Product Manual - Orion Li
Contents
1. Orion BMS Thermistor Expansion Module Product Manual document revision 2 ET2DCC04 E 5 Revision A Model metal case Revision B Model plastic case Product Description The Orion BMS thermistor expansion module provides up to an additional 80 thermistor inputs beyond the 4 that are supported by the main unit for monitoring temperatures on large battery packs or situations where every cell temperature needs to be monitored Up to 10 thermistor expansion modules can be used together with one BMS for a total of 804 thermistors Product Specifications e Operates with the Orion BMS from Ewert Energy Systems BMS sold separately or can be used as a standalone temperature monitoring device e Full automotive operating and sensing temperature range 40C to 80C e High noise immunity e Communicates via CANBUS and can operate on several different CANBUS frequencies 125 Kbps 250 Kbps 500 Kbps 1000 Kbps e Highest and lowest thermistor values are transmitted both via CANBUS and analog outputs e Can be configured to measure between 1 and 80 thermistors Installation amp Wiring All four thermistor connectors the larger of the two different types of connectors on the thermistor expansion module are identical in pin out Connector Overview Power Connector Thermistor Thermistor Thermistor Connector Expa nsion Connector 61 80 Module 1 20 Thermistor Connector 41 60 Thermistor Co2. l Eg Thermistor Utility Sle Connect to Board Disconnect From Bo mA Thermistor Mumber Current Temperature Populated Fault Exit Chrl 0 Baudrate 100 Kbps Max Thermistors i Loaded Thermistors 0 Sophy Changes Automatically Populate Clear Errors Status Disconnected Thermistor Utility File Help Thermistor Mumber Current Temperature Populated Fault Firmware version Diw Fault Status OFF Baudrate 100 Kbps CAM ID Max Therrmistors Connect To Thermistor Board Loaded Thermistors Connection Settings Selected CoNdapter COP SO we CANBUS Baud Rate Kbps 500 kBitisec we Connect Cancel Sool Changes Automatically Populate Clear Errors Status Disconnected Step 2 Examine which thermistors are populated loaded and adjust these values accordingly Any thermistors that are not loaded into the board connectors should be unchecked unpopulated to prevent an error code fault code from getting set Thermistor Utility File Help Firmware Version Faulk Status Baudrate CAN ID Max Thermiskors Loaded Thermistors 50 Status Connected Thermistor Mumber Current Temperature Populated k a PJ mn cn Ln sees s E Ce E Es Po cn PJ wn PJ mn 10 Ph cn _ amp _ s at S _ _ Apply Changes Automatically Populate Step 3 Press the Apply Changes for any changes made to take effect Additional Thermistor Utility Feature
3. the expansion module The module will respond and act the same regardless of whether the power A or B signal is used to power it A common configuration might be to use the Power A signal to power the module during normal operation and Power B signal to power it while charging Another common configuration would be to power both A and B signals for redundancy This is the power ground for the board It should be connected to ground This is the CANBUS high wire used to communicate with the Orion BMS This should be shielded and twisted together with CAN L The CANBUS lines should be bridged with either the CAN1 or CAN2 interface on the Orion BMS NOTE There is NO internal termination resistor 120 Ohm between CAN H and CAN L It is the responsibility of the installer to verify that there are exactly two 2 termination resistors in the CANBUS network that the device is being installed in This is the CANBUS low wire used to communicate with the Orion BMS This should be shielded and twisted together with CAN H The CANBUS lines should be bridged with either the CAN1 or CANZ2 interface on the Orion BMS NOTE There is NO internal termination resistor 120 Ohm between CAN H and CAN L It is the responsibility of the installer to verify that there are exactly two 2 termination resistors in the CANBUS network that the device is being installed in Highest Temperature This wire provides a voltage representation 0 3 3v
4. module are designed and manufactured by Ewert Energy Systems Inc which is a research amp development EWERT company focusing on developing solutions for plug in hybrid and electric NERGY systems Vehicles Ewert Energy provides custom solutions as well as off the shelf components
5. conditions until either the power is cycled on the board power reset or the thermistor utility calls for faults to I had an error condition with a thermistor but be cleared via the Clear Errors I fixed the problem and it is still reporting button This feature allows the that there is a fault on that thermistor thermistor board to ignore intermittently faulty thermistors entirely Either power cycle the board or clear the errors using the utility to solve this problem Verify that the thermistor expansion module is powered at least one of the redundant power supplies power A or power B or both is reading 12v Verify that the CANBUS wiring is correct CAN H and CAN L must be correct Verify that there is the proper number of termination resistors on the CANBUS there must be exactly 2 termination resistors 120 Ohm each This can be verified by checking the resistance between CAN H and CAN L It should read approximately 60 Ohm There is NO internal termination resistor inside the thermistor module The Thermistor Expansion Utility cannot establish connection to the thermistor expansion module Electrical amp Product Specifications Thermistor Electrical Specifications 10K NTC Thermistors with a B25 50 value of 3380K Expansion Module Dimensions 14 3 cm W x 9 3 cm L x 4 4 cm H Operating Temperature Range An Ewert Energy Systems Inc Product The Orion BMS and this expansion
