The Left Box and Right Box are each single enclosures holding two stacked modules. The Center Box is a mated pair (Center-Left + Center-Right halves joined together) holding three modules plus the component shelf.
LEFT BOX (single) CENTER BOX (mated pair: CL + CR) RIGHT BOX (single) ┌──────────────┐ ┌────────────────┬─────────────────┐ ┌──────────────┐ │ M1 (L-Top) │ │ M3 (CL-Top) │ Component Shelf │ │ M6 (R-Top) │ │ cells 37-42 │ │ cells 25-30 │ 25"×10.5"×3" │ │ cells 7-12 │ │ PACK POS │ │ │ Orion BMS 2 │ │ │ ├──────────────┤ ├───────────────┤ GV200PA-1 │ ├──────────────┤ │ M2 (L-Bot) │ │ M4 (CL-Bot) │ REC35P1KX │ │ M7 (R-Bot) │ │ cells 31-36 │ │ cells 19-24 │ DHAB S/155 │ │ cells 1-6 │ │ │ │ │ F1, F2, F3, F4 │ │ PACK NEG │ └──────┬───────┘ └───────┬───────┴────────┬────────┘ └──────┬───────┘ │ │ │ │ └──── J1 ────────────┘ └──── J3 ────────────┘ M2- → M3+ HVBD4AXR between M5- → M6+ J2: M4- → M5+ CR shelf and Right Internal busbars (stacked pairs, top-neg to bottom-pos diagonal): INT-L: M1- → M2+ INT-CL: M3- → M4+ INT-R: M6- → M7+ M5 (CR-Bottom) sits below the shelf in the Center-Right half. Only 1 module in that half.
HV Lane: F1 pack fuse + block • DHAB S/155 current sensor • GV200PA-1 main contactor • REC35P1KX negative contactor • HV bus / distribution studs • branch fuse positions (F2, F3, F4, F5)
Control Lane: Orion BMS 2 • Orion thermistor expansion • T9AP1D52-12 charger safety relay • contactor logic relays • heater enable logic • thermal control relays • LV relay/fuse panel • control harness entries
Ground: Scrape/sand bare metal at all mounting points. Use external tooth lock washers. Ground lug → shelf → box → chassis. If box is isolated from chassis (rubber mounts, powder coat), run dedicated ground strap through box to chassis.
| Region | Contents |
|---|---|
| Left Box (underbody, driver side) | M1 (L-Top), M2 (L-Bot), internal busbar, PRV valve, thermistors T1-T2 |
| Center Box — CL half | M3 (CL-Top), M4 (CL-Bot), internal busbar, thermistors T3-T4 |
| Center Box — CR half | M5 (CR-Bot) + component shelf, thermistors T5 + T8 (shelf) |
| Right Box (underbody, passenger side) | M6 (R-Top), M7 (R-Bot), internal busbar, PRV valve, thermistors T6-T7 |
| Between CR shelf & Right box | HVBD4AXR maintenance disconnect |
| Rear drive area (engine bay) | X144, HyPer 9HV motor, B+/B+Precharge/B- terminals, encoder, motor thermistor |
| Rear-right LV area | NLX24 12V battery, Elcon 1kW DC-DC, LV distribution |
| Driver cabin (dash) | CAN Touch Display, Speedhut SOC gauge, tach adapter, throttle, F/R switch, profile switches |
| Exterior (TBD location) | J1772 32A receptacle (J1772R-V2) + mounting bracket |
| Driver side, in front of battery boxes (behind front tire, skid plate protected) | Elcon 6.6kW charger (vented enclosure), CanEV 1500W cabin heater kit |
PACK_POS (M1+, L-Top) │ ▼ HVBD4AXR maintenance disconnect (between CR shelf and Right box) │ ├──→ F4 (10A KLK) → HV Precharge Relay → X144 B+ Precharge │ ▲ coil: 12V key switch │ ▼ F1 (500A / 220V) main pack fuse │ ▼ DHAB S/155 current sensor (ALL current — charge and discharge — passes here) │ ├──→ F3 (20A KLK) → DC-DC HV+ [upstream of GV200. HV− downstream of REC35 — needs REC35 closed] │ ▼ GV200PA-1 main contactor (X144 K1-25/K1-26, external PWM economizer) │ ▼ HV_BUS_POS ──┬──→ X144 B+ ├──→ F2 (60A 20EV) → Elcon 6.6kW Charger HV+ [UPSTREAM of GV200 — plug-and-charge, no key required] └──→ F5 (25A TRM) → CanEV 1500W Cabin Heater (via LEV100 contactor from kit, ~10-11A @ 144V) PACK_NEG (M7−, R-Bottom) │ ▼ REC35P1KX negative contactor (Orion pin 7 Discharge Enable, internal K-coil economizer) │ Polarity sensitive: +A1 = pack side, −A2 = bus side ▼ HV_BUS_NEG ──┬──→ X144 B− ├──→ Charger HV− ├──→ DC-DC HV− └──→ HV Heater return
The X144 controls the positive contactor as part of its precharge/main-contact sequence. The Orion BMS controls the negative contactor via watchdog-backed Discharge Enable. Either system can independently kill HV power.
