Orion jr (48V) Wiring Manual docx
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- The Orion Jr. BMS may not be used in environments where combustible gasses may be present.
Orion Jr. BMS Manual – Rev. 2
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Mounting Physical Mounting The Orion Jr. 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. BMS may not be used in environments where combustible gasses may be present.
The Orion Jr. 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. BMS Manual – Rev. 2
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Wiring the BMS Overview of system connections
Connector locations on the Orion Jr. BMS as looking at the BMS from the top
Orion Jr. BMS Manual – Rev. 2
11
Interfacing the Load and Charger with the BMS
The Orion Jr. BMS constantly calculates maximum current limits for both charging and discharging. These current limits are based on many parameters including pre-programmed maximum amperages (usually specified by the cell manufacture), temperature, cell health, state of charge, and several other conditions. The current limits are automatically determined based on a calculated algorithm to prevent the cell voltages from dropping below or going above the minimum and maximum cell voltages respectively. More information on how the current limits are calculated can be found in the operational manual.
While the BMS can accurately calculate current limits to keep the connected cells within safe operating parameters, the BMS unit itself cannot directly enforce these current limits (i.e.: it is up to the load and charger to respect the limits that the BMS sets). For this, the BMS relies on the installer to provide a means to limit charge and discharge current and can only protect cells when this external means of limiting current is properly connected. The BMS must be able to turn off all charge and all discharge to the battery pack in order to properly protect the cells. Failure to provide an external method to limit
Current Limiting via the digital CANBUS (CAN-enabled units only) Many modern chargers, motor controllers, solar/wind inverters, and other equipment come with a digital CANBUS (Controller Area Network) interface. This digital protocol usually has a method of communicating maximum current limit(s) to the device. For example, almost all CANBUS enabled battery chargers will listen to the BMS and charge at an amperage not to exceed what the BMS instructs them to. Likewise, almost all CAN enabled motor controllers can be configured to listen to the BMS and limit the amount of current the motor can draw to the amperage that the BMS specifies. Motor controllers that support regenerative braking usually will also listen for a maximum charge current in order to limit regenerative braking amperage.
Interfacing with external devices via CANBUS has some significant advantages and is generally the preferred method of controlling external devices whenever a CAN interface is available (with a few exceptions). Because CAN is a digital protocol, the BMS can accurately and quickly specify the current limit to the device. This is particularly useful for applications where a gradual reduction of power either at the end of discharge or end of charge is beneficial or necessary and takes full advantage of the Orion Jr. 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. This also allows a greater portion of the battery to be used. Gradual current limiting is necessary to fully charge a battery pack to 100% state of charge (although in most applications it is desirable only to charge to a maximum of 95% for lifespan reasons, which may not require gradual tapering of the charge in lithium batteries).
The Orion Jr. BMS utility has built-in support for many CAN enabled chargers and motor controllers and has an extremely programmable CAN interface which can be programmed for devices that are not already integrated.
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