Orion BMS

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READ THIS FIRST, Important things to read first that will save you time and possibly a battery pack or BMS. 1 The BMS chassis must be grounded to properly bypass electrical noise to the chassis. ground A grounding lug is provided for this purpose Additionally eternal tooth lock washers. can be used on mounting screws to ensure good electrical connectivity between the chassis. and the Orion BMS Ground straps should be as short as possible using as large gauge wire as. 2 The BMS must have a way of shutting off any connected charger load source or. any other means of charge and discharge The charge safety signal is designed to be used. as an emergency backup if a digital CAN control or digital charge enable signal fails If the. charger does not support an analog shutoff an AC relay can be used in series with the charger. power supply This is your last line of defense if a failure occurs and should not be omitted In. addition to the above safety the battery charger should be programmed such that it does not. exceed the maximum pack voltage such that if a failure occurs the charge energy is limited. 3 The voltage tap connectors should be DISCONNECTED from the BMS when being. wired or when wiring is being modified for personal safety and to prevent damage Wiring. while connected to the BMS may pose a personal safety hazard since the remaining wires. within the cell group can become hot due to internal protection diodes Additionally wiring with. the BMS connected significantly increases the risk of damage to the BMS and damage to. the BMS from mis wiring or misuse is not covered under warranty. 4 Always verify voltage taps are wired correctly before plugging them into the Orion BMS. Failure to do so may result in damage to the BMS Damage to the BMS from mis wiring or. misuse is not covered under warranty and some incorrect wiring may pose a personal safety. issue from energy from the battery pack, 5 Safety disconnects and fuses must be located on a multiple of 36 cells or the BMS must be. wired such than safety disconnects fall on those breaks Read Safety Disconnects and Fuse. Position for more information Failure to comply may cause damage to the BMS if a fuse blows. or if the safety disconnect is removed and will not provide required safety isolation Read the. entire section on BMS wiring before wiring, 6 The BMS is only capable of monitoring cells connected to it is only capable of following. the programming it is given and must be used in a way that it can control the loads to the. entire battery pack Make sure that all cells are connected to the BMS and that all current is. measured by the hall effect current sensor It is the user s responsibility to determine and. supply the correct programming parameters such as maximum cell voltage minimum. cell voltage maximum temperature etc, 7 While every effort is made to ensure that the Orion BMS operates properly under all. conditions it is the user s responsibility to integrate properly into the application such that any. failure is a safe failure For more information please read Failure Modes in the operational. manual The Orion BMS is not to be used for life support systems medical applications. or other applications where a failure could cause damage to property or cause bodily. harm or death, 8 Paralleling separate strings of li ion batteries together requires controls that can disconnect.
each string from each other and special considerations and is not recommended this is. different from paralleling cells inside of a single string. 9 The Orion BMS can be connected to a high voltage battery pack Due to this hazardous. voltages may be present inside the unit There are no user serviceable parts inside the unit and. opening the enclosure will void the warranty Further a damaged unit may pose additional risks. and a users should never attempt to repair an Orion BMS unit. The most up to date Orion BMS manuals can be downloaded for free at www orionbms com. Determining which BMS to order, In order to reduce costs the Orion BMS is offered with various numbers of cell group. locations populated Please carefully read Wiring the BMS before determining how many cell. BMS you require Ideally the BMS can be ordered sized to the actual number of cells you. have however depending on the placement of fuses safety disconnects or and any high. resistance busbars wires the BMS may need to be sized for substantially more cells than the. pack actually has For example a battery that has 48 cells may require a BMS that supports 60. or 72 cells depending on where high impedance busbars or fuses are located The Orion BMS. is available in increments of 12 cells from 12 cells to 180 cells Multiple units can be connected. together in series to support more than 180 cells, The following table shows the standard available ordering options Additional custom. configurations can be requested,108 Cell Size Enclosure. BMS Size Cell Groups Populated BMS Size Cell Groups Populated. 12 1 48 S 1 2 and 4 5,24 1 2 60 1 2 3 4 5,24 S 1 and 4 72 1 2 3 4 5 6. 36 1 2 3 84 1 2 3 4 5 6 7,36 S 1 2 and 4 96 1 2 3 4 5 6 7 8.
48 1 2 3 4 108 1 2 3 4 5 6 7 8 9, S ordering options are designed to provide 2 5kV isolation between cell groups. 180 Cell Size Enclosure,BMS Size Cell Groups Populated. 120 1 2 3 4 5 6 7 8 9 10,132 1 2 3 4 5 6 7 8 9 10 11. 144 1 2 3 4 5 6 7 8 9 10 11 12,156 1 2 3 4 5 6 7 8 9 10 11 12 13. 168 1 2 3 4 5 6 7 8 9 10 11 12 13 14,180 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15.
Included with the standard BMS, Voltage tap connectors crimps number depends on the number of cells ordered. Power connector crimps, Current sensor connector crimps BMS side current sensor side included if current. sensor is ordered with BMS,HV Pack voltage sensor connector crimps. Ordering Options, The Orion BMS is available with different number of cell groups populated to reduce. costs For example a BMS with 72 cells is available such that an application requiring. less than that does not require a 108 cell version. Non standard CAN termination point options, 2 size enclosures are available maximum of 108 or 180 cells.
