GLV Maintenance Manual...ADC Code is the 12-bit value read by the sensor and Vref is 2.5V according...

GLV Maintenance Manual

ECE 492 - Spring 2019

Latest Revision: 5/10/2019 Prepared by: Maxwell McFarlane

Abstract This document is intended to satisfy GPR001 of the LFEV-2019 Statement of Work as a maintenance manual for the GLV system as it is implemented in the DYNO integration phase of the formula electric vehicle project.

Table of Contents Executive Summary 3

Charging the GLV Battery 3

Calibration 3

Principal of Operation 4

GLV MAINTENANCE MANUAL 1

Safety Loop 1 4

Safety Loop 2 4

Car Operation – Starting GLV 5

Car Operation – Operator Cutting Power 5

Car Operation - Resetting the Safety Loop 5

GLV Break Out Board (BOB) PCB Operation 5

Block Diagrams 6

GLV Systems Block Diagram 6

6

GLV BOB Block Diagram 7

7

Safety Loop Diagram 0

Schematics/Layouts 1

GLV BOB rev.4.2 Schematic (L19_GLV_07) 1

GLV BOB rev.4.2 PCB Layout (L19_GLV_07) 2

Mechanical Drawings 3

L19_GLV_01 (8U Rack Panel) 3

L19_GLV_02 (Top Panel) 4

L19_GLV_03 (SCADA_Screen_MountBrackets) 6

L19_GLV_04 (Cockpit Panel) 7

L19_GLV_05 (Right Side Panel) 8

L19_GLV_06 (Left Side Panel) 9

Interconnectivity Diagram 10

Bill of Materials 11

GLV BOB BOM (L19_GLV_07) 11

GLV Enclosure BOM ( L19_GLV_01, L19_GLV_02, L19_GLV_03) 14

GLV COCKPIT & SIDE PANELS BOM (L19_GLV_04, L19_GLV_05, L19_GLV_06) 17

Quality Assurance Testing Results 18 Errata 26


L19_GLV_07 26

L19_GLV_02 26

Appendix A: 27

Acknowledgments 32

Disclaimer 32


Executive Summary Because the GLV system is implemented without software, maintenance of the system generally involves ensuring the wiring is correct throughout the system (see Interconnectivity Diagram). It is also important to ensure that the chips on the GLV PCB are functioning properly (see Quality Assurance Testing Results). The mechanical components of the GLV system do not require regular maintenance.

Charging the GLV Battery The GLV Battery must be charged for proper operation of the GLV system. The GLV battery can be charged using a PST-G100-24F8 charger. This charger charges the 24V battery at 1.5A, and it includes a plug and forget algorithm which allows it to be plugged in without the possibility of overcharging the battery. The charger has lights which indicate when the battery has finished charging.

Calibration The chips on the GLV PCB are calibrated using specific resistors and capacitors. Resistors are clearly labeled in the PCB Schematic. Two 2.2KΩ resistors (R7 and R8) used for current limiting into the opto-isolator. There is a 120Ω terminating resistor (R6) between the positive and negative CAN lines. Two 20kΩ pull-up resistors (R4 and R5) are used as pull-up resistors for I2C. Current limiting resistors are sized at 1kΩ (R9 and R10). All caps on the board are .1uF decoupling caps. There is a 15A circuit breaker between the GLV battery and the GLV system and a 10A circuit breaker between the GLV system power and other subsystems (These circuit breakers were analyzed and designed to satisfy EV6.1. The GLV battery circuit breaker was sized by the peak total current draw from the GLV system (around 15A). The subsystem circuit breaker was sized by the total current draw of the GLV system without including the safety loop peak current draw (around 7A). Refer to the Appendix: GLV Power Analysis for more information. Current and Power Sensing The ina226 chip on the GLV BOB is used for measuring current and power in the GLV system. There are several steps in order to calibrate this sensor. There is a calibration register that needs to be set. Its value is found using the following equations:

1) !"# = %.%%'() *+,,-./012∗456+./

2) !7889:;<=> = @ABCD+D

EBF-G/-H)IJ *+,,-./

The CAL value from equation (1) is the value programmed to the calibration register in the ina226 chip. A 0.01Ω resistor (R3) is used as a shunt resistor. When testing on board, this resistance was found to be


( °C ) = 25 + defg ( ) . j'P ∗ ( ) . ' /

0.02Ω, so when calibrating the ina226 chip, specify a shunt resistance of 0.02Ω. Maximum Expected Current in equation (2) is measured in amperes. After calculating these, the current and power are found from the following equations:

3) !7889:; = =6+./KLM/AN-∗*O< )%PQ

4) RST98 = *+ ,,-./∗>+5KLM/AN-

)%%%% The ShuntVoltage is measured by the chip and found in the shunt voltage register. The BusVoltage is also measured by the chip and should be the same voltage provided by the GLV system. Temperature Sensing The AD5593R chip is used for temperature sensing. Its temperature coefficient is found to be 20 ppm/°C. The following equation is used to calibrate the AD5593R temperature data.

