Posts by agmatthews

agmatthews · Jan 21, 2022

Hi Tom,
What size printer to you print your Hyper 9 on?
Do you have the STL files available?
-Andrew

agmatthews · Jan 22, 2022

VintageVolts said:
Hi Andrew,
I have a Makerbot Replicator 2, it's quite an old machine now but is a super reliable beast! its build plate is 285 x 153mm, and can print 155mm tall. This was printed in PLA and stuck together with superglue.

I have put the STLs i made on Thingiverse - Netgain Hyper 9 DHV Motor . Just for reference, the manufacturers CAD files are here on go-ev , so all credit to them!
At time of writing, Thingiverse doesn't seem to have actually published my thing (it 404s), so fingers crossed it appears soon.

Thanks Tom,
All available on Thingverse now
Ttime to blow the dust off and level up the printer bed and see if it still works.
A

agmatthews · 2023-01-11T17:38:22-0500

asymptonic said:
Considering a flange mount connector like this for all the low voltage signals to and from my battery box.

And if you are using an Orion BMS then they recommend using gold plated pins on any connectors to ensure the BMS can measure cell resistance correctly, which you can get for the Deutsch connectors.
A

agmatthews · 2023-01-26T20:44:58-0500

Hi,
Few hours late - I blame being down under in a time zone for the other side of the world

I have an Orion BMS2 in my Land Rover build with 7 Tesla Modules
My ORION BMS is the 48-S version (note the "-S")
I have this version so I can get the 7 modules split into 3 battery boxes and have fuses and disconnects in each box without any risk of a fuse blow or a disconnect also blowing the BMS

I will have one box each under passenger and drivers seats (2 modules each), and one under the bonnet (3 modules)
Each box will have an Amphenol MSDM5002 with 500A fuse and I have a Gigavac maintenance disconnect between the two seat boxes

I decided to set everything up on the 'bench' to check and finalise my design while I worked on removing the rust from the chassis and bulkhead
In this case the 'bench' is a rack holding the 150kg of batteries

Gas Electrical wiring Machine Electronic engineering Engineering

The table below is what I used to be doubly sure I had every thing right before I plugged in the BMS
As you have different battery modules (3S4P versus 6S74P in the Tesla bricks) the the battery cell numbers will be all wrong for you. Also if you have a different version BMS (ie a "48" versus a "48-S") then the "BMS Harness Connector" numbers in my table wont match your BMS and your 'disconnects' will need to be located differently to mine - but the pattern in my table might helpful

The wiring tool got me started - but like you I had to figure out the mystery 'minus' pins

The key thing for me was to watch the voltage rise by the right amount as I probed the connector pins very carefully BEFORE I plugged them into the ORION
I measured total voltage increase from pin "1-" as ground all the way up to and past 150V and wrote them down - its too easy to accept the number you see on the multi meter but when you commit it to paper your brain does a double check - Both times I had the wrong number it was because I had either probed the wrong pin, or read the meter wrong - the pencil and paper helped me
I then went back and measured each cell group's voltages using its own 'minus' pin as a 'local ground' to double double check

I then borrowed (hired) a Cell tap validator to be EXTRA sure I had it right
I had to wait for another week to get it and spend a few dollars but it was good insurance (it showed I was OK to go)

-Andrew

My BMS version:

