MAC 5000 — FULL WIRING SCHEMA (v1) Author: SUE (for Josh / Jedi Security) Date: 2025-09-25 ============================================================ A. SYSTEM OVERVIEW (Functional Blocks & Nets) ============================================================ [BATTERY BANK] --(Main Disconnect S1)--> (Main Fuse F1) --> (Precharge Rpre + Kpre) --> (Latching Contactor K1) --> [DC BUS +BATT] --> (Shunt SH1 / Hall Sensor HS1) --> (Motor Controller MCTRL) --> (Motor M1) Generator/Alt (G1) driven by M1 --> (3-Phase Bridge Rectifier BR1) --> [DC OUTPUT BUS +GEN] --> (Bulk Caps Cbulk / Supercap Bank SC1) --> ├─> (Inverter AC-1) -> 120 VAC OUT (CB120A) ├─> (Inverter AC-2) -> 120/240 VAC SPLIT-PHASE OUT (CB240A/CB240B, GFCI) └─> (DC-DC Buck B12) -> 12 VDC OUT (F12) Control & Telemetry: - RPM Encoder (ENC1) or Hall sensors to RPM Control PCB (CTRL1) - Servo Magnetic Brake (SV1) driven by CTRL1 - LCD Meter Panel (LCD1) reads: VBatt, IBatt (via SH1/HS1), Vout-AC, Vout-12V, RPM, Temp - E-Stop (ESTOP) in series with K1 coil and CTRL1 enable - Grounding: Chassis GND (PE) tied to safety earth; Signal GND isolated (SGND) via ISO amplifiers/isolators Primary Nets: - +BATT / -BATT : Battery bus after K1 - +GEN / -GEN : Rectified generator bus after BR1 - +12 / 0V : 12V accessory/control bus - AC120, AC240 : Inverter outputs ============================================================ B. PROTECTIVE DEVICES & SAFETY ============================================================ - F1 (Main DC Fuse): Slow-blow, sized for peak inrush and motor surge (see Table D). - CB120A, CB240A/B: Thermal-magnetic breakers for AC outputs. Use GFCI on 120V receptacles. - F12: Inline fuse for 12V DC output rail. - ESTOP: Latching mushroom switch, NC in series with K1 coil and CTRL1 enable. - K1: Main latching contactor (coil powered via CTRL1 + ESTOP chain). - Kpre + Rpre: Precharge relay & resistor to limit inrush to MCTRL and Cbulk/SC1. - SH1 or HS1: Current sensing (shunt for DC bus + isolated amplifier, or Hall-effect sensor). ============================================================ C. WIRING SCHEMATIC (ASCII BLOCK DIAGRAM) ============================================================ Legend: --- heavy power wiring; -.- low voltage control; [ ] device; ( ) protective/aux PE = Protective Earth (chassis ground) PE (Earth Stud) | Chassis---*-----------------------------------------------> (Bond all exposed metal) | [Battery Bank +]---S1---F1---Rpre---Kpre---K1 Main---+---------------------> +BATT | [SH1/HS1] | +-----+-----------------> MCTRL + (High Current) | [Battery Bank -]-------------------------------------------+-----------------> MCTRL - (High Current) | PE (through star ground; avoid loops) MCTRL U/V/W ====> M1 (Motor) ====> G1 (Generator/Alternator shaft-coupled) G1 3-phase ~~> BR1 (3ph rectifier) ~~> +GEN ---- Cbulk/SC1 ----> DC Distribution | +--> Inverter AC-1 --> CB120A --> 120V OUT (GFCI) +--> Inverter AC-2 --> CB240A/B --> 240V OUT (split-phase) +--> B12 (DC-DC Buck) --> F12 --> 12V OUT Control & Telemetry (low voltage): +12V/0V ---> CTRL1 (RPM Control PCB) ENC1 ----.-> CTRL1 RPM-IN SV1 <---'-> CTRL1 PWM/Servo-Out (with flyback/driver as needed) LCD1 <--- VBatt, IBatt (via amplifier/isolator), Vout-AC sense (via PT), RPM, Temp ESTOP (NC) -----> CTRL1 ENABLE IN -----> K1 COIL + (series) K1 COIL - -> 0V Isolation Notes: - Use DC/DC isolated modules or ISO-amps for sensing between power and logic domains. - Route HV and LV in separate conduits; cross at 90° only when necessary. ============================================================ D. WIRE GAUGE & FUSE SIZING GUIDELINES ============================================================ (Assumptions — edit to your hardware ratings) - Battery bus peak current (motor start): up to 150–200 A (size F1 accordingly, e.g., 200–250 A slow-blow). - Continuous motor current: 60–100 A (AWG 4–2, silicone or welding cable recommended). - G1 to BR1 to DC bus: 40–80 A (AWG 6–4 depending on length). - Inverter inputs: sized to inverter continuous power (e.g., 2 kW inverter ~ 2000W/12V ≈ 167A -> AWG 2). - 12V accessory/control: 22–18 AWG for logic; 16–14 AWG for servo or relay coils as needed. Example Gauges (Copper, short runs, chassis-mounted): - Battery + / - main: AWG 2 (or 1/0 if >200A or longer runs) - MCTRL + / - to Motor: AWG 4–2 (per controller spec) - G1 3-phase to BR1: AWG 10–8 (phase leads), shielded if noisy - +GEN bus to inverters: AWG 4–2 (per inverter spec) - 12V control distribution: 18 AWG Always verify with local codes and specific device manuals. ============================================================ E. INPUT/OUTPUT PANEL & BREAKER LAYOUT ============================================================ Front Panel (Left->Right): [Starter Button] [ON/OFF Toggle] [ESTOP] [LCD Panel] [12V DC Port (F12)] [120V AC (GFCI, CB120A)] [240V AC (CB240A/B)] DC Bay (inside electrical bay): S1, F1, Kpre, Rpre, K1, SH1/HS1, Cbulk/SC1, BR1, B12, DC distribution blocks, ground/earth stud. Motor Bay: MCTRL, M1, coupling to G1, encoder ENC1, temperature sensor TS1. ============================================================ F. SIGNAL & SENSE WIRING (CTRL1) ============================================================ - ENC1_A/B/Z -> CTRL1 (differential if possible; twisted pair, shield to SGND at CTRL1 end only) - HS1/SH1 amp out -> CTRL1 ADC_IN (isolated) - PT (Potential Transformer) for AC sense -> ISO-AMP -> CTRL1 ADC_IN - TS1 (NTC/PT100) -> CTRL1 analog input with proper biasing - SV1 (Servo Brake) -> CTRL1 PWM/Servo output (separate supply if high stall current) - LCD1: via I2C/UART/CAN as supported; use opto/isolated transceivers where HV proximity exists. ============================================================ G. PART TAG KEY (Cross-Ref) ============================================================ S1 Main battery disconnect switch (manual) F1 Main DC fuse (slow-blow, per current) Rpre Precharge resistor (sized for MCTRL & Cbulk/SC1) Kpre Precharge relay/contactor K1 Main latching contactor (coil via CTRL1 + ESTOP) MCTRL Motor controller (DC/BLDC/FOC per selection) M1 Motor/Prime mover G1 Generator/Alternator, shaft-coupled to M1 BR1 3-phase rectifier bridge Cbulk/SC1 Bulk capacitor / Supercap bank on +GEN bus AC-1 Inverter 120 VAC AC-2 Inverter 120/240 VAC split-phase CB120A Breaker for 120V output (plus GFCI) CB240A/B Breakers for 240V split-phase B12 DC-DC buck converter for 12V rail SH1/HS1 Current sensing (shunt or Hall) LCD1 LCD panel meters CTRL1 RPM control PCB / logic ENC1 Encoder / Hall RPM feedback SV1 Servo magnetic brake actuator ESTOP Mushroom emergency stop (NC) ============================================================ H. INSTALL NOTES ============================================================ - Separate conduits: HV power vs LV control. Keep at least 150 mm separation where practical. - Use star-ground at a single chassis earth stud; isolate signal ground and reference at CTRL1. - Add ferrite cores on sensor leads where they exit the bay; keep LV cables twisted & short. - Label both ends of every wire with heat-shrink markers matching the Wiring Table IDs (W##). - Torque check all lugs; use locking hardware; strain relief every 15–20 cm on heavy cables. - Verify precharge timing: Kpre closes first (through Rpre), then K1 closes after voltage delta < 10%. (end of schema text)