NetGain HyPer 9-DHV Motor Controller and Kit.

The product description for the HyPer 9-DHV controller is as follows:

Type:  ACX1T50000100
Model:  AC-1X 120/144 V 500 A  112 SWS
SN:  9735730003

The controller can operate in the range of 90 to 180 volts.  This 1992 BMW 325i build will operate at a nominal 144 volts.

DSC06595 Top view of the controller.  Terminal bolts are in the plastic bag.

DSC01163 Detail picture of supplied hardware which includes five M8-1.25x20 hex head bolts (torque to 15Nm max)with washer and lock washers.  These are used for the -B, +B, U1,V1, and W1 terminals.  Also included is a M4-0.7x10 bolt (torque to 2.5Nm max)with both washers.  This is used for the +B pre-charge terminal. The outer diameter of the M8x20 Zinc plated bolts was measured to be 7.82 mm. 

Lock washer ID =  8.29mm, flat washer ID = 8.44mm.     Updated 6-22-2021

DSC06598 side end view of controller.  The black plastic housing is attached to the Aluminum heat sink (base) with four T10 Torx bits (two are shown in the picture).  Updated 9-15-2021

DSC06597 of the 35 pin connector.

Edited 6/8/2023

DSC01891 showing a dust cap that was printed for the K1 port on the SME AC-X1 (or X144) Controller/Inverter.   Ken (a member of the electric auto club FVEAA) made the cap with a Ender Pro 3 and he has posted the file here:

 https://www.printables.com/model/500848-sme-ac-x1-k1-port-cover  

The cap fits perfectly.  We added a few small drops of bathtub Silcone sealer on the inside edges of the cap to further increase the grip of the cap while we are working with the controller.   

DSC06601 showing the mounting holes at the corners of the base of the controller's Aluminum heat sink.  The mounting holes are 6.5 mm diameter and are 197 mm and 147 mm center to center.

The kit purchased from NetGain included the following:

HyPer 9-DHV 3 phase motor  (pictures shown previously in 9/24/19 blog posting)
Hyper-Drive X144 controller  (for up to 144 volts operation) Serial number 9735730003
500 Amps with Standard Ampseal Wire Harness
Gigavac GV200PA-1 contactor
HTS: 8501.32.4500

DSC06593 of the components included in the kit in addition to the motor and controller.  In the center of the picture is the bag of terminal pins for the motor encoder and motor thermistor plugs attached to the motor.  Starting at 12:00, the black plastic 3 phase terminal cover, pre-charge relay, Gigavac main contactor relay, computer cable (bottom right), USB to cable, and wire cable bundle with red Ampseal 35 pin connector.

DSC06596 Picture of the 35 pin Ampseal connector.  Updated 9-18-2021

A full description of how the crimped wires are installed in the AMPSEAL connector can be found here:   https://www.youtube.com/watch?v=uXTkm_XV2OY

It appears that this video (  https://www.youtube.com/watch?v=v157tIIQGEc ) discusses the crimping tool used for the AMPSEAL 16 contacts.  Updated 10-5-2021

                                        (picture of Gigavac to be added)

DSC0   of the Givac 500 amps main contactor relay.

DSC06677 Top view of the pre-charge relay.

DSC06678  Side view of the pre-charge relay.

The HyPer 9-DHV user manual can be found here:

https://www.go-ev.com/PDFs/HyPer_9HV_IS_User_Manual_REV08.pdf 

Chiller Plate Fabrication Part 2- Machining Steps

DSC06687 Picture showing the Aluminum chill plate version 1.0 after the majority of the CNC work had been completed.

DSC06686 During fabrication a small layer of Aluminum was left on the bottom of the plate which when eventually removed provided a brilliant smooth surface on both the top and bottom faces of the plate.

The final chiller plate dimensions match the controller base dimensions and they are described in the previous post.

DSC06602  The 1.25" wide channels allow for good flow and contact surface.  The final weight of  chill plate version 1.0 was 708.23 grams.

DSC06627 Showing the internal view of the 0.125" NPT inlet and outlet ports on the side of the chiller plate.  updated 2/7/2020   Pilot holes drilled with 0.332" (Q) drill ($7.19) and tapped with 1/8-27 NPT tap ($6.19).  updated 3/18/21  The center to center spacing was initially 38.1mm,  but later chill plate version 2.2 provided an increased center to center distance of 50.8 mm to accommodate larger footprint 90 degree elbow fittings.  updated 9/7/21

updated 3/18/21

DSC06628 Gasket adhesive that was used to secure the Chiller Plate to the base of the controller.  One source is Advanced Auto Parts part number 22072 at $4.49.  EVWest indicates that white silicone should not be used as it degrades over time. 

