Orion BMS 2 Cell Resistance

mtrehy · Post by **mtrehy** » Thu May 15, 2025 7:55 pm

Hi All,

I have got a fault code P0A07 Discharge Limit Exceeded.

Within the fault code recorded data I can see discharge limit has been reduced due to cell resistance (although I can't see the extent of the reduction or what the discharge current was at the time of the fault)

I don't know what is good /bad, right / wrong in terms of cell resistance, but the resistances seem to be fairly consistent at least. I can't see any settings within the Orion software that are related to derating discharge current due to cell resistance.

I have 12 x 5.3kw Tesla Modules, Zero EV CCS.

Obviously I want to try to resolve this problem - it seems to only manifest when I have the car (and drive it hard).

I have pasted the Orion Fault data below and would be very grateful for any help!

Cheers

<html>DTC Code: <b>P0A07 - (Discharge Limit Enforcement Fault)</b></html>
<html>Sub-code 1: <b>[INF1] (Discharge Limit Exceeded [Enable Relay Populated])</B></html>
Firmware Version: 3.7.0
Serial Number: L58B6B0B
Time Since Power-On: 4.0
Time Since Faults Occurred: 0.0
Time Since Faults Cleared: 605.0
Is-Ready Power Status: 0.0
Is-Charging Power Status: 1.0
Multi-Purpose Input Status: 0.0
Multi-Purpose Input 2 Status: 0.0
Multi-Purpose Input 3 Status: 0.0
Always-On Power Status: 1.0
Errors Present: 0.0
Charge-Enable Output Active: 0.0
Discharge-Enable Output Active: 0.0
Charger-Safety Output Active: 1.0
Multi-Purpose Output Active: 0.0
Multi-Purpose Output 2 Active: 0.0
Multi-Purpose Output 3 Active: 0.0
Multi-Purpose Output 4 Active: 0.0
Multi-Purpose Enable Active: 0.0
DCL Reduced Due To SOC: 0.0
DCL Reduced Due To Cell Resistance: 1.0
DCL Reduced Due To Temperature: 0.0
DCL Reduced Due To Cell Voltage: 0.0
DCL Reduced Due To Pack Voltage: 0.0
Reduced Due To Voltage Failsafe: 0.0
Multi-Unit Comm Failsafe: 0.0
CCL Reduced Due To J1772: 1.0
CCL Reduced Due To SOC: 0.0
CCL Reduced Due To Cell Resistance: 0.0
CCL Reduced Due To Temperature: 1.0
CCL Reduced Due To Cell Voltage: 0.0
CCL Reduced Due To Pack Voltage: 0.0
CCL Zero Because Charge Complete: 0.0
Maximum cell number: 0.0
Pack Charge Current Limit (CCL): 8.0
Pack Charge Current Limit (CCL) kW: 2.0
Maximum Pack CCL: 300.0
Pack Discharge Current Limit (DCL): 0.0
Pack Discharge Current Limit (DCL) kW: 0.0
Maximum Pack DCL: 1000.0
Pack Amperage (Current): 3.4
Average Pack Amperage: 3.3
Pack kW: 2.2
Pack Voltage: 259.9
Summed Pack Voltage: 259.95
Pack Open-Circuit Voltage: 260.1
Pack State of Charge (SOC): 43.5
Pack Amp-hours: 100.7
Pack Resistance: 0.046
Pack Depth of Discharge (DOD): 56.0
Pack State of Health (SOH): 100.0
Total Pack Cycles: 7.0
Simulated Pack SOC: 0.0
Simulated Mode: 24.0
Requested Simulated Mode: 8.0
Highest Temperature ID: 1.0
Lowest Temperature ID: 2.0
Shortest Wave (Isolation): 2.709
Average Wave (Isolation): 4.969
Internal Heatsink Temperature: 23.0
CANBUS 1 Flags: 1.0
CANBUS 1 Errors Present: 0.0
CANBUS 2 Flags: 37089.0
