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Orion BMS 2 Standard & Up to 180 Cells Extended
24-36-48-60-72-84-96-108-180 Cells-Batteries
0.5-5v LiFePO4, LiNCM, LiMn2O2, LiFeMnPO4
Li-Ion, LiPo, LiFeYPO4, LiCoO2, LiMn2O4
USA Stock and Support
orion-bms2-standard&extended
Orion BMS 2 Standard & Up to 180 Cells Extended <br> 24-36-48-60-72-84-96-108-180 Cells-Batteries <br> 0.5-5v LiFePO4, LiNCM, LiMn2O2, LiFeMnPO4 <br> Li-Ion, LiPo, LiFeYPO4, LiCoO2, LiMn2O4 <br> USA Stock and Support
Orion BMS 2 Battery Management System Standard Size
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Description

24-36-48-60-72-84-96-108 to 180 Cells/Batteries

EV Orion BMS 2 (Battery Management System)

0.5-5v LiFePO4, LiNCM, LiMn2O2, LiFeMnPO4

Li-Ion, LiPo, LiFeYPO4, LiCoO2, LiMn2O4

Orion BMS Standard or Up to 180 Cells Extended Size

2-4 Day USA Shipping

 

BMS Fundamentals Explained


Instructions for Paralleling Strings of Batteries

  

Configuration

Controller Price US$

6ft Cell-Tap Harness

Current Sensor

I/O Harness

8x2m Thermistors

CANdapter

Total Price US$

13-24 Cells

780

34

49

30

46

67

1,006

25-36 Cells

880

38

49

30

46

67

1,110

37-48 Cells

930

66

49

30

46

67

1,188

49-60 Cells

1,010

80

49

30

46

67

1,282

61-72 Cells

1,100

92

49

30

46

67

1,384

73-84 Cells

1,150

112

49

30

46

67

1,454

85-96 Cells

1,230

125

49

30

46

67

1,547

97-108 Cells

1,310

138

49

30

46

67

1,640

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 Company of Utah 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.   An OBD2 Connector. These are present in modern vehicles or are available for purchase ($29) for hardwiring into the Orion CANBUS cable.

2.   An OBD2 to Bluetooth Adapter ($19) Torque requires an external device to interpret the OBD2 data.

3.   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.

4.   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*).

 

http://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

14 – CAN Low

Orion BMS CAN1 or CAN2 Low

4 – Chassis Ground

12v Ground

5 – Signal Ground

12v Ground

16 – Battery Voltage

+12V (power for adapter)

 

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 $339)

(1 Week Rental $48)

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

Price
Price with Options:
$780.00


(Discounts, if applicable, will show in the "Shopping Pallet")

24, 36, 48, 60, 72, 84, 96, or 108 to 180 Cells/Batteries EV Orion BMS 2 (Battery Management System)
Configuration?
6ft (1.8m) Cell-Tap Wiring Harness?
OR ---- 12ft (3.6m) Cell-Tap Wiring Harness?
Main Connector I/O Wiring Harness - 6 ft
(CAN1 wires - 12ft, CAN2 wires - 4ft.)
Current Harness?
Dual Range Current Sensor Needed?
CANdapter?
Basic SOC Display?
SOC Display with Data Logging?
Connect Remote Monitoring System?
CANbus to OBD2 Hardwiring Cable?
OBD2 to Bluetooth Adapter?
Cell Tap Validator Tool?
Intelligent Thermistor Expansion Module
With 6ft Wiring Harness?
Number of Thermistors Needed?
Complete USA Based Product Support
Comes with every order!
Shipping Method?
If buying without batteries shipping costs $30
If buying with batteries shipping will be quoted separately
Delivery Date Needed? Enter it here:

Special Instructions? Enter them here:

Quantity
 

 

* SHIPPING/PAYMENT OPTIONS *

 

There are 2 ways to get an exact quote for the base shipping for your Orion BMS 2 Standard Size order.

1.  Contact us at (801) 449-0681 9am-5pm Monday-Friday or email [email protected] or go through our Contact Us page

 

Or

 

2. Place your order by clicking in the shopping pallet “Proceed To Checkout”

a. Enter your information so we can get you a shipping quote

b. Select the “Shipping Method” of preference

c. Confirm the “Choose one payment method” has “Shipping Quote Request” selected

d. Click the “Check Out” button

e. You’ll receive a confirmation email of your request, as will we

 

We’ll research the exact shipping cost and send you an invoice to your PayPal or email or you can add it to your pallet in $1 Shipping Increments for your Orion BMS 2 Standard Size order.

 

 

Quantity discounts show in the “Shopping Pallet”.

 

We love to meet or beat any competitor’s price!

 

Higher volume discounts, price matching or questions?

Contact Carl, our resident specialist.

9am-9pm Mon-Sat MDT

(801) 449-0681

or email

[email protected]

Or

[email protected]

or through our Contact Us page

 

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