To mount the chiller plate to the controller, the bottom surface of the controller and the top surface of the chiller plate are cleaned (brake cleaner or solvent) and then Gasket Maker is applied to the top  surface of the chiller plate.  The bolt holes are aligned and the two parts are clamped together for curing for 24 hours.  Any excess silicone can then be trimmed from the sides.  During fabrication of the chiller plate, if a small beveled edge is machined onto one of the top outer edges of the chiller plate, the bevel can allow for insertion of a chisel so that a mallet can then be used to separate the two parts later if needed.

Alternative Chill Plate Design - Faster Flow Design

The inlet inner diameter of a 1/8" NPT hose nipple is 0.307" (thin wall schedule 10) and 0.269" (standard wall schedule 40).  Thus for a schedule 40 pipe fitting, the cross sectional area is 0.227 square inches.  This cross sectional area will define the flow rate at a given inlet pressure.  Once the cooling fluid enters the plate, the larger cross sectional area (rectangle 1.25" wide and 0.50" tall, 0.625 square inches ) results in a flow rate that is only 36.3% of the inlet flow.  It is not known how much heat must be removed from the controller when it is under full load.  It is possible that a different design with only 0.75" channel width and the same 0.50" depth, will not have any material impact upon performance, but we will make one and test it.  This design is much simpler, although tedious to fabricate, when manually operating a Bridgeport.

DSC06698 Showing the smaller 0.75" width channels in an alternate design chill plate version 2.0. The final weight of this design is 708.41 grams.

DSC06697 Edge on view showing the input and output NPT threaded holes for version 2.0 at the far side and on this plate the addition of two extra threaded ports holes at the front edge for optional sensors.
updated 2/7/2020
updated 9/7/21

DSC06782 Edge on view showing placement of 0.125" brass plugs installed into sensor ports of version 2.0 with sensor.

updated 9/7/21

DSC06795  Multiple copies of these plates version 2.0 were fabricated and they are available to others by contacting William at sales@narchem.com .

updated 2/19/2020

DSC06792  Picture of McMaster Carr (part 5346K13, $1.19 ea.) straight brass barbed for 1/4" hose ID that was used when the center to center holes was only 1.0" (chill plate version 2.0).   The ID of the straight fitting is 0.18".

updated 9/7/21

 
DSC06794 Picture of McMaster Carr (part 53525K11, $2.67 ea) of the 90 degree elbow brass barbed for 1/4" hose ID that was used when the center to center holes was 1.50" (chill plate version 2.1) and there was additional space for rotation of the fitting during installation.  The ID of the 90 degree elbow is 0.18".

updated 9/7/21

Chiller Plate for Hyper 9-DHV motor.

Chiller Plate for HyPer 9-DHV

The three phase controller designed for the HyPer 9-DHV has an operating temperature range of -40' C to +95' C.  At 80' C the controller will enter Thermal Cutback Mode, and at 95' C, the controller will shut down in an effort to save itself.   The manufacturer recommends a chiller plate for any application that exceeds 200 amps of continuous use.  A chiller plate can be purchased at the same time the motor is purchased or added later as needed.  Our plan is to test the limits of the HyPer 9-DHV motor, so we are confident that we need a chiller plate, and we will connect it to a circulating pump and a small radiator.

The Aluminum 6061 chill plate (DSC06602) version 1.0 dimensions exactly match the controller base dimensions and they are 210 mm x 160 mm.  The centers of the mounting holes (6.5 mm) for both are located at the corners  of a rectangle that is 197 mm x 147 mm.  All internal walls are 0.125" (3.175 mm).  The overall chiller plate is 0.625" (15.9 mm) thick with channel depths of 0.50" (12.7 mm).   The inlet and the outlet ports are both  0.125" NPT.   Prior to machining the Aluminum plate is about 1487 grams and when completed it weighs about 713 grams.

Edited 10/21/19,
Edited 12/13/19

DSC06602 picture of the top view of the HyPer 9DHV Chill Plate. Version 1.0

DSC06603 picture of the 0.125" inlet and outlet ports for the Hyper9DHV chill Plate.  Version 1.0

The four mounting holes in the chiller plate align exactly with the four mounting holes of the controller.  After application of an RTV type of sealant, the chiller plate is bolted cavity upward between the base of the controller and the mounting platform located directly above the motor.

Swap out of Warp 11 DC motor with a Hyper 9DHV 3 Phase Motor.

