Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Ewert Energy Systems Orion Jr. 2 BMS
Summary of Contents for Ewert Energy Systems Orion Jr. 2 BMS
- Page 1 Wiring & Installation Manual Revision 3.3 The Orion Jr. 2 BMS by Ewert Energy Systems is designed to manage and protect Lithium ion battery packs and is suitable for use in stationary energy storage and small mobile applications such as...
-
Page 2: Table Of Contents
Orion Jr. 2 BMS Wiring Manual Table of Contents SAFETY: READ THIS FIRST ........................ 4 Determining which BMS to order ......................7 Overview of Theory of Operation ......................8 Mounting .............................. 9 Physical Mounting ..................................9 Thermal Information ................................. 9 Wiring the BMS .......................... - Page 3 Orion Jr. 2 BMS Wiring Manual Why Orion Jr. 2 BMS Internal Fuses Blow ..................37 What causes the fuses to blow? ............................. 37 Reason: Altering wiring with the BMS connected (or loose busbar) ..................38 Reason: Cell tap wires reversed............................. 40 Reason: Accidental contact to cell tap ............................
-
Page 4: Safety: Read This First
Orion Jr. 2 BMS Wiring Manual SAFETY: READ THIS FIRST Important things to read first that will save you time and possibly a battery pack or BMS. This product is designed to be integrated into an application. Integration must be performed by a qualified person trained in electrical engineering and familiar with the characteristics and safety requirements of lithium batteries. - Page 5 9.) The Orion Jr. 2 unit is rated for working voltages not to exceed 60 volts DC (48 VDC nominal). The Orion Jr. 2 BMS may not be used if the voltage between any two points in the battery pack or the voltage between any 2 pins on the BMS will exceed 60 VDC at any point in time.
- Page 6 Orion Jr. 2 BMS Wiring Manual ALWAYS READ THE MANUAL BEFORE USE The most up to date Orion Jr 2 BMS manuals can be downloaded at: www.orionbms.com/downloads...
-
Page 7: Determining Which Bms To Order
Orion Jr. 2 BMS Wiring Manual Determining which BMS to order The Orion Jr. 2 BMS is available off the shelf in two configurations – with CANBUS and without CANBUS. Both standard configurations support 1 to 16 cells. In larger volumes, customized versions of the Orion Jr. -
Page 8: Overview Of Theory Of Operation
Orion Jr. 2 BMS Wiring Manual Overview of Theory of Operation The Orion Jr. 2 protects and monitors a battery pack by monitoring several sensors and uses several outputs to control charge and discharge into the battery. The BMS measures inputs from cell voltage taps, the total pack voltage tap, a hall-effect current sensor, and thermistors. -
Page 9: Mounting
The BMS and all wiring connecting to the BMS should be mounted such that it is separated from flammable materials. The Orion Jr. 2 BMS may not be used in environments where combustible gasses may be present. -
Page 10: Wiring The Bms
Orion Jr. 2 BMS Wiring Manual Wiring the BMS Overview of system connections Connector locations on the Orion Jr 2. BMS as looking at the BMS from the top... -
Page 11: Interfacing The Load And Charger With The Bms
Orion Jr. 2 BMS’s capabilities. For example, if the BMS is being used in a light vehicle, it is desirable for the vehicle to gradually slow down when the battery is exhausted rather than suddenly cut out when the battery is depleted. -
Page 12: Current Limiting Via The Analog Voltage Outputs
Current limiting via the analog voltage outputs. The Orion Jr. 2 BMS is equipped with two analog voltage outputs which can be used to communicate the amperage limits to external devices. Pin 16 (Discharge Current Limit or DCL) and Pin 5 (Charge Current Limit or CCL) are both outputs which range from 0 to 5 volts and provide an analog representation of the maximum current limits (0V = 0%, 5V = 100% of the maximum limit). -
Page 13: Digital Rs232 Serial Communication
Orion Jr. 2 BMS Wiring Manual Digital RS232 Serial Communication The Orion Jr. 2 unit must be programmed using a computer and the Orion Jr. 2 BMS utility in order to operate. The BMS will not function until programmed. The necessary utility can be downloaded from www.orionbms.com/downloads. -
Page 14: Main Input/Output (I/O) Connector
Orion Jr. 2 BMS Wiring Manual Main Input/Output (I/O) Connector Looking into back of connector (wires coming toward viewer) Signal Name Description 1. Charge Enable Signal An open drain digital on/off signal used to signal to a load that the (Out) load can charge the battery. - Page 15 Orion Jr. 2 BMS Wiring Manual 5. Charge Safety Signal An open drain digital on/off signal used as a safety switch for a (Out) charger. This signal is normally connected to the charger or 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.