O`* *LH-ab c.J h∗ P%i' 5) U9VW98X;789

K,-l))

ADC Code is the 12-bit value read by the sensor and Vref is 2.5V according to the GLV BOB setup. All calibration was designed to satisfy D004.

Principal of Operation The GLV system provides 24V DC, in accordance with Article EV1.2 of the FSAE 2019 competition rules, to power all low voltage electrical systems as well as the four AIRs on the two TSV battery packs. The GLV system includes a safety loop which was designed in accordance with the Formula Hybrid Rules. The safety loop was I/O integrated in the dyno room on two rack mount panels. The safety loop is implemented on a PCB which interfaces with the safety loop I/O and provides GLV battery data to VSCADA. The safety loop is designed in order to satisfy the shutdown circuit specified in EV7.1 of the FSAE 2019 competition rules.

Safety Loop 1 The safety loop is composed of two loops. Safety loop 1 runs through the a circuit breaker, the GLV master switch, then the right E-stop, then the left E-stop before providing power to the car subsystems. It then passes through the Insulation Monitoring Device (IMD), and Accumulator Management System (AMS) relays (this is designed to satisfy EV7.2 - EV7.9 of the FSAE 2019 competition rules). When power is provided to the car subsystems, the GLV LED on the cockpit panel will turn on.

Safety Loop 2 Safety loop 2 is only powered when a jumper is placed between itself and the end of Safety loop 1 (this is designed to satisfy EV2.11.3 of the FSAE 2019 competition rules). This loop then passes back through the


IMD to the Brake Over-Travel switch (this is designed to satisfy EVT7.3 of the FSAE 2019 competition rules). Once the Brake Over-travel switch closes, the SCADA relay receives power. This relay, when closed by the SCADA, will then route power to the Master Reset (This relay can be programmed to be normallyopen or normally-closed depending on the jumper in J4). Once the Master Reset receives power the Fault Led will turn off (this is designed to satisfy EV9.4). Once the Master Reset is pressed, both of the Safety System OK(SSOK) Lamps should turn on as well as the Safe light in the cockpit (this is designed to satisfy EV9.3). Only once the Cockpit BRB is closed and the Cockpit Reset Button has been pressed will the Tractive System Voltage (TSV) Master Switch receive power. When the TSV Master Switch (TSVMS) is closed, the AIRS will receive power. The AIRS+ Led in the cockpit and the Tractive System Active Light (TSAL) fwill then illuminate (this is designed to satisfy EV9.1).

Car Operation – Starting GLV The GLV system requires an operator on the outside of the car to turn the master switches and press Master Reset before the car can start. The driver is required to press the cockpit reset after the Master Reset is pressed to start the car. This will energize the AIRs if there are no safety loop faults in the GLV powered subsystems.

Car Operation – Operator Cutting Power The GLV safety loop allows an operator on the outside of the car to turn off the GLV system entirely or turn off power to the AIRs using the exterior E-stops and master switches. The Driver only has access to the driver E-stop so that the driver can turn off the AIRs if needed, but the driver cannot cut power to the entire GLV system or power down subsystems. There are several relays in the GLV which can trip the safety loop. The SCADA relay and the AMS relays are all controlled by on-board processors which will trip the loop if certain thresholds are passed (this was designed to satisfy EV2.11.2). The IMD will also open the safety loop if there is an insulation fault between high voltage and ground.

Car Operation - Resetting the Safety Loop If an external device trips the safety loop, it must be reset using both the Master reset button and the Cockpit reset button. However, in the case that the driver decides to disable power from the AIRS using the Cockpit E-stop, then the driver can reset power to the AIRS by just pressing the Cockpit reset.

GLV Break Out Board (BOB) PCB Operation The BOB encompasses most of the routing for the safety loop, and it provides data to the Raspberry Pi (VSCADA) through CAN, and I2C. CAN is routed to VSCADA through the GLV PCB so that TSV, Cooling, and TSI can relay information to VSCADA. On board chips communicate through I2C to relay the voltage and current of the GLV battery as well as the temperature of the PCB to VSCADA. Each of these values will be displayed on the VSCADA screen. The Raspberry Pi receives power from a 24V to 5V DC/DC converter. There is a relay on the BOB which allows VSCADA to trip the safety loop. There are additional relays allowing the GLV system to trip the safety loop. All items are produced according to GPR005 in the 2019 Statement of Work.