Key ON ├─→ 12V to Orion READY (pin 2) + X144 K1-24 (via permission chain) ├─→ Orion self-checks pass │ └─→ Discharge Enable (pin 7) activates → REC35 closes (3.8A inrush / 0.13A hold) ├─→ 12V energizes HV precharge relay │ └─→ pack voltage → B+ Precharge → X144 caps charge (4428µF) └─→ X144 precharge complete → K1-25/K1-26 → GV200 closes → HV BUS LIVE
Key OFF or fault ├─→ X144 stops torque → opens GV200 (positive breaks first) └─→ Orion drops pin 7 → REC35 opens (negative breaks) → HV BUS DEAD
┌── CAN → X144 (stop torque) ✓ Bus C (250K)
├── CAN → Elcon (stop charging) ✓ Bus B (250K, CAN-3865)
├── Pin 7 (Discharge Enable) → REC35 coil ✓ Opens negative path
BMS detects ────├── Pin 8 (Charge Enable) → regen interlock ✓ Stops regen charge
fault ├── Pin 6 (Charger Safety) → T9AP relay ✓ Kills charger 12V wake
├── Pin 26 (Kill Authority) → perm. chain ✓ Kills X144 K1-24
└── Inertia switch (crash) → perm. chain ✓ Physical crash cutoff
Permission Chain:
12V fused → Ignition/READY → Inertia Switch → Orion Pin 26 relay → X144 K1-24
Charger Shutdown (3-tier):
Tier 1: CAN via Bus B (CAN-3865: charger self-stops after 5 sec w/o valid msg)
Tier 2: Pin 6 → T9AP1D52-12 → charger 12V wake killed
Tier 3: AC relay in series with mains → physical power cut
PACK− ◄── M7 (R-Bot) ── cells 1-6 ── 0V to 22V ──┐
M6 (R-Top) ── cells 7-12 ── 22V to 44V │
───[J3 jumper: right box → center-right]─── │ Connector 1
M5 (CR-Bot) ── cells 13-18 ── 44V to 67V │ (Groups 1-3)
───[J2 jumper: center-right → center-left]── │ Cells 1-36
M4 (CL-Bot) ── cells 19-24 ── 67V to 89V │
M3 (CL-Top) ── cells 25-30 ── 89V to 111V │
───[J1 jumper: center-left → left box]─── │
M2 (L-Bot) ── cells 31-36 ── 111V to 133V ──┘
═══════════════ 2.5kV ISOLATION BOUNDARY ═══════════════
M1 (L-Top) ── cells 37-42 ── 133V to 155V ──┐ Connector 2
(taps 43-48 all tied to cell 42+) │ (Group 4)
PACK+ ◄── M1+ ──────────────────────────────────────────┘ Cells 37-42
Cells 19 and 31 sit at external jumper boundaries (J2 and J1). Measure actual jumper cable resistance with a milliohm meter and enter compensation values in the Orion BMS utility. Also verify tap progression with DMM before connecting to Orion: each step should be ~3.7V, rising from PACK−. Taps 42–48 should read the same voltage.