-
Page 16: Wiring Main Connector
Wiring Main Connector Fusing Important: As with all electrical devices, all wires connected to the Orion Jr. 2 BMS unit must be current limited at their source. Any circuit connecting to the BMS must be current limited with an appropriately sized fuse (or other current limiting device) to prevent overloading wires in the event of a short. - Page 17 Lithium-ion cells can be destroyed in one cycle when over-discharged. Ready Power Source: This is the primary power source for the Orion Jr. 2 BMS unit. This power source can be thought of as the “ignition” power source when the BMS is used in mobile applications.
-
Page 18: Led Status Light
Controller Area Networks (CAN) require exactly two 120 ohm termination resistors on the two physical ends of the bus to operate properly. Unless specifically ordered without, the Orion Jr. 2 BMS contains one 120 ohm termination resistor inside the unit. A CANBUS can have many nodes attached to a single bus. -
Page 19: Wiring Digital Signal Outputs
Orion Jr. 2 BMS Wiring Manual Wiring digital signal outputs The Orion Jr. 2 has 6 signal level digital I/O outputs - Charge Enable, Discharge Enable, Charger Safety, Multi Purpose Enable, Multi Purpose Output 1, and Multi Purpose Output 2. These outputs are open drain outputs which means that they do not source any current or voltage, but rather pull down to ground and sink current when they are turned on. - Page 20 One is commonly used as an output to signal whether an error code is present and can be used to drive an error LED, such as the LED on the Orion Jr. 2 BMS basic display board. These outputs are...
- Page 21 Orion Jr. 2 BMS Wiring Manual outputs are not watchdog backed and will not turn off in the event of certain faults. These two outputs should not be used as the sole mechanism to control charge sources or discharge loads.
- Page 22 Orion Jr. 2 BMS Wiring Manual A sample schematic for connecting the open drain outputs with an opto-isolator (resistor values must be calculated based on voltage and opto- isolator requirements). If the signals will be used to drive relays with coils larger than 175mA, contactors, or other loads, an amplification method must be used so that the BMS does not sink more than the maximum allowable current.
-
Page 23: Checking Open Drain Outputs
Orion Jr. 2 BMS Wiring Manual Checking open drain outputs Open drain outputs will read zero volts on a voltmeter whether or not they are on since they sink current rather than source it. A simple method for testing the outputs is to connect an LED or small light bulb (under 100mA) between the output pin and +12v. -
Page 24: Thermistors (Pins 10, 12, 16, And 8)
The thermistors sold with the BMS are 10K NTC thermistors with a B25/50 value of 3380K. Other B values can be used with the Orion Jr. 2 BMS by changing the B value in the profile configuration settings. One end of the thermistor is connected to the appropriate thermistor pin and the other is grounded to the thermistor ground pin. -
Page 25: Wiring Voltage Taps
Disconnect and Fuse Locations” for more information. The Orion Jr. 2 BMS is designed to manage as many as 16 cells, up to a maximum possible voltage of 60V DC, whichever is lower. For the purpose of this document, a “cell” refers to one or more cells directly paralleled together. - Page 26 Orion Jr. 2 BMS Wiring Manual Wiring - Full 16 Cells The above image is standard wiring when used with 16 cells. Rules for fewer than sixteen cells ● If fewer than twelve cells are populated in group 1 or fewer than four cells in group 2, unpopulated cells in that group must all be connected to the positive terminal of the highest potential cell in that group.
- Page 27 Orion Jr. 2 BMS Wiring Manual Wiring Example - 15 Cells Wiring example for 15 cells in series. Tap 16 and 15 both attach to positive terminal on cell 15. Wiring Example - 8 Cells Wiring example for eight cells in series. Taps 8-16 are unused and left disconnected.
-
Page 28: Safety Disconnects And Fuse Position
The Orion Jr. 2 BMS has internal protection diodes within each cell group that can pass current from one cell to another if the voltage of the adjacent cell is more than 5V or less than 0V. -
Page 29: Current Sensor
Orion Jr. 2 BMS Wiring Manual Current Sensor The standard current sensors sold with the Orion Jr 2 are a combination of two current sensors built into a single unit for improved accuracy. One of the current sensor channels is smaller than the other and is used for measuring small currents while the other is used for measuring larger currents. - Page 30 Orion Jr. 2 BMS Wiring Manual Current Sensor Pinout Description 1 (A) +5V Current Sensor Power 2 (B) Current High Channel 3 (C) Current Sensor Ground 4 (D) Current Low Channel Wire side of current sensor connector that connects to the BMS...
