monitoring – Traction EV

Thunderstruck Motors Ground Fault Monitor GFM 2.0 HVIL Isolation Monitor

james — Sat, 08 Jun 2024 09:21:20 +0000

Thunderstruck Motors Ground Fault Monitor GFM 2.0 measures the isolation between an
electrical system ground and a separate High Voltage (HV) isolated system. It is designed for use
in a wide range of Electric Vehicle (EV) systems and is highly configurable.
The GFM measures isolation between the two systems by applying a known resistance between
the low voltage ground and both HV buses (positive and negative) in an alternating sequence,
then measuring the very small resulting current. The advanced measurement algorithm allows
the GFM to make accurate measurements in rapidly changing and noisy systems. The isolation
measurement is reported in several forms: fault resistance, ohms/volt, and average fault
location. Symmetrical, asymmetrical, intermittent, and capacitive faults can all be measured by
the system.
The GFM intelligently uses measured isolation metrics to evaluate two configurable fault
thresholds (warning and fault). The GFM has two outputs that may be configured to represent
these faults, allowing an operator to create warning lights and system interlocks. The present
state of the fault, the number of occurrences, and the history of each fault is available to the
user. These fault conditions, as well as all measurements, are available over CAN bus using sID
(standard ID) and eID (extended ID) based protocols

Features:

Rapid and accurate isolation measurement
Highly configurable
Wide voltage range (30-500V)
Fault location detection
2x programmable outputs
1x CAN Bus
All measurements and information available over CAN bus
CAN control of isolation measurement
Factory calibrated
Built in compatibility with:
- Dilthium Design MCU
- Dilthium Design EV Display
- Fellten CCS Controller

Manuals and Software Downloads

GFM 2.0 Manual
DBC file available upon request

This item will have $4.95 shipping included in the price.
A small flat-rate shipping fee of $9.95 is already factored into the price, so there are no extra charges at checkout.

The post Thunderstruck Motors Ground Fault Monitor GFM 2.0 HVIL Isolation Monitor appeared first on Traction EV.

Orion 2 Battery Management System BMS 24 Cell Complete Kit

james — Mon, 25 Aug 2025 22:53:16 +0000

Orion 2 BMS Battery Management System

The Orion BMS is one of the leading battery management systems on the market today. Known for its durability, flexibility, and American-made quality, it has been trusted for more than a decade by OEMs, Motorsports teams, and DIY builders to safeguard lithium-ion battery packs.

Significantly smaller enclosure size for 24-72 cell configurations.
Roughly 40% lower weight on all models due to the new enclosure design and streamlined (removable) heatsink. Minimum heat dissipation requirements apply.
Considerable boosts in measurement accuracy and processor speed allow for more advanced calculations and logic.
Direct hardware support for several popular charging protocols including hardware support for both SAE J1772 Type1 and IEC Mennekes Type 2 (directly interfacing with the pilot / proximity lines) and CHAdeMO for DC fast charging. CCS2 is also possible with the addition of the Fellten CCS2 System, contact us for more information.
Wider input power voltage range (now 12v-24vDC compatible) for better support on heavy vehicles and equipment. The Orion 2 BMS remains fully compatible with 12v applications.
Ability to directly drive certain contactors on select inputs (bypassing the need for intermediate signal relays in some situations)–see supporting documentation for details.
Completely redesigned multi-unit series configuration (now using Remote Cell Tap Expansion Modules). This greatly simplifies connecting multiple units together in series and improves the overall reliability.
New Status LED on the unit to indicate power status and the presence of faults.
Addition of 2x new Multi-Purpose Output pins with programmable functions.
Significant algorithm and software enhancements to improve overall system accuracy for parameters such as State of Charge and pack health.

Capable of measuring up to 24 battery cells connected in series.
Configurations available in increments of 12 cells in series.
Centralized design provides high EMI and noise immunity.
Performs intelligent cell balancing (passive).
Calculates state of charge (SOC).
Uses professional automotive-grade locking connectors.
Calculates discharge current limit (DCL) and charge current limit (CCL).
Can measure cell voltages between 0.5v and 5.0v.
Dual (x2) CANBUS 2.0B interfaces which (fully programmable).
OBD2 diagnostic protocol support.
See the complete list of features: https://www.orionbms.com/features/basic-features
Link: Orion 2 Specifications Sheet pdf

Comes with

2 x 24 cell harnesses
I/O Harness
Hall Current Sensor
Thermistor Harness with 8 inputs
CANdapter for programming via PC

Manuals Downloads

Link: Orion 2 BMS Wiring Manual

Link: Orion 2 BMS Operation Manual

This item will have $19.95 shipping included in the price.
A small flat-rate shipping fee of $19.95 is already factored into the price, so there are no extra charges at checkout.

The post Orion 2 Battery Management System BMS 24 Cell Complete Kit appeared first on Traction EV.

Dilithium Design Master Control Unit MCU

james — Thu, 01 Dec 2022 03:11:35 +0000

Thunderstruck’s Dilithium Design Master Control Unit (MCU), combines features of the BMSC, EVCC all in one conveniently sized unit. This device controls battery charging, cell management, and display functions. It has 5 programmable inputs and 5 programmable outputs, two CANbus interfaces, and two IsoSPI interfaces that connect to BMS measurement units. The MCU supports existing 24-cell BMS Satellite units. The MCU also handles charging communication protocol for Type 1 (J1772) and Type 2 (Mennekes) ensuring safe charging and throttle interlock drive away protection.