Block Diagrams GLV Systems Block Diagram

Figure 1 GLV Higher-level System Block Diagram


GLV BOB Block Diagram

Figure 2 GLV Break out Board Block Diagram

Safety Loop Diagram

Figure 3 GLV Safety Loop Block Diagram

CARMAN MAINTENANCE MANUAL 1

Schematics/Layouts

GLV BOB rev.4.2 Schematic (L19_GLV_07)

Figure 4 GLV BoB rev.4.2 PCB Schematic


GLV BOB rev.4.2 PCB Layout (L19_GLV_07)

Figure 5 GLV BOB rev4.2 PCB Layout


Mechanical Drawings


Figure 1 Front View of CarMan


Figure 2 Right Side Panel of CarMan


Figure 3 Left side Panel of CarMan


Figure 4 Back View of CarMan


Figure 5 Relay Board of CarMan


Figure 6 TSI Panel of CarMan


Figure 9 Screen Display Panel of CarMan


Figure 11 Right Side Panel


Figure 12 Left Side Panel


Figure 13 Top View of Motor Controller Enclosure


Figure 13 Front View of Motor Controller Enclosure


Figure 13 Left View of Motor Controller Enclosure


Figure 13 Right View of Motor Controller Enclosure


Interconnectivity Diagram

Figure 13 Interconnectivity Diagram of CarMan







Bill of Materials

GLV BOB BOM (L19_GLV_07)

Description Supplier Supplier P/N Unit Cost

Quantity PO PO Price

CAP CER 0.1μF ±10% 50V X7R 0805 Digikey 478-1395-1-ND $0.10 6 $0.60

RES SMD 10K OHM 1% 1/8W 0805 Digikey RMCF0805JT10K0C T-ND $0.10 12 $1.20

RES SMD 0.001 OHM 1% 1W 1206 Digikey CSNL1206FT1L00CT -ND $0.65 1 $0.65

RES SMD 120 OHM 5% 1/8W 0805 Digikey RMCF0805JT120RCT -ND $0.10 1 $0.10

RES SMD 1K OHM 5% 1/8W 0805 Digikey 311-1.0KARCT-ND $0.10 4 $0.40

RES 2.1K OHM 1% 1/8W 0805 Digikey RMCF0805FT2K10C T-ND $0.10 1 $0.10

RES SMD 200 OHM 1% 1/8W 0805 Digikey RMCF0805FT200RC T-ND $0.10 1 $0.10

LED YELLOW/GREEN CLEAR 0805 SMD Digikey VAOL-S8GT4CT-ND

$0.40 6 $2.40 TERM BLK 3POS SIDE ENTRY 5MM PCB Digikey WM13971-ND

$1.60 3 $4.80 MOSFET P-CH 50V 130MA SOT-23 Digikey BSS84CT-ND $0.24 1 $0.24

RELAY GEN PURPOSE SPDT 16A 24V Digikey Z2618-ND

$2.17 4 $8.68 DGTL ISO 2.5KV 2CH I2C 8SOIC Digikey 296-34872-1-ND $4.32 1 $4.32


IC REG LINEAR 5V 100MA 8SO Digikey 497-1182-1-ND $0.35 1 $0.35

CONN RCPT TYPEA 4POS R/A Digikey ED2989-ND $0.50 1 $0.50

OPTOISO 3.75KV 2CH DARLNG 8DIP (Opto-Isolator) Digikey CLA186-ND

$2.17 2 $4.34 2 Position Rectangular Housing Connector Receptacle Black Digikey WM10385-ND

$0.51 2 $1.02 CONN HEADER VERT 40POS 2.54MM Digikey S1012EC-40-ND

$0.51 3 $1.53

DC/DC CONVERTER 5V 20W Digikey 102-2927-ND $33.8 5 1 $33.85

IC ADC I/O PORT (ADC/DAC & Temp I2C) Digikey AD5593RBRUZ-ND

$7.90 1 $7.90 IC MONITOR PWR/CURR BIDIR 10MSOP (Current Monitor) Digikey 296-29034-1-ND

$3.44 1 $3.44 DIODE SCHOTTKY 100V 3A DO214AC Digikey

SK310A-LTPMSCTND $0.60 4 $2.40

Connector Header Through Hole 10 position 0.224" (5.70mm) Digikey

WM16846-ND $4.83 1 $4.83 Connector Header Through Hole 4 position 0.224" (5.70mm) Digikey WM16837-ND

$3.95 2 $7.90 Connector Header Through Hole 2 position Digikey WM16836-ND

$3.41 2 $6.82 Connector Header Through Hole 6 position 0.224" (5.70mm) Digikey WM16838-ND

