Ewert Energy Systems Orion Jr. 2 BMS Manual de usuario

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

golf carts and material handling equipment.

 Orion Jr. 2 BMS Wiring Manual  
 
2 
 
 
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 .................................................................................................................................. 10 
Interfacing the Load and Charger with the BMS.............................................................................. 11 
Current Limiting via the digital CANBUS (CAN-enabled units only) .......................................................................................11 
Current limiting via the analog voltage outputs.......................................................................................................................12 
Current limiting via an on/off signal from the BMS..................................................................................................................12 
Notes for specific applications................................................................................................................................................12 
Digital RS232 Serial Communication ............................................................................................... 13 
Straight Through Pinout .........................................................................................................................................................13 
Mating Connector Part Numbers ............................................................................................................................................13 
Main Input/Output (I/O) Connector ................................................................................................... 14 
Wiring Main Connector...................................................................................................................... 16 
Fusing ....................................................................................................................................................................................16 
Power Supplies ......................................................................................................................................................................16 
LED Status Light ....................................................................................................................................................................18 
Wiring CAN interfaces ............................................................................................................................................................18 
Wiring digital signal outputs....................................................................................................................................................19 
Checking open drain outputs..................................................................................................................................................23 
Wiring the multipurpose input.................................................................................................................................................23 
Wiring the analog 0-5V outputs ..............................................................................................................................................23 
Thermistors (Pins 10, 12, 16, and 8) ......................................................................................................................................24 
Wiring Voltage Taps........................................................................................................................... 25 
Safety Disconnects and Fuse Position ...................................................................................................................................28 
Current Sensor.......................................................................................................................................................................29 
Wiring for high impedance cables and busbars......................................................................................................................30 
Skin effect issues due to AC currents.....................................................................................................................................32 
Transients...............................................................................................................................................................................33 
Wiring Errors ..........................................................................................................................................................................34 
Voltage tap harness lengths ...................................................................................................................................................34 
Internal Isolation .....................................................................................................................................................................35 
Fuses on voltage tap wires.....................................................................................................................................................35 
Physical routing and installation of wires................................................................................................................................35 
Verifying Cell Voltage Tap Wiring...................................................................................................... 36 

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....................................................................................................................................41

Reason: Transients (and shorts within the high voltage battery pack)....................................................................................41

Reason: Extremely weak cell, internal cell failure (fairly rare) ................................................................................................42

Fuses in the Orion Jr. 2 BMS .................................................................................................................................................42

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. Proper integration, selection of components, wire selection,

installation, routing of cables and interconnects, and the determination of the suitability of this product

for the application are fully the responsibility of the integrator. Do not use this product if you are unsure

if you have the necessary skills to complete this integration.

1.) The BMS must have a means of controlling and shutting off any connected charger, load,

source or any other means of charge and discharge. At least two shutoff mechanisms should be

present to turn off a charger. 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 the 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 if a failure occurs.

2.) The voltage tap connectors must be DISCONNECTED from the BMS while any battery wiring

is being modified for personal safety and to prevent damage. Wiring while connected to the BMS

may pose a personal safety hazard and/or fire risk since the remaining wires within the cell group can

become electrically ‘hot’ due to internal protection diodes. Additionally, wiring with the BMS connected

significantly increases the risk of damage to the BMS. Damage to the BMS from mis-wiring,

misuse, or altering battery wiring while the BMS is connected is not covered under warranty and may

pose a personal safety and/or fire risk. Immediately disconnect the BMS from the battery if the

BMS is damaged.

3.) Always verify voltage taps and current sensor wires are wired correctly before plugging them

into the Orion Jr. 2 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 risk or fire risk from energy from the battery pack. Please see the section “Verifying Cell Voltage

Tap Wiring” for methods of testing to ensure the voltage taps are wired properly. Immediately

disconnect the BMS from cells if it is incorrectly wired. Leaving the BMS connected to cells when

incorrectly wired may drain incorrectly wired cells, even when the unit is turned off which may

permanently damage connected cells.

4.) All battery packs must be protected from over-current with a suitable current limiting device such as

a fuse. If a fuse or safety disconnect is positioned between the first and last cell of a battery

pack, they must be wired in certain ways. If you are using a fuse or safety disconnect between the

first and last cell, it is critical to read the entire section on Safety Disconnects and Fuse Positions

before wiring the BMS. Failure to comply may result in catastrophic failure of the BMS from full

stack potential present across two adjacent cell taps if a fuse blows or if the safety disconnect

is removed. Read the full wiring manual before wiring the BMS, especially the cell tap

Orion Jr. 2 BMS Wiring Manual

harnesses.