The new MCU display (purchased separately) shows

Pack State Of Charge (SOC)
kilo watts to and from the pack
Current to and from the pack
cell voltage
cell temperature
Faults and Alerts

The Dilithium Design MCU boasts a great new feature which we are very excited about: it supports CAN capable Speedhut gauges for fuel State of Charge, pack current, pack voltage, and temperature. Speedhut CAN capable gauges are fully customisable allowing either factory look install or an all-out custom look!

The MCU has been designed as an expandable platform, with additional features planned for future upgrades. The MCU case is a 4.1 x 2.65 x 1.1 inch plastic enclosure with mounting flanges.

Feature List

Original BMSC and EVCC features including cell balancing and reporting, thermistor reporting and charge control
Type 1 J1772 support with auto-start and Type 2 Mennekes compatibility
Controls up to 4 Thunderstruck Chargers for high-speed charging
Hall sensor input for current counting SOC reporting to Dilithium or analog display
MCU support for CAN capable Speedhut gauges for fuel State of Charge, pack current, pack voltage, and temperature.
User configurable parameters via text-based freeware user interface
Display drivers for Dilithium Design Display, Curtis Engage II, Speedhut
Five programmable inputs and five programmable outputs – useful for sending and receiving status alerts
12v switched output for controlling an external device such as powered battery packs and relays
PWM Output for driving resistive sensor analog fuel gauges
Two independent canbus networks configurable for 250kbs or 500 kbs baud rates
Two IsoSPI networks for Dilithium BMS satellites for up to 288 cells
CANOpen and OBDII Support

Comes with

Master Control Unit with integrated BMS, Charge and Display controllers
Connectors (4, 5, 8 and 10 pin Harting)
Wire release tool for connectors
Low voltage wiring (1 metre lengths, various colors)
12v Light/Buzzer (for operator alert)
120 Ohm canbus termination resistor
Harness Test Board

Associated Equipment

Dilithium Designs BMS Satellite BMSS
– BMS Satellite units with 2×12 24 cells each and can be linked together for up to 96 cell packs

Thunderstruck Motors TSM2500 CAN Enabled Charger with EVCC
– MCU controls one to four TSM chargers over canbus for custom charging solutions

Type 1 J1772 Charge Port with 1 metre pre-terminated harness
– Connects to MCU for EVSE source control and connection safety

Type 2 Inlet Port with 1 metre pre-terminated harness
– Connects to MCU for EVSE source control and connection safety

Speedhut Gauges
– CAN Enabled Gauges for use with Dilithium Designs MCU

MCU Display
– Touch Screen Display for quick and easy battery pack referencing and monitoring

Manuals and Software Downloads

MCU Manual Version 1.3
MCU Output Examples
Charger Connector Diagram
Charger Troubleshooting Guide
Serial Port Utilities Installation
Putty Install Video
BMS Wiring and Testing Video
PC Software
Mac Software
BMS Loop External Switching Note

This item will have $9.95 shipping included in the price.
A small flat-rate shipping fee of $9.95 is already factored into the price, so there are no extra charges at checkout.

The post Dilithium Design Master Control Unit MCU appeared first on Traction EV.

Dilithium Design BMS Satellite BMSS

james — Fri, 06 Aug 2021 05:30:12 +0000

The Dilithium Design BMS system is very powerful and simple to use. The BMS works in series and parallel systems up to 96 cells with the addition of BMSS Satellites. Multiple BMSC systems may be added together for even larger systems. The BMSC controller has a processor and cell measurement board, the satellite just contains a cell measurement board. The BMSC can measure between 4 and 24 cells, each satellite can measure between 4 and 24 cells.

The Dilithium Design BMS Satellite integrates easily via CAN network with the TSM2500 charger, EVCC and Touchscreen Display, product links to those items below.

Measure 4-24 Cells
Add up to 3 Satellites for additional 24 cells per Satellite
Multiple BMSC can be added together for systems over 96 Cells
10 Thermistor inputs on BMSC, 10 Thermistor inputs per BMSS
Programmable Low Cell Voltage Cut Out and High Cell Voltage Cut out
Balance 170mA per cell or 1Watt

Comes with

2 x 24 cell harnesses
2 x 2 p connector

Link to: Dilithium Designs BMS Controller BMSC

Link to: Thunderstruck Motors TSM2500 CAN Enabled Charger with EVCC

Dilithium Design BMS Satellite: Manuals and Software Downloads

Link to: BMS Quick Start Guide

Link to: BMS User and Installation Manual Version 2.2

Link to: BMS User and Installation Manual Version 2.1

Link to: BMS User and Installation Manual Version 2.0

Link to: Serial Port Utilities Guide

Link to: PC Software (.zip)

Link to: Mac Software (.zip)

Link to: BMS Loop External Switching Note

This item will have $4.95 shipping included in the price.
A small flat-rate shipping fee of $4.95 is already factored into the price, so there are no extra charges at checkout.

The post Dilithium Design BMS Satellite BMSS appeared first on Traction EV.

Dilithium Design Battery Management System | BMS Controller BMSC

james — Fri, 06 Aug 2021 04:56:51 +0000

The Dilithium Design Battery Management System (BMS) system is very powerful and simple to use. The Battery Management System works in series and parallel systems up to 96 cells with the addition of BMSS Satellites. Multiple BMSC systems may be added together for even larger systems. The BMSC controller has a processor and cell measurement board, the satellite just contains a cell measurement board. The BMSC can measure between 4 and 24 cells, each satellite can measure between 4 and 24 cells.

The Dilithium Design Battery Management System integrates easily via CAN network with the TSM2500 charger, EVCC and Touchscreen Display, product links to those items below.