$4.28 2 $8.56


10 Position Rectangular Housing Connector Receptacle Black 0.224" (5.70mm)

Digikey WM10389-ND $1.36 1 $1.36


Digikey WM10386-ND $0.67 2 $1.34


Digikey WM10387-ND $0.96 2 $1.92


Socket Contact Tin 14-16 AWG Crimp Digikey WM11981CT-ND $0.25 34 $8.50

CONN D-SUB PLUG 9POS R/A SOLDER Digikey 182-909ME-ND

$1.78 1 $1.78 $121.93

GLV MAINTENANCE MANUAL 27 GLV MAINTENANCE MANUAL 14

GLV Enclosure BOM ( L19_GLV_01, L19_GLV_02, L19_GLV_03)

Description Supplier Supplier P/N Unit Cost

Total Cost

SINGLE BOARD COMPUTER 1.2GHZ 1GB Digi-Key 1690-1000-ND $40.00 $40.00 RASPBERRY PI 10.1" LCD DISPLAY Digi-Key 1597-1102-ND $95.63 $135.63

PiCAN 2 - CAN Interface for Raspberry Pi 2/3 CopperHill technologies PiCAN2-SMPS $59.95 $195.58

CONN RCPT 40POS 0.1 GOLD PCB Digi-Key SAM11925-ND $6.85 $202.43 Standoffs amd Spacers 1.125'' Mouser 534-4835 $0.49 $206.35 Unthreaded Spacer 1/8" OD, 5/32" Long, for Number 2 Screw Size McMaster-Carr 92510A415 $0.77 $212.51

Passivated 18-8 Stainless Steel Pan Head Phillips Screw 2-56 Thread, 5/8" Long McMaster-Carr 91772A082 $4.15 $216.66

USB Connectors USB Female Adaptor Mouser 706-17-200001 $9.43 $226.09 PCF8523 Real Time Clock for Raspberry Pi Adafruit 3386 $5.95 $237.99 CR1220 12mm Diameter - Lithium Coin Cell Battery Adafruit 380 $0.95 $239.89

14U Steel Rack Panel Mouser 546- PBPS19014BK2 $32.76 $239.89

Passivated 18-8 Stainless Steel Pan Head Phillips Screw 8-32 Thread, 3/8" Long

McMaster-Carr 91772A192 $6.88 $246.77

8 x Press Fit Nuts for sheet metal (2-56) McMaster-Carr 95185A105 $9.40 $256.17 Aluminum, 3/16" Hex Size, 1" Long, 2-56 Thread Size McMaster-Carr 93505A217 $3.60 $259.77

Steel Phillips Screws 2-56 McMaster-Carr 90272A079 $3.28 $263.05


8-32 Thread Size, for 0.03" Minimum Panel Thickness McMaster-Carr 95185A155 $10.59 $280.52

Steel Pan Head Phillips Screws 4-40 Thread, 3/8" Long McMaster-Carr 90272A108 $1.65 $282.17

4-40 Thread Size, for 0.03" Minimum Panel Thickness McMaster-Carr 95185A110 $10.29 $302.75

Digital Display Multimeter Amazon B013PKYILS $14.99 $317.74 DT 2 WAY FLANGED RECEPTACLE Deutsch DT04-2P-L012 $4.48 $331.18 Deutsch dt 4 way flange receptacle connector Deutsch DT04-4P-L012 $7.47 $346.12 AHD10-6-12P-L Digi-Key 889-1062-ND $10.05 $356.17

DT04-8PA TE-Connectivity DT04-08PALE11

$10.49 $366.66

Deutsch dt 12 way flange receptacle connector Deutsch DT04-12PAL012

$10.53 $377.19

USB Panel Mount Connector Amazon B07CZDXJGX $8.99 $386.18 USB/HDMI Panel Mount Connector Amazon B077T853NZ $11.90 $398.08 CIR BRKR THRM 10A 250VAC 32VDC Digikey Q503-ND $2.23 $400.31 CIR BRKR THRM 15A 250VAC 32VDC Digikey Q504-ND $2.04 $402.35 Splined Press-Fit Threaded Standoffs with Open End McMaster-Carr 92985A110 $12.78 $415.13

Male-Female Threaded Hex Standoff Aluminum, 1/4" Hex Size, 1" Long, 4-40 Thread Size

McMaster-Carr 93505A436 $0.61 $420.01

Aluminum Unthreaded Spacer 3/16" OD, 1/8" Long, for Number 4 Screw Size McMaster-Carr 92510A688 $0.33 $422.65



Male-Female Threaded Hex Standoff Aluminum, 3/16" Hex Size, 1/2" Long, 4-40 Thread Size