CANBUS 2 Errors Present: 1.0
J1772 Plug State: 1.0
J1772 AC Amp Limit: 10.0
J1772 AC Power Limit: 2400.0
J1772 Proximity Detect Voltage: 0.0
J1772 AC Voltage (0v = N/A): 0.0
Low Temp ASIC ID: 8.0
Low Temp ASIC: 25.0
High Temp ASIC ID: 7.0
High Temp ASIC: 34.0
Low Temp RB ID: 1.0
Low Temp RB: 26.0
High Temp RB ID: 2.0
High Temp RB: 27.0
Low Temp Heatsink ID: 1.0
Low Temp Heatsink: 23.0
High Temp Heatsink ID: 1.0
High Temp Heatsink: 23.0
Highest battery temperature: 18.0
Lowest battery temperature: 17.0
Average battery temperature: 17.0
Actual fan speed (0-6): 0.0
Requested fan speed (0-6): 0.0
Vehicle Speed (KPH): 0.0
Vehicle Speed (MPH): 0.0
Precharge State: 0.0
Parallel Unit Type: 0.0
Watchdog VRFY: 1.0
Main Temperature Sensor #1: 18.0
Main Temperature Sensor #2: 17.0
Main Temperature Sensor #3: 18.0
Main Temperature Sensor #4: 17.0
Main Temperature Sensor #5: 85.0
Main Temperature Sensor #6: 17.0
Main Temperature Sensor #7: 17.0
Main Temperature Sensor #8: 18.0
Lowest Cell Voltage: 3.594
Highest Cell Voltage: 3.616
Highest Cell Voltage ID: 39.0
Lowest Cell Voltage ID: 90.0
Highest Open Cell ID: 39.0
Lowest Open Cell ID: 90.0
Highest Resistance ID: 31.0
Lowest Resistance ID: 24.0
Observed State of Charge: 45.5
Observed Total Capacity: 230.0
Observed Previous Capacity: 230.0
Observed Amphours: 104.8
Average Cell Voltage: 3.61
Lowest Open Cell Voltage: 3.595
Highest Open Cell Voltage: 3.618
Average Open Cell Voltage: 3.613
Lowest Cell Resistance: 0.55
Highest Cell Resistance: 0.74
Average Cell Resistance: 0.64
8v Rail: 7.9
5v Rail: 5.0
3.3v Rail: 3.2
Current Sensor 5v Rail: 4.9
Power Supply (lower than actual): 12.0
Current Sensor ADC #1: 1966.0
Current Sensor ADC #2: 2037.0
Current Sensor Offset #1: 2042.0
Current Sensor Offset #2: 2043.0
Voltage From Fan Sensor (MPI3): 0.0
Cell Balancing Count: 0.0
Extended Balancing Active: 0.0
CANBUS Balance Override: 0.0
Cell Comm Fault Flags: 0.0
Total Historical Runtime (Sec): 9771.0
DTC Flag Status: 0.0
Inst. Cell 1: 3.598
Inst. Cell 2: 3.608
Inst. Cell 3: 3.61
Inst. Cell 4: 3.608
Inst. Cell 5: 3.609
Inst. Cell 6: 3.609
Inst. Cell 7: 3.61
Inst. Cell 8: 3.61
Inst. Cell 9: 3.611
Inst. Cell 10: 3.609
Inst. Cell 11: 3.609
Inst. Cell 12: 3.611
Inst. Cell 13: 3.611
Inst. Cell 14: 3.611
Inst. Cell 15: 3.611
Inst. Cell 16: 3.611
Inst. Cell 17: 3.611
Inst. Cell 18: 3.612
Inst. Cell 19: 3.61
Inst. Cell 20: 3.608
Inst. Cell 21: 3.61
Inst. Cell 22: 3.607
Inst. Cell 23: 3.609
Inst. Cell 24: 3.608
Inst. Cell 25: 3.613
Inst. Cell 26: 3.61
Inst. Cell 27: 3.612
Inst. Cell 28: 3.611
Inst. Cell 29: 3.613
Inst. Cell 30: 3.613
Inst. Cell 31: 3.613
Inst. Cell 32: 3.61
Inst. Cell 33: 3.614
Inst. Cell 34: 3.61
Inst. Cell 35: 3.614
Inst. Cell 36: 3.611
Inst. Cell 37: 3.616
Inst. Cell 38: 3.613
Inst. Cell 39: 3.616
Inst. Cell 40: 3.614
Inst. Cell 41: 3.615
Inst. Cell 42: 3.615
Inst. Cell 43: 3.614
Inst. Cell 44: 3.612
Inst. Cell 45: 3.613
Inst. Cell 46: 3.611
Inst. Cell 47: 3.613
Inst. Cell 48: 3.613
Inst. Cell 49: 0.0
Inst. Cell 50: 0.0