| ID | Location | Module | Type |
|---|---|---|---|
| T1 | M1 rear sensor area | L-Top (cells 37-42) | 10K NTC |
| T2 | M2 rear sensor area | L-Bot (cells 31-36) | 10K NTC |
| T3 | M3 rear sensor area | CL-Top (cells 25-30) | 10K NTC |
| T4 | M4 rear sensor area | CL-Bot (cells 19-24) | 10K NTC |
| T5 | M5 rear sensor area | CR-Bot (cells 13-18) | 10K NTC |
| T6 | M6 rear sensor area | R-Top (cells 7-12) | 10K NTC |
| T7 | M7 rear sensor area | R-Bot (cells 1-6) | 10K NTC |
| T8 | Shelf / electronics airspace | — | 10K NTC |
All same B value. Use Orion thermistor expansion module for channels beyond 8 built-in inputs.
| Bus | Speed | Nodes | Term. End 1 | Term. End 2 |
|---|---|---|---|---|
| A | 500K | Orion CAN1, Speedhut SOC, CANdapter tee | Orion CAN1 internal 120Ω | External 120Ω at Speedhut |
| B | 250K | Orion CAN2, Elcon 6.6kW charger | External 120Ω at Orion CAN2 | Elcon internal 120Ω |
| C | 250K | X144, CAN Touch Display, tach adapter (EVW-CBTH9) | X144 internal (K1-3↔K1-14) | Tach driver internal 120Ω (switch 1 ON) |
Design rules: Twisted pair shielded cable. Ground shield at one point only. Short stubs. All devices share common LV ground (Orion pin 12). Verify 60Ω per bus with power off. Use external CAN isolator if any device has different ground reference.
| Parameter | Value |
|---|---|
| Protocol | CAN-3865 (Elcon proprietary) |
| Baud rate | 250K |
| Command cycle | 1 second (Orion sends voltage/current setpoint) |
| Timeout | Charger self-stops after 5 seconds without valid CAN message |
| Orion config | Select "Elcon/TC" charger profile in CAN2 tab |
| Display | CAN ID | Start Bit | Len | Scale | Type | Units |
|---|---|---|---|---|---|---|
| SOC (Battery Level) | 0x355 | 0 | 16 | 1 | Unsigned | % |
| Pack Voltage | 0x356 | 0 | 16 | 0.1 | Unsigned | V |
| Pack Current | 0x356 | 16 | 16 | 0.1 | Signed | A |
| Battery Temp | 0x356 | 32 | 16 | 0.1 | Signed | °C |
| 12V Battery | 0x210 | 32 | 16 | 0.1 | Unsigned | V |
All Intel (Little Endian). Orion: "Orion SID" + "zero ev ccs". Speedhut warning at 15% SOC.
| TPDO | ID (Hex) | Rate | Contents |
|---|---|---|---|
| 1 | 0x154 | 96ms | Fault, inv temp, motor temp, SOC, speed, torque |
| 2 | 0x155 | 118ms | DC bus current, voltage, motor current, flags |
| 3 | 0x156 | 140ms | Operating time |
SmartView: My ID=1, Role=CO Node, Baud=250K, Heartbeat=Slow.
Requires a 4th TPDO on the X144 (in addition to the 3 Touch Display TPDOs). Configure in SmartView:
Message ID [HEX]: 25 • Uncheck “Add My Node ID” • Real ID = 0x25 • Bytes 1-2: 0 (empty) • Bytes 3-4: Motor 1 – Speed Measured (ABS) [rpm]
DIP switches: SW1 = ON (120Ω termination — replaces external terminator at Display end) • SW2 = OFF, SW3 = ON, SW4 = OFF (4-cylinder pulse for VW Bus flat-4 tachometer)
Wiring: Yellow = CAN-H • Blue = CAN-L • Red = +12V (LV-F5) • Black = GND • Green = analog tach signal output to gauge
Not required for baseline vehicle. Preferred: Waveshare 2-CH CAN HAT+ (isolated, dual-channel, Raspberry Pi). Can bridge/log two buses in-vehicle. The Seeed XIAO CAN board (non-isolated, single-channel) is bench-only.