McMaster-Carr 93505A103 $0.04 $426.39

$426.39


GLV COCKPIT & SIDE PANELS BOM (L19_GLV_04, L19_GLV_05, L19_GLV_06)

Description Manufacturer Manufacturer P/N Supplier Supplier P/N Unit Cost

Total Cost

22MMHW SeriesEmergency Stop Switches IDEC HW1E-LV4F11QD- R-24V Allied 70172680 $55.52 $166.56

Push Button; Panel Mount; 2500 V (1 min.); 10 A; NC; Shrouded; High⁄ Low; Altech Corp. 2ALF3LB-024 Allied 70156696 $22.19 $210.94 Car Rotating Battery/Electrical Master Switch DealExtreme 22003 $7.83 $226.60

Rectangular LED Lights Amber/SSOK Super Bright LED's MDB-A12

Super Bright LED's MDB-A12 $6.49 $246.07

Tractive System Energized Light Encell STB-A35 Amazon B01K9X1ZCE $30.00 $276.07 Panel Mount Indicator (Green) Dialight 6823235142F Digi-Key 350-4053-ND $8.94 $320.77 Panel Mount Indicator (Red) Dialight 682-3132-141F Digi-Key 350-4050-ND $8.94 $347.59

$347.59


Quality Assurance Testing Results SAFETY LOOP QA Test# Description Test Method Expected Results

PASS/FAIL

1.0 Energize Subsystems-24V Power Supplied to GLV Subsystems.

Supplied 24V of power to the GLV system using an external power supply. The 10A circuit breaker, GLVMS, BRBRS, BRBLS, and 10A circuit breaker were closed. The 24V output was measured on J10 (6 pins of GLV power and Can Bus line) on the GLV enclosure.

24V was measured on J10. The GLV LED turned on.

PASS

2.0 Energize AIRS- Power supplied to Accumulator AIRs.

Supplied 24V of power to the GLV system using an external power supply. The GLVMS, BRBLS, BRBRS, TSVMS, circuit breakers, and driver BRB were closed. The exterior master switch and driver reset were pressed.

The GLV LED is on. The SAFETY LED is on. The AIRs LED is on. The FAULT LED is off. The AIRs in the packs closed.

PASS

3.0 Shutdown- All GLV power turns off when the GLVMS or exterior BRBs turn off.

Power was supplied to the AIRs following the procedure in test 2.0. The GLVMS was opened, while checking the output to the J10 pin on the GLV enclosure. This was repeated for both exterior BRBs.

All LEDs turned off. 0V was measured on J10. GLV Subsystems deenergized PASS


4.0 Fault- GLV System stops supplying power to the AIRs in the following situations.

The AIRs were energized following the procedure described in test 2.0. The following faults will be tested. The Master Reset and Drive Reset were pressed at the end of each test to ensure these inputs do not reenergize the AIRs during a fault.

Pass Tests 4.1-4.3

PASS

4.1 Subsystem Fault A subsystem breaks the safety loop. This was tested by removing the final jumper on the SL2TSI J9 Connector on the GLV interconnect panel.

The GLV LED is on. The SAFETY LED is off. The AIRs LED is off. The FAULT LED is on.

PASS

4.2 Driver E-Stop Fault The Driver E-Stop was pressed. The GLV LED is on. The SAFETY LED is on. The AIRs LED is off. The FAULT LED is off.

PASS

4.3 TSVMS Fault The TSVMS was turned off. The GLV LED is on. The SAFETY LED is on. The AIRs LED is off. The FAULT LED is off.

PASS

5.0 Reenergize AIRs after fault.

The faults in test 4.0 should be resettable in the following ways so that the AIRs can be reenergized without cutting power to the GLV powered subsystems.

Pass Tests 5.1-5.3

PASS


5.1 AIRs Reenergize after Subsystem Fault

Ran test 4.1. Fixed the safety loop fault in the subsystem. This was done by plugging the safety loop jumper back into the TSV battery packs, closing the safety loop. Pressed the Master Reset and then the Crash Protection Reset.


PASS

5.2 AIRS Reenergize after Driver E-Stop Fault

Ran test 4.2. Closed the Driver EStop. Pressed the Master Reset and then the Crash Protection Reset.


PASS

5.3 AIRs Reenergize after TSVMS Fault

Ran test 4.3. Reengaged TSVMS. Pressed the Master Reset and then the Crash Protection Reset.


PASS

6.0 Connectivity- The safety loop is wired as shown by the schematic in Appendix A.

The safety loop circuit was traced with an ohmmeter to ensure each connection occurred expected.

Each component was connected as expected.

PASS


7.0 Unexpected Input- The reset buttons should not have any effect on the system if pressed at an unexpected time or in the wrong order.