Inst. Cell 51: 0.0
Inst. Cell 52: 0.0
Inst. Cell 53: 0.0
Inst. Cell 54: 0.0
Inst. Cell 55: 0.0
Inst. Cell 56: 0.0
Inst. Cell 57: 0.0
Inst. Cell 58: 0.0
Inst. Cell 59: 0.0
Inst. Cell 60: 0.0
Inst. Cell 61: 0.0
Inst. Cell 62: 0.0
Inst. Cell 63: 0.0
Inst. Cell 64: 0.0
Inst. Cell 65: 0.0
Inst. Cell 66: 0.0
Inst. Cell 67: 0.0
Inst. Cell 68: 0.0
Inst. Cell 69: 0.0
Inst. Cell 70: 0.0
Inst. Cell 71: 0.0
Inst. Cell 72: 0.0
Inst. Cell 73: 3.613
Inst. Cell 74: 3.613
Inst. Cell 75: 3.613
Inst. Cell 76: 3.613
Inst. Cell 77: 3.612
Inst. Cell 78: 3.614
Inst. Cell 79: 3.612
Inst. Cell 80: 3.613
Inst. Cell 81: 3.614
Inst. Cell 82: 3.614
Inst. Cell 83: 3.615
Inst. Cell 84: 3.616
Inst. Cell 85: 3.608
Inst. Cell 86: 3.61
Inst. Cell 87: 3.611
Inst. Cell 88: 3.598
Inst. Cell 89: 3.611
Inst. Cell 90: 3.594
Inst. Cell 91: 3.603
Inst. Cell 92: 3.606
Inst. Cell 93: 3.607
Inst. Cell 94: 3.604
Inst. Cell 95: 3.605
Inst. Cell 96: 3.606
Inst. Cell 97: 0.0
Inst. Cell 98: 0.0
Inst. Cell 99: 0.0
Inst. Cell 100: 0.0
Inst. Cell 101: 0.0
Inst. Cell 102: 0.0
Inst. Cell 103: 0.0
Inst. Cell 104: 0.0
Inst. Cell 105: 0.0
Inst. Cell 106: 0.0
Inst. Cell 107: 0.0
Inst. Cell 108: 0.0
Open Cell 1: 3.6
Open Cell 2: 3.61
Open Cell 3: 3.612
Open Cell 4: 3.611
Open Cell 5: 3.612
Open Cell 6: 3.611
Open Cell 7: 3.612
Open Cell 8: 3.613
Open Cell 9: 3.613
Open Cell 10: 3.612
Open Cell 11: 3.611
Open Cell 12: 3.613
Open Cell 13: 3.613
Open Cell 14: 3.613
Open Cell 15: 3.613
Open Cell 16: 3.614
Open Cell 17: 3.613
Open Cell 18: 3.614
Open Cell 19: 3.612
Open Cell 20: 3.61
Open Cell 21: 3.612
Open Cell 22: 3.61
Open Cell 23: 3.611
Open Cell 24: 3.61
Open Cell 25: 3.615
Open Cell 26: 3.613
Open Cell 27: 3.614
Open Cell 28: 3.613
Open Cell 29: 3.615
Open Cell 30: 3.615
Open Cell 31: 3.615
Open Cell 32: 3.613
Open Cell 33: 3.616
Open Cell 34: 3.612
Open Cell 35: 3.616
Open Cell 36: 3.613
Open Cell 37: 3.618
Open Cell 38: 3.615
Open Cell 39: 3.618
Open Cell 40: 3.616
Open Cell 41: 3.617
Open Cell 42: 3.617
Open Cell 43: 3.616
Open Cell 44: 3.614
Open Cell 45: 3.615
Open Cell 46: 3.613
Open Cell 47: 3.615
Open Cell 48: 3.615
Open Cell 49: 0.003
Open Cell 50: 0.003
Open Cell 51: 0.003
Open Cell 52: 0.003
Open Cell 53: 0.003
Open Cell 54: 0.003
Open Cell 55: 0.003
Open Cell 56: 0.003
Open Cell 57: 0.003
Open Cell 58: 0.003
Open Cell 59: 0.003
Open Cell 60: 0.003
Open Cell 61: 0.003
Open Cell 62: 0.003
Open Cell 63: 0.003
Open Cell 64: 0.003
Open Cell 65: 0.003
Open Cell 66: 0.003
Open Cell 67: 0.003
Open Cell 68: 0.003
Open Cell 69: 0.003
Open Cell 70: 0.003
Open Cell 71: 0.003
Open Cell 72: 0.003
Open Cell 73: 3.615
Open Cell 74: 3.615
Open Cell 75: 3.615
Open Cell 76: 3.616
Open Cell 77: 3.614
Open Cell 78: 3.616
Open Cell 79: 3.614
Open Cell 80: 3.615
Open Cell 81: 3.616
Open Cell 82: 3.616
Open Cell 83: 3.617
Open Cell 84: 3.618
Open Cell 85: 3.61
Open Cell 86: 3.613
Open Cell 87: 3.613
Open Cell 88: 3.6
Open Cell 89: 3.613
Open Cell 90: 3.595
Open Cell 91: 3.605
Open Cell 92: 3.608
Open Cell 93: 3.609