Current sensor options 200A 500A 600A 750A and 1000A. Various thermistor options are available,Pre assembled wiring harnesses are available. See Purchasing Guide for details on ordering options. Overview of Theory of Operation, The Orion BMS protects and monitors a battery pack by monitoring several sensors. and uses several outputs to control charge and discharge into the battery The BMS relies. on inputs from cell voltage taps the total pack voltage tap a hall effect current sensor and. thermistors Using the programmed settings the BMS then controls the flow of current into and. out of the battery pack through calculating charge and discharge current limits via the CAN bus. or via analog reference voltages or via simple on off digital signals depending on which style. is appropriate for the application The BMS relies on the user to provide external controls that. respect the current limits set by the BMS to protect the batteries as the BMS does not have. integrated switches During and immediately after charging the BMS will balance the cells. using internal shunt resistors based on the programmed settings. The Orion unit monitors each individual cell tap to insure that cell voltages are not too. high or too low in accordance with the values programmed in Using the cell voltages the. amperage going in and out of the pack provided by the current sensor and programmed. values in the battery pack profile the BMS calculates the pack and individual cell s internal. resistance and open cell voltages From those calculations the the maximum charge and. discharge current limits are calculated and adjustments are made to the pack s calculated state. of charge if necessary These calculations are also used in monitoring the health of the pack. Charge and discharge current limits are provided on the CAN bus and can be programmed to. trigger on off digital outputs to allow or deny charging and discharging of the battery pack. Additionally the BMS has many redundant safeties most of which are transparent to. the user For example the BMS monitors each individual cell voltage as well as the total pack. voltage If the 2 voltages disagree by a set amount determined in the programmable profile. the BMS will set an error code and go into a fail safe mode The BMS also can be programmed. to monitor for a breakdown in isolation between the battery pack and BMS s ground to detect a. failure of the current sensor and many other internal failures Please see failure modes in the. operational manual for more information on failure modes. Wiring the BMS,Overview of system connections,Connector locations on the Orion BMS. Ground Lug, A ground lug is provided on the outside of the enclosure The BMS MUST be grounded to a. vehicle chassis or Earth ground if stationary to function properly. Main I O Connector,Signal Name Description, CAN1 H CAN1 L First CAN interface with high and low signal lines With the default.
ordering option this interface includes a termination resistor. CAN2 H CAN2 L Second CAN interface with high and low signal lines With the. default ordering option this interface is without a termination. Always On AM Power Always on battery source This should be connected to a 12v. Source nominal power source which is always powered otherwise. accumulated data is reset If this line is not powered while. READY or CHARGE power source is present an error code is set. READY Power Source This 12v power source should be connected to a 12v nominal. power source whenever the BMS should be active for normal use. This line will cause the BMS to wake up and resume from sleep. CHARGE Power Source This power source should be connected to a 12v nominal power. source whenever the BMS should be active while a charger is. connected This power source should not be active when the. READY power source is active, Power Ground 2x This is the ground for the supply power sources for the BMS All 3. power sources AM READY and CHARGE use this ground For. convenience 2 ground pins are provided for tying multiple grounds. together though only one is needed, Charge Enable Signal An open drain digital on off signal used to signal to a load. Out that the load can charge the battery This would normally be. used to control regen in an electric vehicle or enable a charge. contactor in a stationary application This signal can be used as. a backup to digital CAN communication with a controller This is. a signal current level and should be amplified for controlling large. contactors or relays see electrical specs, Charge Safety Signal An open drain digital on off signal used as a safety switch for. Out a charger This signal must be connected to the charger or be. connected to a relay which enables AC power to the charger such. that the lack of this signal will cause the charger to be inactive. This is a signal current level and should be amplified for controlling. large contactors or relays see electrical specs, Discharge Enable Signal An open drain digital on off signal used to signal to a load that. Out the load can discharge the battery This would normally be used. to control a discharge contactor or to signal to a controller that. discharge must be stopped if this signal is not present This signal. can be used as a backup to digital CAN communication with a. controller This is a signal current level and should be amplified. for controlling large contactors or relays see electrical specs. Fan power signal This signal is used to turn on a relay to supply the battery cooling. fan with power or ground depending on the configuration This is. an on off line that is turned on only when the fan is active. Fan PWM signal This signal is used to control an external switch MOSFET to vary. the battery cooling fan speed This PWM signal is between 10. and 90 duty cycle full range is not used in order to monitor fan. performance, Fan monitor signal The fan monitor signal is used to monitor the external fan voltage.
If the BMS is commanding a certain level of fan power but the. voltage does not match an error code is set, CCL DCL SOC AMPS 0 5V analog outputs that represent charge discharge current. analog 5v outputs limits state of charge and instantaneous amperage available on. rev B Orion BMS units only, Ignition Signal This signal is not used and is reserved for future use It does not. need to be populated,Current Sensor Thermistor Connector. Signal Name Description, Thermistor GND 4x One leg of each of the 4 thermistors should be grounded to one. of these grounds Any thermistor can be grounded to any of the. available thermistor ground pins order does not matter and all can. optionally be grounded to one pin, Thermistor 1 2 3 Three main thermistors returns non grounded lead of the.
thermistor These thermistors are the main battery pack. temperature sensing thermistors that are embedded into the pack. Thermistor 4 This thermistor can be used as either an additional pack thermal. sensor or can also be used as an air intake temperature sensor to. measure ambient air temperature for more intelligent control of the. Current Sensor Vdd 5v supply provided to the external hall effect current sensor. Current Sensor Chan 1 First current sensor channel This is the more sensitive of the 2. can be used on mounting screws to ensure good electrical connectivity between the chassis and the Orion BMS The most up to date Orion BMS set by the BMS to

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