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Orion BMS Operation Manual
Rev 2.1
The Orion BMS by Ewert Energy Systems is designed to manage and protect Lithium ion
battery packs and is suitable for use in electric, plug-in hybrid and hybrid electric vehicles as well as
stationary applications.
Orion BMS Operation Manual
2
Table of Contents
Overview of Theory of Operation ........................................................................................................ 4
Setting up the BMS .............................................................................................................................. 5
Wiring .............................................................................................................................................................................. 5
Software .......................................................................................................................................................................... 5
Testing ............................................................................................................................................................................. 5
How the Orion BMS Works .................................................................................................................. 6
Changing and Uploading Settings ................................................................................................................................... 6
Basic Data Collection ...................................................................................................................................................... 6
CHARGE and READY Modes ......................................................................................................................................... 8
Charge Interlock .............................................................................................................................................................. 8
Charge and Discharge Current Limits ............................................................................................................................. 9
How the BMS Calculates Current Limits ....................................................................................................................... 10
Selecting Current Limit Settings .................................................................................................................................... 12
State of Charge Calculation .......................................................................................................................................... 14
Why SOC Correction Drifts Happen .............................................................................................................................. 15
Determining State of Charge Correction Drift Points..................................................................................................... 17
Temperature Capacity Reduction .................................................................................................................................. 18
State of Health Calculation ............................................................................................................................................ 19
Internal Resistance ....................................................................................................................................................... 19
How the BMS Calculates Internal Resistance ............................................................................................................... 20
Determining Nominal Resistance .................................................................................................................................. 20
Isolation Fault Detection ................................................................................................................................................ 22
Controlling Loads and Chargers ................................................................................................................................... 23
Digital On/Off Outputs (Relay Outputs) ......................................................................................................................... 23
CANBUS Communication ............................................................................................................................................. 29
Analog 5v Outputs ......................................................................................................................................................... 29
How Balancing Works ................................................................................................................................................... 30
Busbar Compensation ................................................................................................................................................... 33
Virtual Battery and Drive Modes.................................................................................................................................... 35
Thermal Management and Fan Controller .................................................................................................................... 36
Multi-Purpose Input ....................................................................................................................................................... 37
Multi-Purpose Output .................................................................................................................................................... 38
Power-On Signal Output ............................................................................................................................................... 39
Collected Statistics (Cell Warranty Data) ...................................................................................................................... 39
Failure Mitigation ............................................................................................................................... 40
Understanding Failure Modes ....................................................................................................................................... 44