| Pin | Name | Dir | Assignment | WD |
|---|---|---|---|---|
| 1 | Always On | Pwr | Fused 12V always-on (required for J1772 wake) | — |
| 2 | READY | Pwr | Keyed ignition 12V, fused 5A | — |
| 3 | CHARGE | Pwr | 12V from AC/DC adapter on J1772 mains | — |
| 4 | SOC Output | Anlg | 0–5V (available; Speedhut uses CAN instead) | No |
| 5 | CCL Output | Anlg | 0–5V charge current limit | No |
| 6 | Charger Safety | OD | T9AP relay → Elcon 12V wake + AC relay | Yes |
| 7 | Discharge Enable | OD | Interposing relay → REC35 K-coil (pin 7 drives small relay, relay switches +12V to REC35 coil BLACK wire) | Yes |
| 8 | Charge Enable | OD | Regen braking permission relay | Yes |
| 10 | MPO3 / Fan Enable | OD | Thermal pump/fan control relay (175mA max) | No |
| 12 | Ground | GND | Common ground — all power sources and CAN | — |
| 13 | MPI1 / J1772 CP | In | J1772 Control Pilot | — |
| 14 | MPI2 / J1772 Prox | In | J1772 Proximity Detect | — |
| 16 | DCL Output | Anlg | 0–5V discharge current limit (NOT watchdog) | No |
| 26 | Multi-Purpose Enable | OD | Kill Authority → permission chain (500mA/4A) | Yes |
OD = Open Drain. WD = Watchdog backed. Current sensor: Pin 1=+5V, 2=High, 3=GND, 4=Low.
| Pin | Name | Connection |
|---|---|---|
| 1 | I/O Ground | 12V negative / chassis ground |
| 2 | CAN-L | Bus C CAN Low |
| 3 | CAN-L RES | Jumper → K1-14 (internal 120Ω) |
| 4 | DI1 (Interlock) | Traction Enable / charge interlock |
| 5 | DI2 (Forward) | Forward direction switch |
| 6 | DI3 (Reverse) | Reverse direction switch |
| 9 | Encoder GND | Motor encoder pin 4 |
| 10 | +12V Out | LIN bus only (200mA max — NOT for Touch Display) |
| 11 | AI1 (Throttle) | EV West hall throttle wiper |
| 12 | I/O Ground | Throttle/thermistor analog ground |
| 13 | CAN-H | Bus C CAN High |
| 14 | CAN-H RES | Jumper → K1-3 (internal 120Ω) |
| 18 | DI5 (Profile 2) | Profile switch → 28% regen (E/S/H mode) |
| 19 | DI6 (Profile 3) | Profile switch → 40% regen (E/S/H mode) |
| 21 | Encoder Sin | Motor encoder pin 2 |
| 24 | Key Switch In | 12V permission chain. MAX 24V — catastrophic failure above! |
| 25 | Coil Return (+) | GV200PA-1 coil terminal X1 |
| 26 | Driver Out 1 (−) | GV200PA-1 coil terminal X2 |
| 32 | Motor Therm | HyPer 9HV thermistor pin 2 |
| 33 | Encoder Cos | Motor encoder pin 3 |
| 35 | +5V Out | Encoder pin 1 + throttle 5V supply |
Profiles: none=coast (0% regen), K1-18=28%, K1-19=40%. Clone nominal voltage: 144.00V. Disconnect throttle/phase before loading uncalibrated clone.
