|
Configuration
|
Controller Price
US$
|
6ft Cell-Tap
Harness
|
Current Sensor
|
I/O Harness
|
8x2m Thermistors
|
CANdapter
|
Total
Price US$
|
|
13-24
Cells
|
796
|
48
|
49
|
50
|
48
|
67
|
1,058
|
|
25-36
Cells
|
896
|
75
|
49
|
50
|
48
|
67
|
1,185
|
|
37-48
Cells
|
946
|
98
|
49
|
50
|
48
|
67
|
1,258
|
|
49-60
Cells
|
1,026
|
123
|
49
|
50
|
48
|
67
|
1,363
|
|
61-72
Cells
|
1,116
|
150
|
49
|
50
|
48
|
67
|
1,480
|
|
73-84
Cells
|
1,166
|
173
|
49
|
50
|
48
|
67
|
1,553
|
|
85-96
Cells
|
1,246
|
198
|
49
|
50
|
48
|
67
|
1,658
|
|
97-108
Cells
|
1,326
|
225
|
49
|
50
|
48
|
67
|
1,765
|
Typical Complete Kit contains the
following components
Component price increases if ordered
without the controller
Summary of
Major Improvements of the Orion BMS 2
·
Significantly smaller enclosure size for 24-72 cell
configurations.
·
Roughly 40% lower weight on all models due to the
new enclosure design and streamlined (removable) heatsink. Minimum heat
dissipation requirements apply.
·
Considerable boosts in measurement accuracy and
processor speed allow for more advanced calculations and logic.
·
Direct hardware support for several popular
charging protocols including hardware support for SAE J1772 (directly
interfacing with the pilot / proximity lines) and CHAdeMO for DC fast charging.
·
Wider input power voltage range (now 12v-24vDC
compatible) for better support on heavy vehicles and equipment. The Orion 2 BMS
remains fully compatible with 12v applications.
·
Ability to directly drive certain contactors on
select inputs (bypassing the need for intermediate signal relays in some
situations)–see supporting documentation for details.
·
Completely redesigned multi-unit series
configuration (now using Remote Cell Tap Expansion Modules). This greatly
simplifies connecting multiple units together in series and improves the
overall reliability.
·
New Status LED on the unit to indicate power status
and the presence of faults.
·
Addition of 2x new Multi-Purpose Output pins with
programmable functions.
·
Significant algorithm and software enhancements to
improve overall system accuracy for parameters such as State of Charge and pack
health.
Main
Specifications:
·
A Capable of measuring up
to 180 battery cells per unit connected in series based on configuration.
·
Up to 2x Remote Cell Tap Expansion Modules can be
connected to measure higher voltage battery packs (up to 800vDC max).
·
Configurations available in increments of 12 cells
in series.
·
Centralized design provides high EMI and noise
immunity.
·
Performs intelligent cell balancing (passive).
·
Calculates state of charge (SOC).
·
Uses professional automotive-grade locking
connectors.
·
Calculates discharge current limit (DCL) and charge
current limit (CCL).
·
Can measure cell voltages between 0.5v and 5.0v.
·
Dual (x2) CANBUS 2.0B interfaces which (fully
programmable).
·
OBD2 diagnostic protocol support.
Standard
Features:
The Orion
BMS implements an extensive list of features designed to protect the battery
pack. These features include:
- Live
system support direct from Orion
- State
of charge calculations.
- Cell
over-voltage and under-voltage protection.
- Intelligent
battery balancing (passive).
- Battery
charger control.
- Pack
temperature monitoring.
- Monitors
health of battery pack.
- 200mA
cell balancing
Cells are
protected from over-voltage, under-voltage, over-current, over-temperature, and
under-temperature based on the programmed minimum and maximum values in the
battery profile.
Intelligent,
efficient cell by cell balancing is provided to maximize the usable range of
the battery. The BMS also monitors the
health of both individual cells and the total pack and will trigger error
trouble codes if either the pack or individual cells are in poor health.
· Capable of measuring
up to 108 cells connected in series based on configuration.
· Configurations
available in increments of 12 cells in series.
· Centralized design
provides high EMI and noise
immunity.
· Performs intelligent
cell balancing (passive).