Open Cell 94: 3.606
Open Cell 95: 3.607
Open Cell 96: 3.607
Open Cell 97: 0.003
Open Cell 98: 0.003
Open Cell 99: 0.003
Open Cell 100: 0.003
Open Cell 101: 0.003
Open Cell 102: 0.003
Open Cell 103: 0.003
Open Cell 104: 0.003
Open Cell 105: 0.003
Open Cell 106: 0.003
Open Cell 107: 0.003
Open Cell 108: 0.003
Cell Resistance 1: 0.6
Cell Resistance 2: 0.69
Cell Resistance 3: 0.65
Cell Resistance 4: 0.69
Cell Resistance 5: 0.64
Cell Resistance 6: 0.58
Cell Resistance 7: 0.72
Cell Resistance 8: 0.69
Cell Resistance 9: 0.65
Cell Resistance 10: 0.69
Cell Resistance 11: 0.64
Cell Resistance 12: 0.71
Cell Resistance 13: 0.62
Cell Resistance 14: 0.69
Cell Resistance 15: 0.64
Cell Resistance 16: 0.69
Cell Resistance 17: 0.63
Cell Resistance 18: 0.57
Cell Resistance 19: 0.7
Cell Resistance 20: 0.67
Cell Resistance 21: 0.62
Cell Resistance 22: 0.67
Cell Resistance 23: 0.62
Cell Resistance 24: 0.55
Cell Resistance 25: 0.58
Cell Resistance 26: 0.7
Cell Resistance 27: 0.65
Cell Resistance 28: 0.69
Cell Resistance 29: 0.64
Cell Resistance 30: 0.58
Cell Resistance 31: 0.74
Cell Resistance 32: 0.7
Cell Resistance 33: 0.66
Cell Resistance 34: 0.7
Cell Resistance 35: 0.65
Cell Resistance 36: 0.59
Cell Resistance 37: 0.58
Cell Resistance 38: 0.69
Cell Resistance 39: 0.65
Cell Resistance 40: 0.69
Cell Resistance 41: 0.64
Cell Resistance 42: 0.58
Cell Resistance 43: 0.69
Cell Resistance 44: 0.68
Cell Resistance 45: 0.62
Cell Resistance 46: 0.67
Cell Resistance 47: 0.61
Cell Resistance 48: 0.56
Cell Resistance 49: 0.87
Cell Resistance 50: 0.87
Cell Resistance 51: 0.87
Cell Resistance 52: 0.87
Cell Resistance 53: 0.87
Cell Resistance 54: 0.87
Cell Resistance 55: 0.87
Cell Resistance 56: 0.87
Cell Resistance 57: 0.87
Cell Resistance 58: 0.87
Cell Resistance 59: 0.87
Cell Resistance 60: 0.87
Cell Resistance 61: 0.87
Cell Resistance 62: 0.87
Cell Resistance 63: 0.87
Cell Resistance 64: 0.87
Cell Resistance 65: 0.87
Cell Resistance 66: 0.87
Cell Resistance 67: 0.87
Cell Resistance 68: 0.87
Cell Resistance 69: 0.87
Cell Resistance 70: 0.87
Cell Resistance 71: 0.87
Cell Resistance 72: 0.87
Cell Resistance 73: 0.57
Cell Resistance 74: 0.68
Cell Resistance 75: 0.63
Cell Resistance 76: 0.68
Cell Resistance 77: 0.63
Cell Resistance 78: 0.57
Cell Resistance 79: 0.69
Cell Resistance 80: 0.69
Cell Resistance 81: 0.63
Cell Resistance 82: 0.68
Cell Resistance 83: 0.63
Cell Resistance 84: 0.57
Cell Resistance 85: 0.59
Cell Resistance 86: 0.69
Cell Resistance 87: 0.64
Cell Resistance 88: 0.69
Cell Resistance 89: 0.63
Cell Resistance 90: 0.58
Cell Resistance 91: 0.69
Cell Resistance 92: 0.67
Cell Resistance 93: 0.62
Cell Resistance 94: 0.66
Cell Resistance 95: 0.61
Cell Resistance 96: 0.55
Cell Resistance 97: 0.87
Cell Resistance 98: 0.87
Cell Resistance 99: 0.87
Cell Resistance 100: 0.87
Cell Resistance 101: 0.87
Cell Resistance 102: 0.87
Cell Resistance 103: 0.87
Cell Resistance 104: 0.87
Cell Resistance 105: 0.87
Cell Resistance 106: 0.87
Cell Resistance 107: 0.87
Cell Resistance 108: 0.87