When the HyPer 9 initially was introduced by Netgain, it was designed for a voltage range between 60 and 130.  NetGains recent introduction of a higher voltage motor HyPer9-DHV (dual shaft high voltage) allows for operation in the voltage range of 90 to 180 volts.  This higher voltage allows the current Tesla based battery pack (6 cells), with nominal voltage of 144 volts, to be used with either the DC or the AC motor.   One of the goals of the build was to create two separate drive trains that can be swapped out with a minimum amount of effort.  In principle, one might be able to drive DC in the morning (high performance) and AC in the afternoon (in cruising mode).  To that end, each motor has now been attached to its own Getrag 5 speed manual transmission, adapter plate, racing clutch, and motor controller.  Using the components previously described in this blog for the Warp 11 drive train,  the adapter plate (8/31/12), hub adapter (8/24/12), and Stage 2 racing clutch (5/3/13)  were all used without modification when combined with the Hyper 9-DHV.  The controller mounting platform, on the other hand, will need to be different to accommodate the different motor and controller dimensions.

In this build the Warp 11 was configured to use the Soliton1 controller, but other brands of controllers could have been used just as effectively.  In contrast, the HyPer 9-DHV can only operate using the factory supplied AC controller that is matched to the motor. 

DSC06606 showing top view of the HyPer 9 -DHV 3 phase motor (serial number H9DHV000025).

DSC06607 showing the terminal and accessory plate end view.  The motor serial number label is located on the standoff that supports the terminal strip.  In older dual shaft motors (shown) the serial number is sometimes harder to read as it can be obstructed.  updated 8/21/21

In this fresh out of the box picture of a single shaft Hyper9 HV motor, the serial number is much easier to read. updated 8/21/21

IMG1794 Showing motor serial numbers and rating.  The sticker on the encoder (center) is the SME serial number for the motor (9704670001).  The NetGain Motors serial number, for this example of a HyPer9 HV single shaft motor, is H9HV000001.  The maximum mechanical rating for this motor is 8,000 rpm.  The S1 rating (continuous operation rating) is 3,600 rpm. 

A chart that describes the various S Ratings and Duty Cycles of  electric motors can be found here: 

https://endless-sphere.com/forums/viewtopic.php?t=328  

updated 8/23/2021

DSC06605 showing the drive end view.  There are four mounting holes located at 45 degrees and 135 degrees

DSC06608 showing the three phase terminals at the accessory plate end.  These hex head bolts are Zinc plated M10-1.5x15 and the measured outer diameter of the bolts is 9.82 mm (0.3865 inch).  Updated 6/22/2021

Netgain001 Photo of disassembled Hyper 9HV 3 phase motor provided by Hunter at Netgain Motors.

updated 11/16/2019


                             

DSC01913 Showing how the motor windings (red at bottom) are crimp connected (shown exposed on the left) to the W, U, and V terminals shown in picture DSC06608 above.  updated 7/4/2023

Comparison of the HyPer 9 DHV with the Warp 11

                                              HyPer9 DHV                   Warp 11

Voltage Range                       90-180                              48-170
Voltage Nominal                   144                                    144
Current                                   500                                    up to 2000
Efficiency Peak                      95%                                  91.3%
kW Peak                                 100 kW @ 170 volts        340 kW
kW Continuous                       38 kW @ 3600 rpm         32 kW
RPM Peak                               8000                                 5800
RPM Nominal                         3600                                 2200  
Torque                                     162 lb-ft @ 0 rpm            135 lb-ft @ 450 amps
Regen                                       yes                                   none
Motor Diameter (end plate)     9.25"                                11.5"
Motor Diameter (body)            8.66"                                 
Motor Length (face to face)     14.625"                            17.46"
Motor Weight (pounds)            120                                   229
Controller Weight                     7.77                                  33
Shaft                                          double ended                   double ended
Shaft diameter                           1.125  (keyed 0.25")       1.125  (keyed  0.25")
Mounting bolt pattern               B Face (Warp 9)  4 x       B Face (Warp 9)  8 x 3/8-16
Insulation                                  Class H                             Class H
Software                                    Smartview                        Soliton 1
Terminal Studs                          8 mm-1.25
Brushes                                      none                                 Dual Wafer Helwig Carbon
Motor Type                                SRIPM                            Series Wound DC

The HyPer9 DHV data sheet can be found here: 
https://www.go-ev.com/PDFs/HyPer_9HV_Sales_Sheet.pdf  

Hyper9 HV User Manual (as of 5/20/2022)  

https://www.go-ev.com/PDFs/HyPer_9HV_IS_User_Manual_REV09.pdf  

Hyper9 User Manual (as of 5/20/2022)

https://www.go-ev.com/PDFs/HyPer_9_IS_User_Manual_REV09.pdf  

updated 5/20/2022

The Warp 11 data sheet can be found here:
https://www.go-ev.com/PDFs/002_05_06_WarP_11_Sales_Sheet.pdf 

updated 10/27/2019