Hazard Wiring - Circuit 4/6

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Major System Category: ISIS
Task: Hazard lights
Parts:
Prerequisite Tasks:
Additional Costs:
Time Requirement: 3 hours
Date Started: November 7, 2013

Date Completed:  November 7, 2013

The hazard lights are one of those circuits that runs the length of the car. This circuit was assigned to Power Cell #4, which did not get installed until Fall 2013. However, the planning and preliminary wiring for this circuit took place in Fall 2012. I had to think about how this was going to work out 14 months prior to getting this done.

Hazard circuit terminal block. This located on the center aluminum panel in the front bay. This photo was taken prior to mounting Power Cell #4.

I decided that once I had the hood installed and centered, it was never coming off the car again. I made this decision for a couple of reasons:

1. There are too many systems tied into the hood (e.g. head lights, fog lights, signals, sensors, grille).
2. The hood is not symmetrical. Prior to mounting the hood, I spent three days with the cross hatch laser level figuring out that it was off center. Once I had it mounted on the car, I decided I was not taking it off again.

The yellow wire in the lower left is the hazard circuit coming out of the left front turn signal and going through the conduit along the hood above the grille.

The hazard lights are located on the four corners of the car. Regardless of the power cell location, I was going to end up running wires a long way. I have gotten better at the concept that even though car is approximately 16 feet long, a wire run like this is probably closer to 20 feet due to path down into the tunnel and back up around the engine bay.

This is the other side of the hazard circuit coming out on the right front of the car. The yellow wires run to the other signal then through the conduit to the terminal block.

I mounted a terminal block where one side is daisy chained (i.e. all sockets are wired together on one side). This means a single power lead distributes power to all ports on the terminal block. Based on my design, I knew where Power Cell #4 was going to be mounted, so prior to purchase I built the hazard circuit terminal block next to the power cell location and wired the circuit into the front signals. I also ran wires to the rear of the car for the rear signal lights. This conduit comes out at the rear of the tunnel close to the cable box for the manual parking brakes. The rear power leads are split to go around the engine bay and up to the rear lights.

The yellow wires are the rear leads from the terminal block. They run under the Vintage Air unit through a large conduit to the rear end of the tunnel. The braided cable is the cross over pipe for the fuel tanks.

By law (as I understand it), the car is required to have a physical hazard switch. The switch is slated to be mounted on the center console below the touch screen and forward the gear shift. Since I am using ISIS, I just need to run the signal wire and a ground to this switch to complete circuit.

The hazard circuit (yellow wires) split to the left and right into conduits that work around the engine bay to the rear lights. The rectangular item in the lower left background is the cable box for the manual brakes. These run under the engine.

These are circuits enclosed in wire loom that run around the engine bay and next tot he splash guards.

Horn - Circuit 1/9

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Major System Category: ISIS Wiring
Task: Mount Horn.
Parts: Horn and ISI wiring
Power Cell: 1
Circuit: 9 - ORANGE
Master cell: BLUE/YELLOW
Prerequisite Tasks: Mount Power Cells
Additional Costs: N/A
Time Requirement: 2 hours
Date Started: March 30, 2013
Date Completed: March 30, 2013

Anybody who has stuck their head under the front hood of the GTM realizes that space is a premium commodity. Since I moved the header tank to the engine compartment, moved the window washer fluid bottle to the passenger side, mounted the ISIS power cells on the center panel above the cooling fans and plan to mount the Escort 9500 radar/laser detectors behind the grill on the reinforced area below the radiator, I needed to find a home for the horns.

This is the bracket I fabricated to hold the horns. It is bolted to one of the eyelets for the Corvette overflow tank. This was replaced by the header tank.

I ended up mounting the horn on the passenger side ahead of the wiper motor and window washer fluid bottle. This is where the Corvette overflow tank is normally installed. However, I have replaced the overflow tank with a header tank mounted above the fuel pump behind the fuel tanks in the engine bay to eliminate the issue of "burping" the coolant system.

These are the mounted horns on the passenger side just forward on the middle panel. The horn is bolted to the bracket that is bolted tot he frame. The pig tail connector has the extended wires attached. The green one is connected tot he power lead coming off the power cell and the black will be attached to the forward passenger side ground point.

I fashioned a bracket out of angle aluminum so I could use the the eyelet on the frame for the overflow tank to secure the horns.This uses the Corvette bracket that comes with the horns. I ensured the hood and the Vraptor hood louvers had sufficient clearance. These louvers drop into the hood area approximately 1 to 1.5 inches.

I extended the pig tail connectors so I could reach the front grounding point, and connect to the horn circuit. I did the normal butt splice, cover in heat shrink insulator and wrap in black electrical tape.