tom91 · Post by **tom91** » Thu May 15, 2025 8:25 pm

This behaviour is when you draw any power out of the pack when trying to charge. The Orion is very shit in this regards.

Any current out is flagged as DCL error when you have charge power "Is-Charging Power Status: 1.0".

mtrehy · Post by **mtrehy** » Thu May 15, 2025 8:30 pm

THanks Tom, appreciate the reply

So the line: "Is-Charging Power Status: 1.0" means that the fault occurred when charging?

So you think this has nothing to do with cell resistance?

Is there any way to stop this from happening?

Cheers

tom91 · Post by **tom91** » Thu May 15, 2025 8:33 pm

So the line: "Is-Charging Power Status: 1.0" means that the fault occurred when charging? Yes snap shot shows key values so this indicates when it is getting Is-Charging power. This is all down to how you wired it.

What setup do you have regarding all HV components? The BMS is powered because you are looking to charge, but you are not providing charge quick enough into the pack and something else, probally dcdc, starts to draw power.

mtrehy · Post by **mtrehy** » Thu May 15, 2025 8:43 pm

I have the early type Zero EV CCS and think I followed the HV setup to the letter in the manual....

Is there anyway to try to test whether the dc/dc is the culprit. Problem isn't happening regularly. I cleared the code and tried charging maybe 10 or so times and all ok but really can't have this fault happening often!

Could it be the cheapo 13a home charger that the owner is using?

Much appreciated

tom91 · Post by **tom91** » Thu May 15, 2025 8:48 pm

Who knows wat causes it only when you can reproduce it reliably can you try resolving it.

Back when I was dealing with Ewert Energy myself, back when I worked at Zero-EV, turned out the Orion can not be adjust to be more lenient for this fault. It might have changed, I will check the latest config software.

tom91 · Post by **tom91** » Thu May 15, 2025 8:52 pm

https://www.orionbms.com/faultcodes/DTC ... 0Fault.pdf

Some more info on this. Can you attach the Orion profile so I can take a peak?

Feel free to reach out to me via my email found via my websites.

mtrehy · Post by **mtrehy** » Thu May 15, 2025 9:04 pm

THanks, I've read all of that several times but not entirely got my head around it. My code is subcode #1:

"The BMS has detected discharge current leaving the battery that exceeds the published Discharge Current Limit (Discharge Enable Relay is NOT
enabled in the configuration settings)."

I do have Discharge Enable Relay enabled but don't think that it is used for the main contactors

tom91 · Post by **tom91** » Thu May 15, 2025 9:08 pm

You can tweak your DCL fault time settings, id raise it from 1s to 30s or something. But if you cannot current reproduce the fault it sort of is a shot in the dark.

mtrehy · Post by **mtrehy** » Thu May 15, 2025 9:15 pm

I'll give that a go, thanks. I'll have to teach the owner how to clear the fault codes, just in case.

Do I need to worry about the DCL Reduced Due to Cell Resistance?

Cheers

tom91 · Post by **tom91** » Thu May 15, 2025 9:16 pm

mtrehy wrote: ↑Thu May 15, 2025 9:15 pm DCL Reduced Due to Cell Resistance?

Not right now, unless it starts popping up when ready power is on.

Orion BMS 2 Cell Resistance

Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance

Re: Orion BMS 2 Cell Resistance