The following unexpected inputs did not affect the system.

Pass Tests 7.1-7.2

PASS

7.1 Master Reset or Driver Reset pressed after AIRs energized.

Followed procedure in test 2.0 to energize the AIRs. Pressed the Master Reset. Pressed the Driver Reset.

No changed occurred.

PASS

7.2 Driver Reset pressed before master reset when energizing AIRs after startup.

Followed procedure in test 1.0 to energize GLV powered subsystems. Ensured there were no subsystem safety loop faults as indicated by on SAFETY LED. Pressed Driver Reset.

The GLV LED is on. The SAFETY LED is on. The AIRs LED is off. The FAULT LED is off. The AIRs were not energized.

PASS

GLV BOB QA *all pin references are to only the GLV BOB rev.4.1 schematic Test# Description Test Method Expected Results

PASS/FAIL

1.0 Grounding Pass Tests 1.1-1.4 PASS

1.1 Airs grounded Continuity Test Connection between GLV_RTN and AIRs- PASS


1.2 Can grounded Continuity Test Connection between GLV_RTN and CAN_GND

PASS

1.3 Temp Sensor

grounded Continuity Test Connection between

5V_RTN and U2-14 PASS

1.4 Volt and Amp Sensor Chip grounded

Continuity Test Connection between 5V_RTN and U4-7 PASS

1.5 Ground Isolation Continuity Test No connection between 5V_RTN and GLV_RTN No short between 5V_RTN and 5V No Short between GLV_RTN and 24V

PASS

2.0 Communication (CAN, I2C)

Pass Tests 2.1-2.4 PASS

2.1 CAN+ Continuity Test DB9-p8 is connected to J7-p1 PASS

2.2 CAN- Continuity Test DB9-p4 is connected to J7-p6 PASS

2.3 CAN_SHIELD Continuity Test DB9-p3 is connected to J7-p3 PASS

2.4 Display CAN data Check SCADA Motor Controller / TSI data is displayed by SCADA

PASS

2.5 SDA Continuity Test SDA is connected to P1p1 PASS


2.6 SCL Continuity Test SCL is connected to P1p3 PASS

2.7 Display I2C data Check SCADA GLV temperature, current, and voltage sensor are displayed by SCADA

PASS

3.0 Power Pass Tests 3.1-3.6 PASS

3.1 GLV+ active Check LED D7 is on PASS

3.2 5V is active Check LED D9 is on PASS

3.3 GLV+ supply Volt Meter J12-p1 is 24V PASS 3.4 Safety Loop 1

power loss Run Safety Loop QA test 2.0 and use Volt Meter

J6-p1 is 24V PASS

3.5 Safety Loop 2 power loss

Run Safety Loop QA test 2.0 and use Volt Meter

J6-p2 is 24V PASS

3.6 5V supply Volt Meter P2-p1 is 5V J10-pVBUS is 5V PASS

3.7 Power Isolation Continuity Test GLV+ is not connected to 5V PASS

4.0 Relays Pass Tests 4.1-4.8 (Must supply 24v to J2-p1 for the following)

PASS

4.1 SCADA CONTROL ON

Supply P1-p5 with 5V. Check SCADA LED.

On board LED SCADA is on PASS

4.2 SCADA CONTROL OFF

Supply P1-p5 with 0V. Check SCADA LED.

On board LED SCADA is off PASS


4.3 MASTER RESET relay ON

Supply J3-1 and J3-2 with 24V. Then remove 24V supply from J3-2. Check MRESET LED

On board LED MRESET is on PASS

4.4 MASTER RESET relay OFF

Run test 4.3 then remove the supply from J3-1. Check MRESET LED

On board LED MRESET is off PASS

4.5 COCKPIT RESET relay ON

Supply J5-2 and J5-4 with 24V. Then remove 24V supply from J5-4. Check CPR LED

On board LED CPR is on PASS

4.6 COCKPIT RESET relay OFF

Run test 4.5 then remove the supply from J5-4. Check CPR LED

On board LED CPR is off PASS

4.7 DYNO relay ON Supply J3-p4 with 24V. Check

DYNO LED On board LED DYNO is on PASS

4.8 DYNO relay OFF Remove J3-p4 with 24V. Check DYNO LED

On board LED DYNO is off PASS

4.9 SCADA relay NC programming

Disconnect SCADA from GLV. Connect J4-p3 to J4-p2 with jumper. Continuity test between J6-p1 and J3-1.

Continuous

PASS

5.0

SCADA relay NO programming

Disconnect SCADA from GLV. Connect J4-p1 to J4-p2 with jumper. Continuity test between J6-p1 and J3-1.

Discontinuous

PASS

5.1 DYNO relay NO programming

Connect J11-p3 to J11-p2. Check pins J8-p1 and J8-p2. Resistance test.

