There's no difference in the Orion Utility when using these special order units and a regular one.

CrAzY_DrIveR wrote: ↑Sat Nov 09, 2024 7:22 pm 20x1.6=32mm2

The busbars of the 62kwh pack are the same size.

You can check if it is nickel with a small magnet.

It looks like it's probably nickel plated copper, it's not magnetic. I was thinking it might be feasible to drill a series of divots in the part of the terminal that's pulled away from the cell stack to reduce the thickness in those areas, and ...

does it seem feasible to you to try to manually charge up a single cell?

I don't feel confident telling you that this will work/is a good idea/won't damage your batteries. Your best option is to charge the whole pack with a BMS and let it take care of balancing the cells. However, I think you ...

There is a hardware difference between the BMS that I linked and a new Orion 2. They were special ordered from the factory from my understanding.

Any regrets?

Yes, that's one of the biggest things I would change if I did it all over again. The most I've seen my pack output is 600amps. I'm using Jon Volk's tune for the LDU so I haven't tuned the parameters according to my setup, but that 600amp mark seems to be right in line with my ...

I imagine the full width of the battery module is out of the size for laser chamber box?


I'm not quite sure, I wouldn't even know how to look for someone with a laser welder in my area.


If the area where the red spacers are below would have sufficient space, a row of small screws (like 2mm ...

Hi everyone,

After some very frustrating BMS issues, I discovered that the terminal of one of my cells had been pulled off of the cell stack.

Here is the module with the cover off

IMG_1947.jpeg

Here is the terminal in question

IMG_1949.jpeg
IMG_1948.jpeg

I have a traction wire attached ...

Thank you for your reply. I think I've found the issue.

I decided the module itself needed a visual inspection. I removed the front cover:

IMG_1947.jpeg

When trying to remove the black plastic piece at the top of the upper image, I noticed something. The left terminal is clipped onto the black ...

Thank you both for your responses. I religiously wear high voltage gloves in these situations after an instance of naked fingers in the HVJB.

It shouldnt light up. If it only blinks then your inverter caps discharged.

Using an AC incandescent bulb, I did tests with all the polarity/cell ...

Try to connect incandesent light bulb to chassis ground and HV minus.

That's a handy trick! Unfortunately (fortunately) the lightbulb did not light.

Do you use bare copper in your tap wires? I would suggest replacing them with tinned wires.

I have been using bare copper wire, but I doubt this ...

Hi everyone, I have an Orion BMS 2 connected to a 62kwh leaf pack. I have blown fuses on the same cell on two Orions already, and am having issues on the same cell with my current one at the moment. I had purchased my previous two BMS from eBay under the same seller, and they were special ordered ...

I was thinking about this for my project also. But I am thinking of maybe going with an accelerometer they are quite cheap. Something like a aduino as a comparator and wired inline with the break switch. That would allow you to choose at what rate of decel you want the lights to come on at (or if ...

I am doing something quite similar. My setup uses a dual hall throttle and i would like to use CAN for transmitting the regen, by means of pedal travel. not sure which value to send on.


I’m not familiar with controlling the OI board over CAN, is that how you’re handling control of the OI board ...

Yes, I was planning on using that second throttle input before I started playing around with CAN. I was mostly wondering which cables on the iBooster I would route to that throttle input.

Hey everyone, after a bit of driving with a one pedal setup (running Jon Volk's tune) I have realized that my brake lights are not turning on during regen. After a bit of investigation, I realized the wire coming out of the OI LDU board that I was planning on running to my brake light switch is ...

Ok, very good to know. Thanks for the warning as well, seems like you have some experience

Hi everyone, I have been starting to drive my car recently and want to set current limits. However, I have opened contactors on a motor while spinning it before and killed an inverter, so I'm scared to trigger any kind of error. When I have my parameters set to TripMode AllOn or Keep DC switch ...

Hi everyone, after a couple years of working on this conversion I finally am able to drive my car. I am using a 62kwh Leaf pack with a Tesla LDU and there doesn't seem to be much documentation on the max current I can pull from these cells. I decided to do some data logging with my Orion 2 BMS today ...

I assume you've already read the threads about switching your A/B wires on the 4 pin encoder connector. I can't recall if that would affect the hand-turn test you're doing or not. Are your encoder wires shielded? I was bench testing with a brand new harness that did not have the cables shielded for ...

Awesome, I've decided to run my setup like this. I couldn't get the "charge enable" or "charge safety" features to work on the Orion which is strange, it looks like Actia was using the "charge enable." I have the multipurpose enable function set to float high if any cell goes above a certain voltage ...

This is very helpful, I might run my setup like this. In this configuration, does the BMS just interrupt the loop when the pack is at full voltage since the EVCC isn’t receiving information through CAN?

Yes, one of the limited features of the BMS I’m using is that it only has one CAN bus. I can see the CAN data in the EVCC terminal but it labels the messages as “unknown.”

Hey everyone,

I bought a TSM2500 with an EVCC from Thunderstruck a little bit ago, before I knew I was going to be using an Orion 2 BMS for my build. I want to let the EVCC handle the J1772 control and charge tapering because the Orion BMS I have is a limited functionality version from an Actia ...

Do you have the CANdapter for interfacing a PC with the Orion BMS?