| ID | Rating | Type | Protects |
|---|---|---|---|
| F1 | 500A / 220V | Pack fuse block | Main pack short circuit |
| F2 | 60A | 20EV fuse/block | Charger HV branch (UPSTREAM of GV200 — plug-and-charge) |
| F3 | 20A | KLK 10×38mm | DC-DC HV branch (upstream of GV200) |
| F4 | 10A | KLK 10×38mm | Precharge path (reduced from 20A; measure inrush, may go to 5A) |
| F5 | 25A | TRM (from CanEV kit) | CanEV 1500W HV cabin heater (~10-11A @ 144V) |
| ID | Function | Source |
|---|---|---|
| LV-F1 | Orion Always On (pin 1) | 12V battery (unswitched) |
| LV-F2 | Orion READY (pin 2) | Ignition switch |
| LV-F3 | Orion CHARGE (pin 3) | J1772 AC/DC adapter |
| LV-F4 | CAN Touch Display (5A) | Switched 12V |
| LV-F5 | EV West tach adapter | Switched 12V |
| LV-F6 | Speedhut SOC gauge | Switched 12V + lighting |
| LV-F7 | Throttle / signal protection | Switched 12V |
| LV-F8 | Main relay / control feed | Switched 12V |
| LV-F9 | Cabin heater blower (12V 3-speed) | Switched 12V |
| LV-F10 | Pump / fan control logic | Switched 12V |
| ID | Function | Control Source | Notes |
|---|---|---|---|
| R1 | Main contactor (GV200) | X144 K1-25/K1-26 | External PWM economizer |
| R2 | Negative contactor (REC35) | Orion pin 7 → interposing relay | Pin 7 drives small relay (≤175mA), relay switches +12V to REC35 K-coil BLACK wire |
| R3 | HV precharge relay | 12V key switch | F4 (10A) → B+ Precharge |
| R4 | Charger AC safety | Orion pin 6 | T9AP1D52-12. Contacts: fused 12V → charger wake + AC relay coil |
| R5 | DC-DC enable | READY OR CHARGE (diode-OR) | Runs during both driving and charging. Two diodes from READY and CHARGE → enable pin. |
| R6 | HV cabin heater | Cabin enable + interlock | Tyco LEV100 contactor (from CanEV kit) + 25A TRM fuse. Downstream of GV200 — driving only. |
| R7 | Controller loop pump | READY power (continuous) | Loop 1: SC-WP pump, runs continuously. No intermittent cycling. |
| R8 | Battery loop pump | READY power | Loop 2: SC-WP pump, always on, active thermal |
| R9 | Cooling radiator fan | Auto (temp sw #2) | Loop 2: SC-FAN, kicks on above threshold |
| R10 | Loop 1 radiator fan | Auto (temp sw #1) | Loop 1: fan on large radiator in engine bay. Thermostatically controlled. |
| R11 | 12V fluid heater 1 | Manual switch | SC-WH inline heater, battery warming |
| R12 | 12V fluid heater 2 | Manual switch | SC-WH inline heater, battery warming |
| R13 | Future generator enable | Future | Yonda 144V (not baseline) |
| Interface | On Charger | Mating (Build) | Pins |
|---|---|---|---|
| LV / CAN | Molex 348302001 | Molex 334722006 | 10:+12V 5A • 11:CAN_H • 12:CAN_L • 17:GND |
| AC Input | Amphenol HVSL633023A | HVSL633063 | 1:AC N • 2:AC PE • 3:AC L |
| HV Output | Amphenol HVSL362022A | HVSL362062 | 1:HV+ • 2:HV− |
| Interface | Connector | Pins |
|---|---|---|
| Signal / CAN | DJ7041-1.5-21 | 1:CANH • 2:CANL • 3:CAN_GND • 4:ENABLE |
| HV Input | Tyco 2103124-4 / mate 2103177-4 | 1:DC+ • 2:DC− • 3:HVIL • 4:HVIL |
| LV Output | M8 studs | Bolted + / − terminals |
Components: X144 chill plate (EVW-H9CP-3) → pump (SC-WP Smart Car, R7, continuous) → large radiator + fan (R10, thermostatically controlled via TEMPSWITCH #1) in engine bay → expansion tank (TBD — need to buy second tank or share)
Control: Pump runs continuously when READY power is active. Fan (R10) controlled thermostatically via temp switch #1 — kicks on above threshold. Engine bay passive airflow is NOT sufficient alone per peer review (belt-driven fan removed, turbulent wake zone). This loop’s only job is to cool the controller.
