Full Wiring 1 — Power: generation, storage & heavy runs

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fw1_power FULL WIRING SHEET 1 of 5 — POWER GENERATION, STORAGE & HEAVY RUNS (rev 3.32 — Option B: combiner on the BED board, sheet 7) Every + run fused at its SOURCE (bus bar or battery terminal). Battery-to-battery trunk fused BOTH ends. Negatives NEVER fused. Pure copper only (CCA: upsize 1-2 ga + fuse to real ampacity). GROUND = star: front - bus bar is the star point; ONE chassis bond front only (never bond the bed = ground loop -> audio whine + CAN errors). LEGEND:  red = +12V power (thickness ~ gauge)  ·  black = negative/ground  ·  orange = charge source  ·  purple dashed = ESP32 control cluster_start STARTER SIDE (factory + winch — OUT OF SCOPE except DC-DC tap) cluster_front FRONT (hood) cluster_bed BED alt Alternator (factory) sbatt Starter battery (lead-acid, factory) alt->sbatt factory cable wbuf 2nd lead-acid (winch buffer) charged by alternator sbatt->wbuf starter-side feed (per winch install) winch 12K winch — OWN circuit + contactor (never on house bank) wbuf->winch own heavy circuit + contactor (out of scope) dcdc VEVOR 40A DC-DC charger (alternator-only; LiFePO4 14.4/13.6 profile; ignition / V-sense = no parked drain) wbuf->dcdc 6 AWG · FUSE 50A AT the starter/buffer battery fpos FRONT + BUS BAR dcdc->fpos output: 6 AWG (4 if long) · FUSE 50A AT front + bus fneg FRONT - BUS BAR (STAR POINT) dcdc->fneg dedicated negative cbox Computer fuse / relay box (SHEET 2) fpos->cbox 6-8 AWG · FUSE 40-60A AT front + bus (own cable — star, never off the inverter) frame TRUCK FRAME (clean metal) fneg->frame 2-4 AWG bond — THE ONLY CHASSIS TIE (reference for CAN / DI senses / GreenYi) b100 FEENCE 100Ah LiFePO4 (hood house) b100->fpos main feed · FUSE 100-150A AT battery + terminal b100->fneg dedicated negative cbox->fneg dedicated negative bpos BED + BUS BAR bpos->fpos TRUNK + : 2 AWG (1/0 if inverter ever runs off front) FUSE BOTH ENDS 125A (not 100A — the force-merge surge ~120A would nuisance-blow it; see Sheet 6) pre PRE-CHARGE bypass Bosch relay + 5R 25-50W resistor (Sheet 2: RLY-PC) bpos->pre 16-18 AWG (small) bneg BED - BUS BAR (NO chassis bond here!) bneg->fneg TRUNK - : match + gauge · NO FUSE (the bed<->front ground) b440 Bed 300-440Ah LiFePO4 (REMOVABLE — Anderson SB175 + handle) b440->bneg dedicated negative cont CONTACTOR 150-200A continuous-duty, NO = fail-safe OPEN b440->cont 4 AWG (2 for headroom) · FUSE 100-150A AT battery + terminal · SB175 cont->bpos 4 AWG pre->cont bypass around contactor inv WZRELB 800W inverter (camp/tool AC only — NOT the OptiPlex path; DO NOT chassis-ground) inv->bpos 2-4 AWG (per manual) · FUSE 100-150A AT bed + bus inv->bneg dedicated negative (NEVER chassis) mppt EPEVER 30A MPPT (in bed, cool) mppt->bpos 6-8 AWG · FUSE 40A AT bed + bus mppt->bneg dedicated negative sol 400W solar (4x 100W Newpowa) sol->mppt 10 AWG panel wiring (series/parallel per array) esp BED Waveshare board (Option B — sheet 7) combiner runs LOCALLY on the bed board esp->cont close only when V matches (coil via Sheet-2 RLY-O5) esp->pre O6: pre-charge FIRST, then contactor

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