https://www.orionbms.com/manuals/pdf/orionbms2_purchasing_guide.pdf

And my spreadsheet

Pack Number	Molex plug	Molex pin	Battery name	BMS Name	BMS Harness connector	BMS Harness group	BMS harness pin	Continuity test	BMS Harness colour	test Voltage	measured Voltage
1	1	1	Cell 1	Cell 1	1	1	1		orange	3.7
1	1	2	Cell 2	Cell 2	1	1	2		orange	7.3
1	1	3	Cell 3	Cell 3	1	1	3		orange	11.0
1	1	4	Cell 4	Cell 4	1	1	4		orange	14.7
1	1	5	Cell 5	Cell 5	1	1	5		orange	18.3
1	1	6	Cell 6	Cell 6	1	1	6		orange	22.0
1	1	7	neg	Cell 1 minus	1	1	1-		Black	0
1	1	8	x
1	1	9	T1	Thermo 1
1	1	10	T2
1	1	11	T2
1	1	12	T1	Thermo 1
2	2	1	Cell 1	Cell 7	1	1	7		orange	25.7
2	2	2	Cell 2	Cell 8	1	1	8		orange	29.3
2	2	3	Cell 3	Cell 9	1	1	9		orange	33.0
2	2	4	Cell 4	Cell 10	1	1	10		orange	36.7
2	2	5	Cell 5	Cell 11	1	1	11		orange	40.3
2	2	6	Cell 6	Cell 12	1	1	12		orange	44.0
2	2	7	neg
2	2	8	x
2	2	9	T1	Thermo 2
2	2	10	T2
2	2	11	T2
2	2	12	T1	Thermo 2
3	3	1	Cell 1	Cell 13	1	2	13		red	47.7
3	3	2	Cell 2	Cell 14	1	2	14		red	51.3
3	3	3	Cell 3	Cell 15	1	2	15		red	55.0
3	3	4	Cell 4	Cell 16	1	2	16		red	58.7
3	3	5	Cell 5	Cell 17	1	2	17		red	62.3
3	3	6	Cell 6	Cell 18	1	2	18		red	66.0
3	3	7	neg	Cell 13 minus	1	2	13-		Black	0.0
3	3	8	x
3	3	9	T1	Thermo 3
3	3	10	T2
3	3	11	T2
3	3	12	T1	Thermo 3
4	4	1	Cell 1	Cell 19	1	2	19		red	69.7
4	4	2	Cell 2	Cell 20	1	2	20		red	73.3
4	4	3	Cell 3	Cell 21	1	2	21		red	77.0
4	4	4	Cell 4	Cell 22	1	2	22		red	80.7
4	4	5	Cell 5	Cell 23	1	2	23		red	84.3
4	4	6	Cell 6	Cell 24	1	2	24		red	88.0
4	4	7	neg
4	4	8	x
4	4	9	T1	Thermo 4
4	4	10	T2
4	4	11	T2
4	4	12	T1	Thermo 4
5	5	1	Cell 1	Cell 25	2	4	1		orange	91.7
5	5	2	Cell 2	Cell 26	2	4	2		orange	95.3
5	5	3	Cell 3	Cell 27	2	4	3		orange	99.0
5	5	4	Cell 4	Cell 28	2	4	4		orange	102.7
5	5	5	Cell 5	Cell 29	2	4	5		orange	106.3
5	5	6	Cell 6	Cell 30	2	4	6		orange	110.0
5	5	7	neg	Cell 25 minus	2	4	1-		Black	0.0
5	5	8	x
5	5	9	T1	Thermo 5
5	5	10	T2
5	5	11	T2
5	5	12	T1	Thermo 5
6	6	1	Cell 1	Cell 31	2	4	7		orange	113.7
6	6	2	Cell 2	Cell 32	2	4	8		orange	117.3
6	6	3	Cell 3	Cell 33	2	4	9		orange	121.0
6	6	4	Cell 4	Cell 34	2	4	10		orange	124.7
6	6	5	Cell 5	Cell 35	2	4	11		orange	128.3
6	6	6	Cell 6	Cell 36	2	4	12		orange	132.0
6	6	7	neg
6	6	8	x
6	6	9	T1	Thermo 6
6	6	10	T2
6	6	11	T2
6	6	12	T1	Thermo 6
7	7	1	Cell 1	Cell 37	2	5	13		red	135.7
7	7	2	Cell 2	Cell 38	2	5	14		red	139.3
7	7	3	Cell 3	Cell 39	2	5	15		red	143.0
7	7	4	Cell 4	Cell 40	2	5	16		red	146.7
7	7	5	Cell 5	Cell 41	2	5	17		red	150.3
7	7	6	Cell 6	Cell 42	2	5	18		red	154.0
7	7	7	neg	Cell 37 minus	2	5	13-		Black	113.7
7	7	8	x
7	7	9	T1	Thermo 7
7	7	10	T2
7	7	11	T2
7	7	12	T1	Thermo 7
7	7	1	Cell 6	Cell 42	2	5	19		red	154.0
7	7	1	Cell 6	Cell 42	2	5	20		red	113.7
7	7	1	Cell 6	Cell 42	2	5	21		red	0.0
7	7	1	Cell 6	Cell 42	2	5	22		red	0.0
7	7	1	Cell 6	Cell 42	2	5	23		red	0.0
7	7	1	Cell 6	Cell 42	2	5	24		red	0.0

agmatthews · 2023-02-06T04:54:54-0500

Looking good!

On your example image should Byte 4 on the blue line be “1” to command “start charging”?
That would be listed as byte 5 in this document https://evwest.com/support/Elcon CAN Specification 2019.pdf

I have found you have to be careful with the byte order in Orion CAN messages (ie endian)
but your example looks ok

agmatthews · 2023-02-06T05:13:14-0500

I’m using the stealthEV charger / dc-dc and the Orion inbuilt settings for that worked out of the box.

I’ve have been expanding the Orion CAN data to interface via a micro controller to the hyper 9 controller, a display, and status LEDs on the type 2 charge connector.
eg

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