P1

A7-P1

37-PinD Conn.

DT06-2S

GLV BatteryA13

W18-?Disconnect for pack operation

Items for

Dyno only

J135-Pin

P1DT06-12SA

W21P2

35-PinMotor Cont.Conn.

P1DT06-8SA

W23

W22

DT06-12SAP1

P1DT06-12S

GLV ChargerA12

W1-?

BRAKE LIGHT

TSAL RIGHT

12

LV GNDTS Energized Light 16/2 Cable 8/32 Ring

Conn.

WHT BLK

12

LV GNDTS Energized Light

WHT BLK

TSELP1

DT06-2S

W28

W23-?

P21 RED TSV HV P1W152/0 Battery Cable

Tractive System HV

NLS-N-BL-S120-M40A

NLDFT-N-BL-L-S120-M40A

1 RED TSV HV

3/8 RingConn.

These cables come out of the same jack but go to different places

W31P120/3 CanBus CableDT06-6S

SCADA P2DT06-6S

123456

YELGRNBAREGRNWHTBLK

CAN HCAN LSHIELDCHGND24VDC24V RTN

123456

YELGRNBAREGRNWHTBLK

CAN HCAN LSHIELDCHGND24VDC24V RTN

P1DT06-6S

SCADA123456

120 Ohm termination resistor

W32

TSIA3

FWD/REV

READYTO

DRIVESOUND

W31-?

W31-?

W31-?

W31-?

J43-Pin

P2

J94-Pin

P1

J86-Pin

P1

J76-Pin

P1

J64-Pin

P2

J112-Pin

P1

J28-Pin

P1

J38-Pin

P1

P1

J1112-Pin

TSMP

HV+ HV-CHGND

RIGHT SIDE

E-STOP TSVMSGLVMS

MRESET

HVLV

W20-?

W1-?

COOLINGCONTROLLER

A10

J14-Pin

P2P1J3

4-Pin

J46-Pin

P2

J26-Pin

P2

W1-?GLV

Power Supply

W26-?

W11-?

W11-?

W11-?

W15-?

W12-?

TS Energized Light

U

V

W

B+

B-

MOTORCONTROLLER

A9

P2

MOTOR

U

V

W

W11-?

W11-?

W21-?

W33-?

123456

Safety CircuitSafety Circuit RTNMRESETMRESET RTNTSVMSTSVMS RTN

16/6 Cable

WHTORGPNKGRNBLUBLK

123456

GLVMSESTOP RTNMRESETMRESET RTNTSVMSTSVMS RTN

WHTORGPNKGRNBLUBLK

Right side panelP1

DT06-6S

W33

W3-?

W22-?

W35-?

W31-?

W31-?

W31-?

W28-?

TSV POWER

SUPPLY (96V)

J137-Pin

P2

J2ITT CanonLine Drain

P2

J3ITT CanonLine Source

P2

W6-?W6-?

W25-?

TSAL LEFTConnect to TSI where packs are during Dyno room testing instead of the packs

W2-?

P112/3 Cable

W2 GLV Power123

GRNBLKWHT

5VDC +LV RTNCHGND DT06-3S

123

GRNBLK WHT

5VDC +LV RTNCHGNDCrimp

Conn.

CrimpConn.

J16-Pin

CrimpConn.

TBD

TBD

12/3 Cable

W3412/1 Cable

CHGND1 PNK CHGND

8/32 RingConn.

8/32 RingConn.

1 PNK CHGND

GLV Power

J12

ETHERNET

J11

USB

J32-Pin

P1

P1J46-Pin

GLV / SCADA

A1J5HDMI

J612-pin

P1

J73-pin

P1

J94-pin

P1

J106-pin

P1

J133-Pin

P1

J142-Pin

P1

J152-Pin

P1

J1GLV

PORT2 Pins

`

J166-pin

P1

HUFF

CABINETSolenoid

RPM Pick-Up

Strain Gauge

120 VAC Supply

A11

J16-Pin

P1

J26-Pin

While the Huff box is not in use the CANBus cable should be

connected directly between the cooling controller and the TSI

Tachometer

W36-?

123456

TachometerStrain gaugeThrottleThrottle RTNSolenoidSolenoid RTN

16/6 Cable

WHTORGPNKGRNBLUBLK

123456

TachometerStrain gaugeThrottleThrottle RTNSolenoidSolenoid RTN

WHTORGPNKGRNBLUBLK

Motor connectorP1

DT06-6S

W36

CrimpConn.

While the Huff box is not in use W35 should be connected where

the Huff box was

COCKPITA2

LCDDISPLAY

IMDFAULT

FAULT

AIRs

DRIVE

HVPRESENT

SAFETY

RESETE-STOP

DRIVE

InertiaSwitch

GLVPRESENT

J1 HDMI

Select

Scroll

Cruise

CRUISE

P116/3 CanBus CableDT06-3S

UART P2DT06-3S

123

GRNYELBARE

TXRXREF

123

YELGRNBARE

TXRXREF

W35Note the change of colorThis cable is a crossover

20/2 Can busSCADA

123456789101112

PNKBLKBLUORGWHTGRNWHT/BLKPNK/BLKGRN/BLKORG/BLKBLU/BLKBLK/WHT

Brake 24VDC +Brake 24VDC +Brake PressureBrake Over-TravelAPPS 1 10VDC +APPS 1 SignalAPPS 1 RTNAPPS 2 5VDC +APPS 2 SignalRTN GLVSpareSpare

J51-Pin

A3-P2

Car.vsdxCar Top Level Diagram