Resistance should be 1k ohm. PASS

5.2 DYNO relay NO programming

Connect J11-p1 to J11-p2. Check pins J8-p1 and J8-p2. Resistance test.

Resistance should be Overload. PASS

5.0 LED & OPTOISOLATION

Pass Tests 5.1-5.3 PASS


5.1 Jumper Disconnect Supply 24V to J2-p1 without a jumper between J6-p1 and J6-p4. Volt Meter

The voltage on SAFETY LED is 0V. The voltage on Fault LED is 5V. The voltage on F1 is 0V. The voltage on F2 is 0V.

PASS

5.2 Jumper Connect Supply 24V to J2-p1 with a jumper between J6-p1 and J6-p4. Volt Meter

The voltage on SAFETY LED is 24V. The voltage on Fault LED is 0V. The voltage on AIRs LED is 0V. The voltage on F1 is 5V. The voltage on F2 is 0V.

PASS

5.3 Air Power Supply 24V to J6-p2. The voltage on AIRs LED is 24V The voltage on F2 is 5V

PASS


Errata

L19_GLV_07 The BOB is a board that is meant to manage the GLV system within the Electric Vehicle used in Lafayette College. More specifically, the board is used to convert 24V to 5V for the SCADA system, as well as manage the relays for the safety loop, connect the resets and E-Stops to the safety loop, provide power to the TSI, Cockpit, Airs, and Cooling systems as well as several lights on the car. GLV BOB Errors:

- J5-p6 should be the Mreset_B signal so that the Safe light turns on in parallel with the SSOKs. - R1 should be a pull-down resistor - P3-4 should swap with P3-3. P3-5 should swap with P3-6. P3-1 should have a 3.3v supply and P3-2 should be a 5v supply. - GLV BOB should have a 3.3v dc/dc converter for the RTC - GLV BOB should be designed with connectors so that it interfaces with L19_GLV_02 more easily. - The Cooling subsystem should only receive power when the AIRs close.

L19_GLV_02 The Top panel is supposed house the GLV BOB, SCADA, and their wiring. This panel is intended to be a panel that can be installed onto the car easily. Top panel Errors:

- J10 should be larger so that the flange can be on the outside of the panel. - The holes that hold both the GLV BOB and the SCADA should have 4-40 pressfit inserts so that the components don’t fall out

accidentally.


Appendix:

GLV Parts Number List: Part# Name L19_GLV_01 8U Rack Panel L19_GLV_02 Top Panel L19_GLV_03 SCADA_Screen_MountBrackets

L19_GLV_04 Cockpit Panel L19_GLV_05 Right Side Panel L19_GLV_06 Left Side Panel L19_GLV_07 Break Out Board L19_GLV_08 Shore Power L19_GLV_09 Battery L19_GLV_10 Charger

GLV Power Analysis: GLV Total system current consumption:


Safety Loop current consumption:

Ref Description Manufacturer Manufacturer P/N Supplier

Supplier P/N Quantity

Peak Current (A)

Quiescent Current (A)

Digital Display Multimeter Bayite PZEN-31 1

Rectangular LED Lights Amber/SSOK

Super Bright LED's MDB-A12

Super Bright LED's MDB-A12 2 0.18 0.18

GLV BOB RELAY GEN PURPOSE SPDT 16A 24V

Omron Electronics Inc

G5LE-1-E DC24 Digikey Z2618ND 4 0.07 0.08

AIRS Accumulator Isolation Relays Gigavac GX14CB 4 6.40 0.39

Discharge Relay Digikey Z1032-ND Digikey Z1032-ND 1 0.083 0.083

6.73 0.73 GLV Powered System current consumption:

GLV Description Supplier Supplier P/N Suppl y (V)

Quantit y

Peak Current/uni t (A)

Quiescent Current/uni t (A)

TP C

TQ C

IC MONITOR PWR/CURR BIDIR 10MSOP (Current Monitor) Texas Instruments INA226AIDGSR 24.0 1 0.000 0.000 0.00 0.00

Ref Description Peak Current (A) Quiescent Current (A) GLV GLV (including Safety Loop) 6.748 2.347

TSI TSI (only GLV powered components) 4.598 0.376 TSV TSV (only GLV powered components) 1.057 0.008

COOLING Cooling 1.315 0.000 SCADA SCADA 0.250 0.219

MC Motor Controller 1.000 0.750

14.967 3.699


OPTOISO 3.75KV 2CH DARLNG 8DIP (Opto- Isolator) Digikey CLA186-ND 24.0 2 0.005 0.005 0.01 0.01 IC ADC I/O PORT (ADC/DAC & Temp I2C)