· Calculates state of
charge (SOC).
· Uses professional
automotive-grade locking connectors.
· Calculates discharge
current limit (DCL) and charge current limit (CCL).
· Can measure cell
voltages between 0.5v and 5.0v.
· Dual (x2) CANBUS 2.0B
interfaces (fully programmable).
· OBD2 diagnostic
protocol support.
See
more in the Purchasing Guide
- Operating Manual (PDF)
- Troubleshooting Manual (PDF)
- Wiring Manual (PDF)
- Software Utility Manual (HTML)
- Orion BMS Technical Specification Sheet (PDF)
- Orion BMS Software Utility (Windows) (Linux) (ZIP) *Note 1: This software requires
a CANdapter to interface with a computer (PC).
CANdapter ($67)
USER
MANUAL
DRIVER.EXE
INSTALLATION
GUIDE
UTILITY
SUITE
§ Converts
CAN BUS traffic to a USB serial interface
§ Comes
with a small suite of software to allow data logging, monitoring and
interaction.
§ Makes simple the job of translating and extracting
information from a CANBUS to a computer for processing and analysis.
§ Communicates over a virtual serial port, making it
operating system independent and very simple to write programs and applications
§ Windows
2000/XP/Vista/7 - Drivers compatible with 32-bit and 64-bit distribution
§ Almost all Linux distributions have the
needed driver integrated into kernel and thus do not need any additional
driver.
Intelligent Thermistor Expansion Module ($240)
USER
MANUAL
MECHANICAL
DRAWING
§ Each
unit monitors up to 80 additional thermistors.
§ Up
to 10 modules can be used together supporting up to 800 thermistors.
§ Operates
with the Orion Battery Management System.
§ Communicates
with BMS via CANBUS (Programmable).
§ Full
automotive operating and sensing temperature range (-40C to 80C)
|
Torque Digital Touch Display
Torque is an application for Android tablets and smartphones
that interfaces with OBD2 enabled devices (via bluetooth or USB) and provides
visual feedback in the form of gauges and digital readouts of the various
parameters and values provided. Due to the flexible OBD2 support of the Orion
BMS, Torque works cleanly with the Orion BMS out of the box and many Orion
BMS customers use this display.
Disclaimer: Ewert Energy
Systems and Electric Car Parts Company are not affiliated with Torque in any
way nor do they guarantee support for Torque. Torque is copyrighted by
its owners. Please contact the authors of Torque directly for support
regarding this software.
Notable Features:
- Integrates
seamlessly with the Orion BMS for displaying parameters and viewing
& clearing error codes.
- Powerful
touch-enabled interface provides easy-to-use display.
- Entire
interface is customizable (gauge type, gauge location, gauge look and
feel, etc).
- Works
on smartphones, tablets and other Android enabled devices (device
MUST have USB host or Bluetooth capabilities depending on which adapter
is used).
- Can
be used to do data logging as well as live web-based performance
streaming.
Torque’s Official Website: http://www.torque-bhp.com
Torque’s Official Forum: http://torque-bhp.com/forums
Required items to use Torque with the Orion BMS
1. A Bluetooth Touch Screen Display (7
inch $197, 8 inch $238, 10 inch $287 all options come with a 2 year Warranty,
Industrial Strength Velcro, 5v 1A Cig Socket Charger, and 120V 15A wall charger/plug). Install your display in a location shaded
from the sun for both longevity of use and screen readability.
2. The Torque App from Google Play. ($4.95 download it
here)
Wiring the Bluetooth/USB OBD2 adapter
to the Orion BMS
Torque connects to the Orion BMS using a bluetooth to OBD2
adapter
(or a
USB to OBD2-Not suggested seeing as you can connect the Bluetooth Adapter to
the hardwired OBD2 Connector and most displays are not able to USB *HOST*).
https://www.electriccarpartscompany.com/assets/images/Torque_Orion_Li-Ion_bms_wiring.jpg
General connection diagram
One of the CAN interfaces on the Orion BMS must be connected to
the OBD2 connector that the OBD2 to Bluetooth (or USB) adapter is plugged
into. A minimum of 5 wires must be connected to the OBD2 connector to
operate:
|
OBD2 Pin #
|
Connect to
|
|
6 – CAN High
|
Orion BMS CAN1 or CAN2 High
|
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14 – CAN Low
|
Orion BMS CAN1 or CAN2 Low
|
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4 – Chassis Ground
|
12v Ground
|
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5 – Signal Ground
|
12v Ground
|
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16 – Battery Voltage
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+12V (power for adapter)
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Full OBD2 Connector Pinout: http://en.wikipedia.org/wiki/On-board_diagnostics.
