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 180 V 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 200 mA 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 up to 180 S

• Orion 02 36‑Cell Base Unit – For medium‑voltage EVs, solar banks, industrial packs

• Orion 02 48‑Cell Base Unit – Manages up to 48 S directly, scalable to 180 S

• Cell Tap Expansion Modules – Add up to 90 extra cells per module; daisy‑chain up to 180 S

 Included Kit Components

The Orion 02 BMS kit includes:

1. Main Controller – The core Orion 02 BMS unit

2. BMS Main Input/Output Wiring Harness – Connects power and control signals

3. Cell Tap Harness Kit – Includes wiring to sense cell voltages

4. CANdapter – USB‑to‑CAN interface for configuration and monitoring

5. Current Sensor – Measures pack current

6. Current‑Sensor Harness with (8) Thermistors – Provides thermal sensing at the current sensor 

 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 (50 A – 1000 A, Hall effect or shunt types)

• Orion BMS Display – Live SOC, fault codes, diagnostics

• Thermistor Sets – Additional pack thermal monitoring

• USB‑to‑CAN Interface Cables – For deeper BMS programming access

• Pre‑Wired BMS Harnesses – Save build time

• CAN Integration Support – For Elcon, TC chargers, Curtis/Cascadia inverters, VCU systems

 Advanced Engineering Services

EVSource offers BMS tuning services, contactor systems, enclosures, and complete HV/12 V integration for any project scale. Contact us to build your Orion 02–based power system from the ground up.

 Field‑Ready Accessories

• SOC Display with Data Logging – Logs parameters to memory card at configurable intervals (100 ms to 10 s)

• Cell Harness Wiring Validator – Verifies cell‑tap wiring integrity before installation

• Thermistor Expansion Module – Adds up to 80 additional thermistors via CAN (expandable to 800 thermistors with 10 modules)

• Orion BMS Connect – Web‑based remote monitoring (PC/Mac, smartphone, tablet) with charts, diagnostics, fault/event logs

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