Power Cell Wiring (Final Draft)

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Major System Category: ISIS Wiring
Task:Finalize ISIS Schematic
Parts: N/A
Prerequisite Tasks:
Additional Costs: N/A
Time Requirement: 10 hours
Date Started: March 5, 2013
Date Completed:  March 10, 2013
ISIS is a microprocessor based electrical system that has decentralized the fusing to power cells. Each power cell handles 10 circuits. Each circuit is fused at the power cell. The power cells are connected to a master cell (which is really nothing more than a traffic cop for signal processing between power, peripherals and switches) via a data bus. This electrical system (as is true with most vehicles) is separate from the ECU system that handles engine sensors, feed back and gauge related measurements. ISIS manages the lights, the door locks, power to the windows and mirrors and so forth.

I have been kicking around the ISIS wiring schematic for over a year now. I put the first draft up in the planning phase in October 2011. Those drawings were fairly crude renderings of where I was headed. The problem is that until I got my hands on the hardware and had completed the build to point where I had the body shell installed and recognized where I could and could not run cables, none of it clicked.

I understand the basic concepts. I can wire and splice and hook connectors together. I can connect my little test battery and see things light up or solenoids fire. What clarified my understanding was handling the physical cables for the master and power cells, comparing this to the basic wiring spreadsheets and recognizing that the wire colors were not ramdom, but had a very specific coding pattern to them. It may seem obvious to others, but once I understood the pattern everything clicked.

This post deals strictly with the power wiring schematics. It does not address the bus, mega fuses, additional modules (e.g. inReserve, inLighten, inVironment). I will cover these issues in separate posts. At present, the current system supports 40 circuits, and 39 are defined.

There are four power cells, plus a master cell. As of this writing, I have 2 power cells and a master cell installed on the car. I started with the basic 3 cell kit and the basic GTM set up.

Power Cell 1 wiring schematic. The following chart explains the wiring diagram. Color code matches the ISIS standard. (The only exception is circuit #5 where I used gray instead of white so it would be visible.) This projected over the front of the GTM chassis. The square that feeds all wires is the power cell box and reasonable represents where I have located it in the car.

Function	Power cell	connector	Circuit	fuse	Power cell wire
Right turn signal (front)	1	B	1	15	brown
Left turn signal (front)	1	B	2	15	Violet
Ignition	1	b	3	25	light green
starter	1	b	4	20	light blue
headlights	1	B	5	20	White
Fog lights	1	A	6	15	Yellow
High Beams	1	A	7	20	Blue
DRL	1	A	8		Green
Horn	1	A	9	10	Orange
Fan Override	1	A	10	25	Tan

Function	Power cell	connector	Circuit	fuse	Power cell wire
Right turn signal (rear)	2	B	1	15	brown
Left turn signal (Rear)	2	B	2	15	Violet
brake	2	b	3		light green
Left seat heater	2	b	4		light blue
right seat heater	2	B	5		White
parking brake	2	A	6		Yellow
Rear sensors	2	A	7		Blue
Fuel Pump	2	A	8		Green
tpms	2	A	9		Orange
Hatch popper	2	A	10		Tan

Power Cell 3 wiring schematic. The following chart explains the wiring diagram. Color code matches the ISIS standard. (The only exception is circuit #5 where I used gray instead of white so it would be visible.) This projected over the front of the GTM chassis. The square that feeds all wires is the power cell box and reasonable represents where I have located it in the car.

Function	Power cell	connector	Circuit	fuse	Power cell wire
right window up	3	B	1		brown
right window down	3	B	2		Violet
left window up	3	b	3		light green
left window down	3	b	4		light blue
left door popper	3	B	5		White
right door popper	3	A	6		Yellow
telescoping steering	3	A	7		Blue
hot plug	3	A	8		Green
front sensors	3	A	9		Orange
Map Lights	3	A	10		Tan

Power Cell 4 wiring schematic. The following chart explains the wiring diagram. Color code matches the ISIS standard. (The only exception is circuit #5 where I used gray instead of white so it would be visible.) This projected over the rear of the GTM chassis. The seat heaters is an approximate location inside the cockpit. The square that feeds all wires is the power cell box and reasonable represents where I have located it in the car.

Function	Power cell	connector	Circuit	fuse	Power cell wire
escort 9500 ci	4	B	1		brown
ars global	4	B	2		Violet
homelink	4	b	3		light green
wiper	4	b	4		light blue
side mirror	4	B	5		White
interior lights	4	A	6		Yellow
hot plug	4	A	7		Blue
cruise control	4	A	8		Green
dash/Parking	4	A	9		Orange
	4	A	10		Tan