The CAN network requires exactly 2 each 120 ohm termination
resistors at each physical end of the CAN network.
Note: The
baud-rate of the connected Orion BMS CANBUS interface must be either 250 Kbps
or 500 Kbps to conform to OBD2 standards. This setting is available
under “Communications Settings” in the BMS Profile section of the BMS
utility.
Note: The OBD2 ECU
ID may be changed from the default value if this ECU ID is integrated into a
vehicle that already uses this ECU ID. It is important that each ECU in
the vehicle have a unique ECU ID. This setting is available under
“Communications Settings” in the BMS Profile section of the utility.
Configuring Torque
The adapter setup portion of Torque is dependent on what OBD2
adapter is being used. Please consult the official Torque documentation /
support forum for assistance getting the adapter interface configured.
The next portion is adding the Orion BMS PIDs (viewable
parameters such as battery voltage and current) to Torque. There are two different
ways to do this.
Method 1 (Manual Entry – For Novice Users):
1. Download the following PDF
file: Orion BMS Torque Extended PIDs (PDF)
2. Open Torque and go to “Settings”
(usually by pressing the bottom left key [looks like an upside down box] on
the phone / tablet and then selecting Settings).
3. Scroll down in the settings list and
click “Manage extra PIDs/Sensors”
4. Press the Menu button again (looks
like upside down box) and press “Add custom PID”
5. Press “OK” to agree.
6. Fill out the appropriate information
from the List of OrionBMS Torque PIDs, starting with the first PID (or
whichever ones are wanted / needed).
7. Repeat steps 3 – 5 for all PIDs
wanted / needed.
8. Return to the Torque main screen by
hitting the Back button (backwards arrow) several times.
9. Press the “Realtime Information”
button on the main screen to go to the gauges screen.
10. Long press (press
and hold) any area on the screen to bring up a list of options about adding /
editing existing gauges. When adding a gauge, the PIDs added manually should
be selectable as options.
11. The gauges should
be updating regularly at this point.
Method 2 (Automatic Entry – For Advanced Users):
Torque provides a secondary method for bulk loading multiple
PIDs into memory by reading them in from a file.
1. Download the following file to the
Android device: Orion BMS Torque Extended PIDs
(CSV)
2. Install a File Manager application
(Astro File Manager is commonly used).
3. Open the File Manager and navigate to
the home Torque folder (commonly this is ‘/mnt/sdcard/.torque’ OR ‘/.torque’.
4. Copy the file downloaded above
(“orionbms_pids.csv”) in to the ‘extendedpids’ folder (which should already
exist).
5. Exit the file manager and re-open
Torque.
6. Go to “Settings” and then scroll down
to “Manage extra PIDs/Sensors”
7. Press the Menu button on the device
(looks like upside down box) and then press “Add predefined set”
8. Select “orionbms_pids” to add them as
a predefined PID list.
9. Return to the Torque main screen by
hitting the Back button (backwards arrow) several times.
10. Press the “Realtime
Information” button on the main screen to go to the gauges screen.
11. Long press (press
and hold) any area on the screen to bring up a list of options about adding /
editing existing gauges. When adding a gauge, the PIDs added manually should
be selectable as options.
12. The gauges should
be updating regularly at this point.
|
Cell Tap Validator Tool
(Purchase $326)
(1 Week Rental $65)
USER
MANUAL
§ Used to determine if the battery tap connectors are properly wired
before connecting to the Orion BMS
§ Improperly wired connectors can cause permanent damage to the
Orion BMS unit that is not covered by warranty
§ Available both for weekly rentals for single use applications as
well as for purchase for OEMs that need the tool for use on an assembly line
