Author Archives: admin
Charger turns off before battery pack reports full state of charge
A charger may shut off before the Orion BMS reports the programmed maximum state of charge for several reasons. The vast majority of problems relating to chargers turning off before the BMS reports maximum state of charge turn out to … Continue reading
Posted in Problems with Charging and State of Charge, Troubleshooting
Comments Off on Charger turns off before battery pack reports full state of charge
Diagnosing sudden jumps in State of Charge (SOC)
The Orion BMS primarily calculates state-of-charge (SOC) by coulomb counting, which is a way of monitoring the amount of current going into or out of the battery pack. However, the BMS also has an algorithm for correcting the calculated state-of-charge … Continue reading
Posted in General, Problems with Charging and State of Charge, Problems with Voltages, Troubleshooting
Comments Off on Diagnosing sudden jumps in State of Charge (SOC)
High resistance cell
Resolving the issue: Step 1. Check the busbars to ensure they are tight. Most of the high resistance issues turn out to be a loose connection or faulty crimps (if applicable), so it is worth checking closely. High impedance from … Continue reading
Posted in Problems with Cells, Troubleshooting
Comments Off on High resistance cell
Discharge or charge relay turns off too soon
Possible Causes: The current limits may be hitting 0A. For the Charger Safety relay and the Charge Enable relay this means that the charge current limit (CCL) might be hitting 0A causing the relay to latch OFF. For the Discharge … Continue reading
Posted in Problems with Charging and State of Charge, Problems with Relays, Troubleshooting
Comments Off on Discharge or charge relay turns off too soon
Relays don’t turn on
Possible Causes: The relay in question may not be enabled in the profile settings. By default, all of the relay outputs on the BMS are disabled. This is done as a safety measure to prevent unintended charging / discharging in … Continue reading
Posted in Problems with Relays, Troubleshooting
Comments Off on Relays don’t turn on
No cell voltages are showing in the utility
This can be caused by: Incorrect Cell Population Settings A Profile that has not been uploaded to the BMS (i.e. default profile on BMS) Cell wiring harnesses not connected to the BMS Cell tap wiring error Voltages within a cell … Continue reading
Posted in Problems Viewing Data in Utility, Problems with Voltages, Troubleshooting
Comments Off on No cell voltages are showing in the utility
Cell voltages drop after the charge completes
Cell voltages drop after the charge completes. This is often the normal behavior of the cell. A cell’s voltage will rise when it is being charged and will begin to drop somewhat after the charge current has been removed. This … Continue reading
Posted in Problems with Charging and State of Charge, Problems with Voltages, Troubleshooting
Comments Off on Cell voltages drop after the charge completes
Not all cell voltages appear in live cell data
This issue can be caused by incorrect cell population settings, wiring errors,, not enough cells in a cell group (wiring error), cell voltages too low, a BMS utility problem, incorrect size of BMS or internal damage to the BMS. Resolving … Continue reading
Posted in Problems Viewing Data in Utility, Problems with Voltages, Troubleshooting
Comments Off on Not all cell voltages appear in live cell data
Cell voltages appear incorrect (when under load)
When cell voltages are correct while sitting, but appear incorrect when the pack is under load, the cause is usually a loose terminal on a battery, a high impedance connection between two cells (such as a long cable, fuse or … Continue reading
Posted in Problems with Voltages, Troubleshooting
Comments Off on Cell voltages appear incorrect (when under load)
Cell voltages appear incorrect (not under load)
Almost all cases of voltages showing incorrectly when the pack is not under load are a result of wiring errors (or a result of damage to the BMS unit from previous wiring errors). If one wiring error exists in a … Continue reading
Posted in Problems with Voltages, Troubleshooting
Comments Off on Cell voltages appear incorrect (not under load)
