Monthly Archives: February 2014
Internal resistance values are incorrect (by a significant amount)
This problem can be caused by Backwards current sensor Current sensor wiring issue (or no current sensor.) Loose cell tap wire, internal damage to the BMS (blown cell tap fuse) BMS has not been able to measure the resistance yet … Continue reading
Posted in Problems with Cells, Troubleshooting
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P0A9C – Battery Thermistor Fault
A thermistor fault is triggered detected if the analog voltage measured from the thermistor is outside of the normal thermal operating range. This error can be triggered if the temperature of the thermistor rises above 81C or drops lower than … Continue reading
Posted in Trouble Codes, Troubleshooting
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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
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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
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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
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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
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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
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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
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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
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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
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