Full Wiring 2 โ€” FRONT computer fuse/relay box (pin-level)

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fw2_relaybox FULL WIRING SHEET 2 of 5 โ€” FRONT COMPUTER FUSE / RELAY BOX, PIN-LEVEL (rev 3.32 โ€” Option B) โš  This is the FRONT box. The combiner relays (RLY-O5 contactor, RLY-PC pre-charge) + the 3 bed/tent CAMP light relays live in a BED relay box driven by the BED board (sheets 6-7), NOT here. Every Bosch ISO mini relay, all pins:  86 = coil + (from fused panel 12V trigger rail)  ยท  85 = coil - (sunk by a controller DO โ€” Waveshare DOs have built-in flyback diodes, no extra diode needed) 30 = main feed (from the box fuse block, fused per circuit)  ยท  87 = switched output to the load.   Relays = True MODS 60/80A 5-pin kit (rev 3.23): leave 87a EMPTY; if coils are diode-suppressed, 85/86 polarity is STRICT (86=+rail, 85=DO). Coil draw ~150mA โ€” DO sink limit 500mA is fine.  Trigger wires (85/86) = 20-22 AWG or solid Cat5 (one Cat5 = 8 triggers; secure every 12in, strain-relieve ends). LEGEND:  red = fused 12V feed  ยท  dark-red = switched load out  ยท  green = trigger rail (86)  ยท  purple dashed = DO sink (85)  ยท  black = ground feed From FRONT + BUS (Sheet 1) 6-8 AWG, 40-60A fused at the bus fblk BOX FUSE BLOCK (ATO/ATC blade fuses) WIRE SIMPLIFICATION rev 3.17: every load run = 16 AWG, fused at 10A or less F1 10A โ€” converter F2 7.5A โ€” accessories F3 10A โ€” Switch B PoE PSU F4 5A โ€” contactor coil F5 โ€” SPARE (compressor OUT of build) F6 7.5A โ€” rock F7 7.5A โ€” underbody F8 7.5A โ€” pods F9 7.5A โ€” amber/marker F10 5A โ€” pre-charge F11 5A โ€” TRIGGER RAIL (all pin-86s) F12 3A โ€” Waveshare 12V F13 3A โ€” Pi 5V buck F14 3A โ€” Cudy + Switch A feed->fblk kc KC HARNESS RELAY (in KC kit, NOT in box) trig gnd 30 87 feed->kc:p30 house 12V, 12 AWG, 20-25A fuse (per KC kit) trig TRIGGER RAIL +12V (F11 5A, 20 AWG, feeds every pin 86) fblk:f11->trig r1 O1 OptiPlex converter โ€” NOT IN THIS PANEL latching doesnt fit the Bosch socket (needs set+reset coils) use a standalone 12V latching relay module (set/reset, 10A+) holds power thru reboot/OTA, resets to true 0W (sec 6.3) or a panel relay wired NC (reboot-safe but ~1W, not 0W) 86 85 30 87 fblk:f1->r1:p30 16 AWG (short run) r2 RLY-O2 accessory cut 86 85 30 87 fblk:f2->r2:p30 16 AWG r4 RLY-O4 camera tier / Switch B 86 85 30 87 fblk:f3->r4:p30 16 AWG (short run) r5 RLY-O5 bed contactor coil 86 85 30 87 fblk:f4->r5:p30 18 AWG r7 RLY-O7 SPARE socket (was compressor โ€” dropped) 86 85 30 87 fblk:f5->r7:p30 (spare) rr RLY-RK rock lights 86 85 30 87 fblk:f6->rr:p30 16 AWG ru RLY-UB underbody 86 85 30 87 fblk:f7->ru:p30 16 AWG rp RLY-PD pods 86 85 30 87 fblk:f8->rp:p30 16 AWG ra RLY-AM amber/marker 86 85 30 87 fblk:f9->ra:p30 16 AWG rpc RLY-PC pre-charge (coil sunk DO-DIRECT by O6) 86 85 30 87 fblk:f10->rpc:p30 16-18 AWG trig->r1:p86 trig->r2:p86 trig->r4:p86 trig->r5:p86 trig->r7:p86 trig->rr:p86 trig->ru:p86 trig->rp:p86 trig->ra:p86 trig->rpc:p86 gnd BOX GND bar -> front - bus (dedicated negative) conv 12V->19V converter (~10A in) + reverse-polarity diode 19V out: see Sheet 5 r1:p87->conv acc Accessory circuits (15-min timer loads) 16 AWG, loads <=5A r2:p87->acc swbp Switch B PoE PSU (12V->53.5V supply or stock adapter โ€” VERIFY) -> LS108GP 16 AWG (~62W PoE + overhead = ~7A @12V) r4:p87->swbp ccoil Contactor COIL (Sheet 1) 18 AWG, ~0.5-1A r5:p87->ccoil lrock Rock lights  16 AWG (<=5A) rr:p87->lrock lub Underbody  16 AWG (<=5A) ru:p87->lub lpd Pods  16 AWG rp:p87->lpd lam Amber/marker  16 AWG ra:p87->lam res 5R 25-50W resistor -> bed + (Sheet 1) 16-18 AWG rpc:p87->res kc:p85->gnd coil gnd (if KC harness grounds locally, follow kit) bar KC light bar 216W / 18A wiring SUPPLIED IN the KC harness kit ยท 20-25A fuse off house bus kc:p87->bar ccoil->gnd coil return kctrig diode-OR trigger: KC dash switch (fail-safe manual) + controller DO (M-DO2 / board DO) kctrig->kc:p86 trigger (mA) do_ Controller DOs (Sheet 3) each sinks one pin 85 to GND 20-22 AWG / solid Cat5 do_->r1:p85 O1 do_->r2:p85 O2 do_->r4:p85 O4 do_->r5:p85 O5 do_->rr:p85 M-DO1 do_->ru:p85 M-DO3 do_->rp:p85 M-DO4 do_->ra:p85 M-DO5 do_->rpc:p85 O6 (DO direct)

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