Components: Pump (SC-WP Smart Car, R8, always on) → 2× 12V inline fluid heaters (SC-WH, R11/R12) → 7× Tesla battery modules → heater core (240mm radiators, always in loop) → cooling radiator (SC-RAD + SC-FAN, always in series) → expansion tank → back to pump
Heating (cold weather): Inline 12V fluid heaters on manual dash switch warm the battery coolant. The CanEV 1500W HV PTC cabin heater also warms the loop indirectly when blower pushes air through the heater core. Both help batteries reach efficient operating temperature.
Cooling (hot weather): Cooling radiator (SC-RAD) is always in series (no bypass valve). Mounted under the bus with good passive airflow at road speed. The SC-FAN (R9) kicks on automatically above a battery temperature threshold via temp switch #2 (TEMPSWITCH). No bypass valve in initial build — can be retrofitted later if cold-weather warmup proves too slow.
Cabin heat: The heater core (240mm radiators) is always in the coolant path but has no airflow unless the CanEV 12V 3-speed blower is activated (manual dash switch). Two cabin heat sources: battery waste heat through the heater core (free), and CanEV 1500W HV PTC element (direct electric heat via ducting). Both feed two dash outlets. Primary vs. supplemental determined by testing — battery waste heat reduces need for electric cabin heat, and cabin heat indirectly helps warm cold batteries.
Control logic: Pump always on when READY. 12V fluid heaters on manual switch. SC-FAN auto above threshold via temp switch. Cabin blower manual 3-speed.
Type: HV PTC self-regulating element with integrated 12V blower, ducting, and dash outlets
Kit includes: PTC heating element • Tyco LEV100 contactor (HV switching) • 25A TRM fuse + holder • 12V 3-speed blower • 3×5A diodes (blower speed control) • 5’ ducting hose • mounting bracket • 2× dash outlets • 3-speed switch
HV connection: Switched HV accessory branch via LEV100 contactor (from kit) and 25A TRM fuse (from kit). Cabin enable logic controls contactor coil.
Dimensions: 6.25″ W × 5.25″ H × 10.5″ L
Voltage range: 96V min – 215V max (covers 126–176V pack range)
Shelf heat budget: BMS balancing ~40W + DC-DC ~100W = ~140W. Monitor T8 during first charge cycles. If >60°C, consider relocating DC-DC.
| Parameter | X144 Inverter | HyPer 9HV Motor |
|---|---|---|
| Derating begins | +80°C (100%) | +135°C (100%) |
| Shutdown | +95°C (50%) | +165°C |
| Cooling ON | +55°C | +110°C |
| Cooling OFF | +45°C | +90°C |
| Item | Qty | Status |
|---|---|---|
| Tesla Model S 5.3 kWh module | 7 | On hand |
| Battery boxes (L, Center mated, R) | 3 | On hand |
| Tesla module through-boards | 7 | On hand |
| Stacked pair busbars (diagonal) | 3 | On hand |
| Tesla right-angle busbars | — | On hand |
| Tesla coolant connectors | 7 pr | On hand |
| PRV blow-off valve | 1 | On hand |
| Additional PRV valves | 2-3 | BUY |
| Item | Qty | Status |
|---|---|---|
| Orion BMS 2 (48S) | 1 | On hand |
| Thermistor expansion module | 1 | On hand |
| Orion CANdapter | 1 | On hand |
| DHAB S/155 current sensor | 1 | On hand |
| Item | Qty | Status |
|---|---|---|
| HyPer 9HV + X144 controller | 1 | On hand |
| GV200PA-1 main contactor | 1 | On hand |
