Orion 02 Battery Management Systems

Orion 02 Battery Management System (BMS) – Professional-Grade Battery Intelligence

Scalable Control. Unmatched Safety. OEM-Ready Performance.

The Orion 02 BMS is a full-featured, high-reliability Battery Management System built for demanding, large-format lithium-ion battery packs. Trusted by OEMs, integrators, and advanced EV builders, this second-generation BMS from Orion by Ewert Energy Systems delivers precise cell management, customizable protection logic, and seamless CAN-based integration with chargers, inverters, displays, and vehicle control systems.

Whether you're building a full-size EV conversion, energy storage system, or industrial/marine power application, the Orion 02 gives you the tools to ensure safe, efficient, and intelligent battery operation.

⚙️ Key Features:

• Voltage Range: Supports up to 180V nominal systems (with expansion)

• Modular Cell Monitoring: From 24 to 180 cells in series via Orion Expansion Modules

• Dual CAN Bus Communication – Fully configurable for charger, inverter, motor controller, display, and auxiliary system communication

• High-Accuracy SOC Calculation – Uses coulomb counting + voltage/SOC mapping

• Passive Cell Balancing – Up to 200mA per cell

• Built-in Safety Logic:

  • Over/under voltage

  • Over/under temperature

  • Short circuit and open wire detection

  • Fault isolation and response modes

🔩 Available Orion 02 BMS Variants:

🔹 Orion 02 24-Cell Base Unit

• Supports up to 24 series cells directly

• Expandable with Orion Cell Tap Expansion Modules (up to 180S total)

• Ideal for modular builds and systems needing high customization

🔹 Orion 02 36-Cell Base Unit

• Supports up to 36S battery configurations

• Suitable for medium-voltage EVs, solar banks, and industrial packs

• Common choice for off-grid, marine, and hybrid systems

🔹 Orion 02 48-Cell Base Unit

• Manages up to 48 cells directly—perfect for high-voltage system cores

• Scalable up to 180S with expansion

• High-end EVs, buses, and large energy storage systems benefit from this model

🔹 Cell Tap Expansion Modules

• Add support for up to 90 additional cells per module (beyond base unit)

• Maintain accuracy and safety with seamless CAN communication

• Daisy-chain compatible for large-scale battery arrays

🛠️ Common Applications:

• EV Conversions & Custom Electric Vehicles

• Stationary Energy Storage Systems (ESS)

• Marine Battery Systems (Hybrid & Electric Boats)

• Utility & Industrial Energy Platforms

• Research, Military, and Aerospace Power Projects

🌐 Built for Engineers. Powered by EVSource.

At EVSource.com, we offer genuine Orion 02 BMS systems, backed by technical expertise and real-world application support. From basic configuration to advanced CAN integration and diagnostics, we help you unlock the full potential of Orion’s industry-leading battery management.

🧰 Optional Accessories & Add-Ons:

• Current Sensors (50A – 1000A) – Hall effect or shunt types for precise current measurement

• Orion BMS Display – Real-time data, fault codes, SOC visualization

• Thermistor Sets – Critical thermal protection for large packs

• USB-to-CAN Interface Cables – Full access to BMS programming tools

• Pre-Wired BMS Harnesses – Save build time with plug-and-play options

• CAN Integration Support – For chargers (Elcon, TC), inverters (Curtis, Cascadia, etc.), and VCU systems

🧠 Need Full-System Engineering?
EVSource offers BMS tuning services, contactor systems, enclosures, and complete HV/12V integration for projects of any size. Contact us to build your Orion 02-based power system from the ground up.

The Orion BMS also has some very useful add on accessories that can save you time and money while programming or in the field:

•SOC Display with Data Logging -- Connects to the BMS via CAN providing parameters to a memory card at a user designated frequency from 100mS to 10 seconds
•Cell Wiring Validator -- Checks the cell tap wiring harnesses to ensure they are wired properly before pluggin them into the system.
•Thermistor Expansion Module -- Allows up to 80 additional thermistors to the system via CAN. If needed, up to 10 Thermistor Expansion Modules can be used together allowing up to 800 thermistors to be used in a system.
•Orion BMS Connect -- An internet based remote monitoring system that allows the user to monitor battery packs via PC/MAC, smartphone, or tablet. It provides instant data, charts of recent history, and diagnostic information including recent events, fault codes, and freeze frame data all on a webpage!

Downloads

Purchasing Guide
Quick Start Guide
Specifications
Wiring and Installation Manual
Operations Manual
Orion to Orion 2 Migration
OBD2 PIDS
Torque PIDS
Wiring Generator
24-72 Cell Manufacturing Drawing
84-108 Cell Manufacturing Drawing
120-180 Cell Manufacturing Drawing
WHAT'S NEW WITH THE ORION 2
ORION TO ORION 2 MIGRATION
Troubleshooting
FAQ
Application Notes