-
Page 31: Wiring For High Impedance Cables And Busbars
Orion Jr. 2 BMS Wiring Manual Wiring for high impedance cables and busbars Voltage measurements are taken by the Orion Jr. 2 with respect to the next lowest cell or the negative wire in each cell group. For example, when the Orion Jr. 2 measures cell 1’s voltage, it measures the voltage between tap 1- and 1. -
Page 32: Skin Effect Issues Due To Ac Currents
Orion Jr. 2 BMS Wiring Manual Voltage drop under load from an uncompensated high impedance busbar (blue) Maximum voltage swing can be calculated if the maximum cell voltage, resistance of the busbar / cable, and maximum amperage are known using the following formulas. Please keep in mind that the resistance of the busbar or cable must include the resistance of the terminal and any crimps. -
Page 33: Transients
Jr. 2 BMS as these configurations can cause damaging transients. Excessive transients may cause damage to the Orion Jr. 2 BMS unit or to connected lithium ion cells. In the event that excessive transients have occurred, the Orion Jr. 2 unit and lithium cells should be immediately inspected or tested for damage as damage can lead to safety risks. -
Page 34: Wiring Errors
Wiring Errors Wiring errors can cause serious damage to the Orion Jr. 2 BMS that is not covered under warranty. The Orion Jr. 2 has internal fuses on each cell tap wire to protect the BMS and connected wiring from excessive currents. -
Page 35: Internal Isolation
1 and 2 for functional purposes only. Fuses on voltage tap wires The Orion Jr. 2 BMS has internal fuses on each of the positive cell tap wires. While these fuses protect the BMS, guard against excessive current flowing through the internal protection diodes, and are... -
Page 36: Verifying Cell Voltage Tap Wiring
It is strongly recommended to use the validation tool before plugging the harness into the Orion Jr. 2 BMS as it is very easy to make an error wiring the harness, and errors may not be obvious. -
Page 37: Why Orion Jr. 2 Bms Internal Fuses Blow
Why Orion Jr. 2 BMS Internal Fuses Blow The Orion Jr. 2 BMS has an internal fuse for each of the cell voltage tap wires. These fuses are designed to blow in over-voltage and reverse-voltage conditions. Sufficient current to blow the fuses will only flow through the tap wires during an over-voltage or reverse-voltage condition. -
Page 38: Reason: Altering Wiring With The Bms Connected (Or Loose Busbar)
Reason: Altering wiring with the BMS connected (or loose busbar) By far, the most common cause of blown fuses and/or more serious damage to the Orion Jr. 2 BMS is when battery pack wiring is altered with the Orion Jr. 2 BMS still connected. While it may seem counter-... - Page 39 In the above example, the total pack voltage is only 13.2 volts, which may not cause damage on an Orion Jr. 2 BMS. However, if this same scenario were to occur on a higher voltage battery pack, internal fuses may blow. The below electrical diagram shows the same situation, but with a larger 158v battery pack (Note: the maximum voltage for the Orion Jr.
-
Page 40: Reason: Cell Tap Wires Reversed
Reason: Cell tap wires reversed The Orion Jr. 2 BMS is designed to survive a single tap wire reversed for short periods of time, but the unit may not survive for longer times or if multiple wires are crossed. Never leave a BMS unit connected... -
Page 41: Reason: Accidental Contact To Cell Tap
Orion Jr. 2 BMS Wiring Manual In the above schematic, cell taps 2 and 3 are reversed. This leads to 6.6v between cell taps 1 and 2 and 3 and 4 with a reverse voltage between taps 2 and 3. In this case, 4 of the zener diodes will conduct and current will flow through the tap wires. -
Page 42: Reason: Extremely Weak Cell, Internal Cell Failure (Fairly Rare)
(or in some cases reverse voltages) that can cause fuses to blow. Fuses in the Orion Jr. 2 BMS The Orion Jr. 2 BMS contains standard fuses, but also contains additional resettable fuses which protect against certain kinds of temporary lower voltage wiring faults. In most cases where the over voltage or reverse voltage conditions are less than 24 volts for less than 10 minutes, the resettable fuses will reset to normal after the fault is cleared.
Need help?
Do you have a question about the Orion Jr. 2 BMS and is the answer not in the manual?
Questions and answers