| REC35P1KX neg contactor | 1 | On hand |
| HV precharge relay | 1 | On hand |
| CAN Touch Display + faceplate | 1 | On hand |
| Serial-to-USB (SmartView) | 1 | On hand |
| Wire harness assembly | 1 | On hand |
| Motor plug kit | 1 | On hand |
| Chill plate + tube | 1 | On hand |
| Adapter plate + motor cradle | 1 | On hand |
| Item | Qty | Status |
|---|---|---|
| Elcon 6.6kW charger | 1 | On hand |
| Elcon 1kW DC-DC | 1 | On hand |
| J1772 32A Receptacle Ver. 2 (J1772R-V2) + bracket | 1 | On hand |
| NLX24 12V battery | 1 | On hand |
| 12V fuse box / ground system | 1 | On hand |
| Item | Qty | Status |
|---|---|---|
| HVBD4AXR disconnect | 1 | On hand |
| 500A/220V pack fuse + block | 1 | On hand |
| 60A 20EV fuse + block | 1 | On hand |
| 20A KLK fuses + holders | 2+ | On hand |
| 12V relay (T9AP1D52-12) | 1+ | On hand |
| 4-fuse holder | 1 | On hand |
| Inertia switch | 1 | On hand |
| Item | Qty | Status |
|---|---|---|
| EV West hall throttle sensor (EVW-TH-HALL) + ball socket | 1 | On hand |
| EV West CAN tach adapter (EVW-CBTH9) | 1 | On hand |
| Speedhut 2-1/16" SOC gauge | 1 | On hand |
| F/R switch | 1 | Planned |
| Profile switches (E/S/H) | 2 | Planned |
| Item | Qty | Status |
|---|---|---|
| CanEV 1500W cabin heater kit (96–215V) | 1 | On hand |
| — includes LEV100 contactor, 25A TRM fuse/holder, 12V blower, ducting, 2× dash outlets, 3-speed switch, diodes, bracket | ||
| Coolant pump (SC-WP Smart Car) | 2 | On hand |
| Coolant pump (Tesla, spare) | 1 | On hand |
| Large radiator + fan (R10) → Loop 1 | 1 | On hand (radiator); fan needs purchase |
| Radiator + fan (SC-RAD + SC-FAN) → Loop 2 | 1 | On hand |
| 12V inline fluid heater (SC-WH) | 2 | On hand |
| Adj. temp fan/pump switch (TEMPSWITCH) | 2 | On hand |
| Expansion tank | 1 | On hand |
| Second expansion tank (for Loop 1) | 1 | BUY |
| Hoses + tubing | Multiple | On hand |
| Item | Qty | Status |
|---|---|---|
| 2/0 AWG orange HV cable | — | On hand |
| 2/0 lugs (various stud sizes) | — | On hand |
| Red/black terminal boots | — | On hand |
| Heat shrink tubing | — | On hand |
| Sealed power connectors | — | On hand |
| Non-metallic cable glands | — | On hand |
| CAT-rated digital multimeter |
| TOLSEN 6-piece insulated hand tool set (on hand) |
| Torque wrench + sockets for HV studs |
| Crimp tools: Deutsch, Ampseal, Molex, lugs |
| Continuity tester |
| Label printer / heat-shrink labels |
| Heat gun |
| Hose clamp tools |
| Coolant fill/bleed funnel |
| Catch pan + spill supplies |
| Eye protection |
| HV-rated insulated gloves (Class 0 min) |
| Non-conductive footwear |
| No metal jewelry during HV work |
| Orion BMS Utility (latest) |
| NetGain SmartView |
| CANdapter (on hand) for Orion |
| CAN Bus Analyzer (CAN-ANLYZR) standalone |
| Serial-to-USB (on hand) for SmartView |
| All manuals in PDF (see Sec. 18) |
| # | Step | Notes |
|---|---|---|
| 1 | Inventory and label every part | Label printer or heat-shrink |
| 2 | Confirm X144 B+ Precharge terminal present (ISO verify) | Between V and W phase outputs |
| 3 | Label battery slots; measure all module voltages | ~22V nominal each |
| 4 | Install busbars + jumpers J1/J2/J3; measure PACK+ to PACK− | ~155V full string |
