Lithium Ion Battery Management System

Main Features Input / Output

• Monitors every cell voltage in series • Easy interfacing with
• Field programmable and upgradeable chargers and loads
• Intelligent cell balancing (efficient passive • On/off outputs for
balancing) controlling charge and
• Enforces min. and max. cell voltages discharge sources
• Enforces maximum current limits • 0 – 5V analog outputs for
• Enforces temperature limits gradual current reduction
• Professional and robust design (improves usable range of battery)
• Monitors state-of-charge • Thermal management controls for battery
• Retains lifetime data about battery history cooling / heating
• Integration with 3rd party smartphone apps
(Torque, EngineLink) and external displays Diagnostic Features
• Diagnostic trouble codes quickly
Battery Compatibility identify and diagnose battery problems
• Compatible with almost all lithium-ion cells • Freeze frame data records exact conditions
• One-click setup for common battery types and battery data when a fault occurred
• Supports 4-180 cells in series per BMS unit (2x • Supports OBD2 automotive protocol for storing
additional remote units can be used in series) diagnostic trouble codes and polling live data
The Orion BMS is a
Battery Calculations Data Logging product of Ewert
• State of Charge (SOC) & Pack Health • Unit tracks total number of battery cycles
• Open-Circuit (sitting) cell voltages • Records detailed lifetime battery usage and Energy Systems, Inc.
• Charge & Discharge current limits environment conditions internally.
• All BMS parameters can be logged using PC
• Internal resistance (for all cells and total pack)
utility software Ewert Energy
Centralized Design • Optional WiFi Connect module can record any Systems is a re-
• No cell tap boards or external circuitry parameters to a memory card or Internet search and devel-
• Fast cell voltage polling (every 25 mS typical) • Internal event logging for easy troubleshooting
• High immunity to EMI and other noise
opment company
• High accuracy cell voltage measurement
Other Features focused on devel-
• Integrated isolation fault detection circuit
• Multiple remote modules may be used in series oping solutions for
2x Programmable CANBUS Interfaces
• CAN2.0B (11-bit and 29-bit IDs supported) • Automotive grade locking connectors plug-in hybrid and
• Independently operate at different baud rates • Temperature compensation for improved electric vehicles and
• Fully customizable message formatting
monitoring in different temperatures
• Field upgradable firmware and settings using
• Integrated status LED for indicating faults other energy stor-
either CAN interface age applications.
Common Applications
• One-click setup for many common chargers
• Electric Vehicles (cars, trucks, busses, boats,
and inverters
heavy equipment, racing, etc)
• ISO-15765 OBD2 protocol compatible
• Hybrid & Plug-In Hybrid Vehicles
• Compatible with CAN-Open and J1939
• Solar and wind energy storage
Charger Support • UPS and peak shaving applications
• Integrated support for J1772 charging stations • Research & Laboratory Testing
• Works with J1772 proximity & pilot signals
• Supports CHAdeMO DC fast charging protocol
Cell Voltage Monitoring Specs Isolation
• Cell voltage measurement resolution of 0.1mV. • Cell taps isolated from input power supply, chassis and I/O
• Maximum individual cell voltage rating: 0.5v to 5v per cell tap. • 2.5kV isolation between each connector of cell taps
• Cell voltage measurement total error <0.25% across full prod- • Isolation allows for use of in-pack safety disconnects and fuses
uct temperature range. • High voltage isolation fault detection circuit to monitor the
• Total pack voltages from 12vDC up to 800vDC (maximum). breakdown of wire insulation
• Supports from 4 to 340 cells per battery pack (requires remote
modules for more than 180 cells, 800vDC maximum). I/O Interfaces
• 2 Digital signal outputs for enabling charge and discharge.
Reliability & EMI Immunity • 1 Digital signal output to control a battery charger
• Operates through the highest class passenger vehicle load • 5 Digital programmable multi-purpose outputs
dump ISO 7637 Class IV (178V, 400mS, 0.5 ohm source.) • 2 Digital programmable CANBUS (CAN2.0B) interfaces.
• Operates through ISO 7637 “cold crank” brownouts down to • 3 Analog 0-5v outputs that represent the following signals:
5v on input supply rail and can operate > 100mS with no Charge / Discharge Current Limits and State of Charge (SOC)
power (with initial voltage of at least 12v) • 1 PWM fan output and fan speed feedback monitor (external
• Meets EN 50498: 2010 EMC Aftermarket Vehicle Directive switch and relay required, uses MPO4)
• Meets European UNECE Reg 10.05 (Replaced Road Vehicle • 8 Thermistor inputs (Can support up to 800 thermistors through
Directive) external thermistor expansion modules (sold separately)
• 1 Dual range current sensor input (measures pack current)
Product Dimensions & Weight (Typical, With Heatsink)
• 24-72 Cells: 7.15” (W) x 6.72” (L) x 2.37” (H) — 2.50 lbs Power Supply
• 84-108 Cells: 9.50” (W) x 6.72” (L) x 2.37” (H) — 3.25 lbs • 3 redundant 12V—24V DC power supplies for reliability
• 120-180 Cells: 15.52” (W) x 6.72” (L) x 2.37” (H) — 4.80 lbs • BMS retains data and settings without power
• Low power sleep mode

Specification Item Min Typ Max Units

Input Supply Voltage 8 30 Vdc
Supply Current—Active (at 25 degrees Celsius) <2 Watts
Supply Current—Sleep (at 25 degrees Celsius, 12vDC) 450 µA
Operating Temperature -40 80 C
Sampling Rate for Current Sensor 8 mS
Sampling Rate for Cell Voltages 25 40 mS
Isolation Between Cell Tap #1 and Chassis / Input Supply 1.5 kVrms
Isolation Between Cell Taps #2+ and Chassis / Input Supply 2.5 kVrms
Isolation Between Cell Tap Connectors 2.5 kVrms
Digital Output Switching Voltage (Open Drain) 30 V
Digital Output Sink Continuous Current (Some outputs can 175 mA
pulse up to 4A for contactors—see wiring manual for details)
Screenshot of Torque smartphone display
Cell Voltage Measurement Range 0.5 5 V
Cell Voltage Measurement Error (over 1-5v range) 0.25 %
Cell Balancing Current 200 mA
Cell Current (Operating) 0.5 mA
Cell Current (Low Power Sleep) 50 µA
Thermistor Accuracy 1 C
Cell Voltage Reporting Resolution 0.1 mV

Optional Specifications
Screenshot of BMS utility
CAN bus speed 125, 250, 500, or 1000 Kbps
Current Sensor Values +/- 200A, 500A, 800A, 1000A Available

161 E. Saint Charles Road Phone: (630) 868-3173 www.orionbms.com

Carol Stream, IL 60188 Fax: (866) 657-5667 www.ewertenergy.com