5.) Make sure that all cells are connected to the BMS and that all current is measured by the current

sensor. It is the user’s responsibility to ensure the BMS is connected to all cells to verify the

BMS has a method to limit current in and out of the pack and to determine and supply the

correct programming parameters (such as maximum cell voltage, minimum cell voltage,

maximum temperature, etc.)

6.) While every effort is made to ensure that the Orion Jr. 2 operates properly under all conditions, it is

the integrator’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 integrator is

responsible for the determination of suitability of wire, wiring methods, interconnects, and complying

with any regulations, standards, or codes. The Orion Jr. 2 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.

7.) Paralleling separate strings of li-ion batteries together requires special considerations and a method

to isolate each string from each other. One Orion Jr. 2 BMS per parallel string is required. The Orion Jr.

2 BMS may not be used with parallel string configurations unless specific external safety

systems are provided. Engineering work by a qualified electrical engineer is required for use

with parallel strings. If you are using the Orion Jr. 2 in a parallel string setup, please see the section

about parallel strings (Note: this is different from paralleling cells inside of a single string which is very

common and can be done with a single BMS.)

8.) Because the Orion Jr. 2 BMS is connected to a high voltage battery pack, hazardous voltages and

hazardous energies may be present inside the unit. There are no user serviceable parts inside the unit

and opening the enclosure or user attempted repairs will void the warranty. Users should never

attempt to repair an Orion Jr. 2 BMS unit. Further, a damaged unit or a unit repaired without

authorization may pose additional safety risks. DAMAGED UNITS SHOULD BE IMMEDIATELY

DISCONNECTED FROM ALL POWER INCLUDING THE BATTERY PACK AND REMOVED FROM

SERVICE. NEVER CONTINUE TO USE A DAMAGED BMS UNIT. Please contact the factory or your

local distributor for repair options. Ewert Energy is not liable for damage caused by user attempted

repairs or continued use of a damaged BMS unit.

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. Orion Jr. 2 units

may not be used in series to obtain pack voltages above the 60V maximum. For applications

requiring working voltages above 60 VDC, please consider our standard Orion 2 BMS.

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

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. 2 unit are available for cost savings including units supporting fewer cells.

Included with the Jr. 2 BMS

●Main BMS unit

Optional

●CANBUS support

●Hall-effect current sensor options

●Pre-assembled wiring harnesses

●Basic displays, data loggers, and PC interfaces are also options

See “Orion Jr. 2 Purchasing Guide” for details on ordering options

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. Using user-programmed

settings, the BMS then controls the flow of current into and out of the battery pack by broadcasting

charge and discharge current limits (via analog voltage references or optionally via a CANBUS) or

through simple on/off digital signals depending on which style is appropriate for the application. The

BMS relies on the user to provide external controls to enforce the current limits set by the BMS to

protect the batteries since 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 Jr. 2 unit monitors each individual cell tap to ensure that cell voltages are not too high or too

low (in accordance with the user-programmed values). 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’s internal resistance, the internal resistance of each cell, and open cell

voltages. From those calculations, 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

CANBUS or serial bus and can be programmed to trigger on/off digital outputs to allow or deny

charging and discharging of the battery pack.

Orion Jr. 2 BMS Wiring Manual

Mounting

Physical Mounting

The Orion Jr. 2 can be mounted in any orientation. Two mounting flanges are provided on the top and

bottom for mounting. The BMS is rated to operate in the temperature range of -40C to +80C and is

designed for use in moderately protected locations. If the BMS will be in a location exposed to harsh

environments such as liquid spray, salt spray, heavy condensation, or other similar conditions, it must

be located inside a suitable protective enclosure which provides sufficient heat transfer and protection

against water ingress and other elements. It should be noted that lithium batteries themselves must

also typically be protected from these harsh environmental elements.

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.

Thermal Information

The Orion Jr. 2 requires unobstructed, adequate ventilation and must not be surrounded or

sealed by thermal insulating material. Blocking ventilation or thermally insulating the unit may

pose a fire hazard. During certain abnormal fault conditions, the unit has the potential to generate as

much as 35 watts of heat. Ventilation must be adequate for this amount of heat even though it will not

be generated under normal use.

During normal use, measurable heat is only generated while the BMS is performing balancing, at which

time the BMS may dissipate up to 12 watts of heat from normal use. Normal heat dissipation is only

around 1 – 2 watts when balancing in inactive.

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

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