Analog Devices Inc. AD5593RBRUZ 24.0 1 0.002 0.002 0.00 0.00

IC REG LINEAR 5V 100MA 8SO

STMicroelectronic s L78L05ACD13TR 24.0 1 0.006 0.006 0.01 0.01

Digital Display Multimeter 24.0 1 0.00 0.00 Rectangular LED Lights Amber/SSOK

Super Bright LED's MDB-A12 24.0 2 0.09 0.18 0.18 0.36

GLV BOB RELAY GEN PURPOSE SPDT 16A 24V

Omron Electronics Inc G5LE-1-E DC24 24.0 4 0.02 0.08 0.07 0.33

Accumulator Isolation Relays 24.0 4 1.60 0.39 6.40 1.55 Discharge Relay Digikey Z1032-ND 24.0 1 0.083 0.083 0.08 0.08

6.75 2.35

TSI Description Supplier Supplier P/N Suppl y (V)

Quantit y



TP C

TQ C

Precharge Relay Digikey GX14CB 24.0 1 1.650 0.097 1.65 0.10 Precharge Control Relay Digikey APAN3105 24.0 1 0.022 0.022 0.02 0.02 24:24 DC/DC Converter Digikey THN_30-2415WI 24.0 1 1.250 0.010 1.25 0.01 IMD Relay Digikey G2R-1A-DC24 24.0 1 0.047 0.047 0.05 0.05 24:(5/10) DC/DC Converter Digikey PDQ10-Q24-D5-D 24.0 1 1.400 1.40 0.00 TSI Board ~ ~ 24.0 1 1.100 0.200 0.23 0.20

4.60 0.38

TSV Description Supplier Supplier P/N Suppl y (V)

Quantit y



TP C TQC


PIC32MZ Microchip PIC32MZ2048EFM06 4-I/PT 24.0 1 0.200 0.20 0.00

24:5 DC/DC Converter CUI Inc PDM2-S24-S5-S 24.0 1 0.083 0.008 0.08 0.01 LT1763CS8-3.3-PBF Linear Tech LT1763CS8-3.3#PBF 24.0 1 0.500 0.50 0.00 Interface_CAN_LIN:MCP255 1-I-SN Microchip MCP2551-I/SN 24.0 2 0.000 0.00 0.00

LTC6820 Linear Tech LTC6820IMS#3ZZPB F 24.0 1 0.006 0.01 0.00

Isolator:TLP291 Toshiba TLP291(GB-TP,SE 24.0 5 0.050 0.25 0.00 LCD Display Crystalfontz CFA533-TMI-KC 24.0 1 0.00 0.00 Relay:G5Q-1A Omron G5Q-1A4 DC24 24.0 2 0.008 0.02 0.00

1.06 0.01

Cooling Description Supplier Supplier P/N Suppl y (V)

Quantit y



TP C

TQ C

YF-S201 1-30L/min Water Flow Hall Counter / Sensor Water control Water Flow Rate Switch Flow Meter Flowmeter Counter WINGONEER YF-S201 24.0 1 0.015 0.02 0.00 PMP-500 Pump, G 1/4 BSP Koolance PMP-500 24.0 1 1.300 1.30 0.00 Nextrox DC/DC Converter Regulator 24V to 12V Nextrox ~ 24.0 1 0.00 0.00 1.32 0.00

SCADA Description Supplier Supplier P/N Suppl y (V)

Quantit y



TP C

TQ C

Raspberry Pi 3b+ ~ ~ 5.0 1 0.500 0.300 0.50 0.30 Mouse ~ ~ 5.0 1 0.100 0.150 0.10 0.15


Keyboard ~ ~ 5.0 1 0.100 0.100 0.10 0.10 RASPBERRY PI 7" TOUCH SCREEN LCD Digikey 1690-1007-ND 5.0 1 0.500 0.500 0.50 0.50 PiCAN 2 Board CopperHill ~ 5.0 1 0.00 0.00

1.20 1.05

Motor Controller Description Supplier Supplier P/N

Suppl y (V)

Quantit y



TP C

TQ C

Motor Controller emDrive500 Emisiso emDrive500 24.0 1 1.000 0.750 1.00 0.75 Table 1: This table shows the entire system current consumption. TPC represents Total Peak Current and TQC represents Total Quiescent Current. The emboldened values in

their columns represent their respective subsystems final expected current.


Acknowledgments

This document is largely based on the documentation used in the Class of 2018 and the Class 2017. We would like to acknowledge the Electrical and Computer Engineering Department and Mechanical Engineering Department for making this project possible.

Disclaimer

While we have made every attempt to ensure that the information contained in this document is complete, understand that there may still be unforeseen errors.

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