| 5 | Install through-boards + thermistors; verify tap progression | ~3.7V per step from PACK− |
| 6 | Bench-power Orion 12V only; save config; verify firmware | Build 42-group corrected profile |
| 7 | Connect X144 via SmartView; save clone; verify ISO logic | Nom voltage = 144.00V; no HV yet |
| 8 | Mount shelf; route HV and control lanes separately | Physical separation between lanes |
| 9 | Wire HV paths: precharge, charger, DC-DC, heater | Verify fuse ratings before energizing |
| 10 | Wire Orion I/O: Always On, READY, CHARGE, safety chain | Test permission chain before HV |
| 11 | Build 3 CAN buses; verify termination + ground + baud | 60Ω per bus, power off |
| 12 | Bring up LV only: 12V, CAN, BMS, displays | Verify cells, temps, CAN traffic |
| 13 | Verify current sensor sign (charge=neg, discharge=pos) | Invert in software if needed |
| 14 | First isolated precharge test | Monitor B+ Precharge ramp |
| 15 | Bring up DC-DC (14V output) → then charger | Verify charge V/I limits |
| 16 | Bring up X144 traction | Wheels off ground! |
| 17 | Spin-sensor commissioning | Throttle disconnected for clone load |
| 18 | Finalize instruments, heater, thermal | After core traction/charging stable |
| ID | Issue | Status | Resolution |
|---|---|---|---|
| 01 | X144 logic type | RESOLVED | ISO locked. K1-24=12V. Precharge via B+ Precharge. |
| 02 | Cell numbering | RESOLVED | M7=cells 1-6 (PACK−) → M1=37-42 (PACK+). |
| 03 | Contactor roles | RESOLVED | GV200=main/pos (X144). REC35=neg (pin 7 via interposing relay). |
| 04 | BMS kill authority | RESOLVED | Pin 26 in permission chain. Watchdog-backed. |
| 05 | Charger safety | RESOLVED | 3-tier: CAN, Pin 6 relay, AC relay. |
| 06 | DC-DC bootstrap | RESOLVED | HV+ upstream of GV200 via F3. |
| 07 | Speedhut type | RESOLVED | CAN SOC gauge @ 500K Orion SID. |
| 08 | CAN topology | RESOLVED | 3-bus: A=500K, B=250K, C=250K. |
| 09 | Thermal loops | RESOLVED | Two-loop: L1 controller passive, L2 battery active + cabin heat. |
| 10 | REC35 coil control | RESOLVED | K-coil via interposing relay. Pin 7 → small relay → REC35 coil BLACK wire. |
| 11 | Touch Display bus | RESOLVED | CAN Bus C @ 250K. Not LIN. |
| 12 | CAN HAT | RESOLVED | Optional. Waveshare 2-CH HAT+ preferred. |
| Document | File / URL |
|---|---|
| HyPer System User Manual Rev.A.1 | HyPer_System_User_Manual_RevA_1.pdf |
| AmpRevolt HV Schematic | AmpRevolt - Hyper 9&9HV High Voltage Schematic.pdf |
| CAN Touch Display Manual Rev.A.1 | Touch_Display_User_Manual_RevA1.pdf |
| Clone File Management QuickGuide | HyPer_Clone_File_Management_QuickGuide.pdf |
| Orion BMS 2 Wiring Manual Rev 1.1 | orionbms2_wiring_manual.pdf |
| Orion BMS 2 Operational Manual | orionbms2_operational_manual.pdf |
| Orion BMS 2 Quickstart Guide | quickstart_orion2.pdf |
| Elcon 6.6kW Charger Manual | 6.6kw_Low-Voltage-HK-LF-115-58-02272024.pdf |
| Elcon 1kW DC-DC Manual | Elcon-TDC-IY_1KW-DC-DC.pdf |
| ELCON CAN-3865 Protocol | elconchargers.com/.../CAN-3865.pdf |
| REC35 Datasheet Rev 5 | REC35_SERIES_DATASHEET_REV_5.pdf |
| Speedhut EV Gauge Instructions | EV_Gauge_Instructions.pdf |
| EV West Tach Driver Manual | evwest.com/.../EV West Tach Driver Manual.pdf |