6. depending on temperature of the highest measured thermistor by the module This can be directly connected to one of the 4 thermistor inputs on the main Orion BMS module if CANBUS communication is not possible OPTIONAL but not recommended Lowest Temperature This wire provides a voltage representation 0 3 3v depending on temperature of the lowest measured thermistor by the module This can be directly connected to one of the 4 thermistor inputs on the main Orion BMS module if CANBUS communication is not possible OPTIONAL but not recommended Software Configuration There are two areas where the software configuration settings regarding the thermistor expansion module support can be adjusted The first is the battery profile in the OrionBMS and the second is settings stored on the actual thermistor expansion module itself CANBUS baud rate CANBUS ID number of populated loaded thermistors etc Setting Up The OrionBMS Profile The following instructions will enable the thermistor expansion module in the OrionBMS battery profile using the official OrionBMS utility as shown below in screen shots These steps assume that the user has already connected to the BMS and downloaded the most recent battery profile from the BMS via the Receive Current Profile From BMS Step 1 Under the Addon Settings tab in the Battery Profile section enable the thermistor expansion module support select which CAN ID the BMS should use
7. ed temperatures to the Orion BMS via CANBUS a secondary method is available using the analog outputs as well In the event of a thermistor fault a thermistor is registering a temperature outside of the maximum temperature sensing range of 40 to 80C the board will flag the offending thermistor as faulty set the error flag and omit that thermistor from the calculated highest and lowest thermistor values Using the Thermistor Expansion Utility not the main Orion BMS utility thermistor faults can be read and cleared and real time thermistor values can be read This is helpful for diagnosing problems and determining temperature variance within a battery pack Troubleshooting Problem Symptoms Likely Cause amp Solution The Orion BMS sets a thermistor fault on this Verify that the thermistor expansion thermistor module module is powered Verify that the CANBUS communication wires are connected properly try connecting to the module using the Thermistor Expansion Utility Verify that the populated thermistor table is properly setup ie only thermistors that are loaded are enabled in the software this can be accomplished through the Thermistor Expansion Utility Verify that the CANBUS baud rate and broadcast identifier are correct both in the Orion BMS profile through the main BMS utility and in the thermistor expansion module settings through the thermistor expansion utility The thermistor board will not clear fault
8. nnector 21 40 Thermistor Connector Looking into back of connector wires coming towards the viewer Therm 15 Therm 14 Therm 13 Therm 12 Therm 11 eee Therm 10 k EET k pinout same for Rev A amp Rev B Signal Name Therm X Thermistor Input This is the input from a given thermistor and should register 0 5v depending on the temperature Therm GND Thermistor Ground This is the ground side of a thermistor In many cases there are several thermistor grounds tied together to reduce connector cost and board space Power Connector Looking into back of connector wires coming towards the viewer midnest PowerA Ground Temp 12v NEG Lowest l CAN Revision A Power Connector Metal Enclosure Looking into back of connector wires coming towards the viewer Highest Temp Short to terminate CANBUS Revision B Power Connector Plastic Enclosure Signal Name Power A 12v Power B 12v Ground NEG CAN H CAN L This is the primary 12v power source for the expansion module The module will respond and act the same regardless of whether the power A or B signal is used to power it A common configuration might be to use the Power A signal to power the module during normal operation and Power B signal to power it while charging Another common configuration would be to power both A and B signals for redundancy This is a secondary 12v power source for
9. s The thermistor utility allows the user to see all the measured thermistor values expressed in degrees Celsius C It also allows the user to see if any fault conditions are set as noted by a checked box in the Fault column on any given thermistors The general Fault Status Signal in the top left corner will turn ON if any thermistors are detected as faulty and will remain active until power to the board is lost or the fault error codes are cleared using the Clear Errors button e The presence of any fault condition with any populated loaded thermistor measured by the board causes an error condition to be sent to the OrionBMS if being used with the OrionBMS The OrionBMS then sets a thermistor fault DTC diagnostic trouble code for the thermistor expansion module e Fault conditions with thermistors can be cleared using the Clear Errors button e The utility can automatically guess which thermistors are loaded if you push the Automatically Populate button This cannot be trusted under all circumstances as it only is aware of thermistors that are connected and properly wired e Any changes made to the configuration either by the drop down menus or the checkboxes must be applied before they take effect this is done by pushing the Apply Changes button Operation During normal operation the thermistor expansion board will constantly be monitoring each populated thermistor and reporting the highest and lowest observ
10. to communicate with the expansion module and select how many modules are being connected E Orion BMS Control Application Fie Data Logging Help Tools a Profile Setup Wizard ee Receive Current Profile From BMS Temperature Compensation Relays Charge Limits Discharge Limits E ettings SOC Settings Thermal Settings CONBUS Settings Se Addon Settings Prius Settings 3rd Party Devices Enable this l This indicates which Aao oe CAN interface the module is on Enable Thermal Expansion Modules 7 Thermal Broadcast Interface ay CAN ID to look for module default 0x80 Thermal Broadcast Identifier ey a a a Number of Thermal Expansion Modules ey Number of modules Step 2 Be sure to upload the new profile to the BMS using the Send Profile Changes To BMS button otherwise the changes will not take effect Setting Up The Thermal Board Software The following instructions assume that the user has installed the OrionBMS thermistor utility available from http www orionbms com support Step 1 Connecting to the thermistor board is fairly straight forward Make sure that a CANdapter http www candapter com is connected to the computer and that the thermistor module is connected to the CANdapter via the CANBUS Also make sure that the thermistor board is properly powered If repeated attempts to connect to the thermistor board fail please consult the troubleshooting section below E gt p 7
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