Orion BMS 02 - Replacement Harnesses

Orion Replacement Harnesses OEM-grade Orion BMS harnesses for Standard (legacy)Orion 02and Thermistor Expansion Modulecontrollers. Choose Main I/O, Current Sensor + Thermistors, Cell Tap harnesses in 6' and 12' lengths, TEM I/O, TEM Extension Harness, or TEM Thermistors. Automotive-grade terminals Correct pinouts Labeled leads Stocked Quick selector Main I/O Harness 6 ft Main I/O harness for Orion Standard (legacy) and Orion 02 controllers. Part SKU Length Compatibility Main I/O Harness CWHMIO3 6 ft (1.8 m) Orion (legacy) & Orion 02 Current Sensor + 8 Thermistors Harness Eight (8) thermistors (2 m each) pre-wired into the current-sensor connector. Part SKU Thermistors Compatibility Current Sensor + 8 Thermistors Harness CWHCRTH8 8 × 2 m Orion 02 only Note: Not for legacy Orion Standard controllers. Cell Tap Harnesses (Orion 02 only) Choose series count and length for your pack topology. 6 ft (1.8 m) Cells SKU Length Compatibility 12-cell tap CWH126G 6 ft Orion 02 only 24-cell tap CWH246G 6 ft Orion 02 only 36-cell tap CWH366G 6 ft Orion 02 only 12 ft (3.7 m) Cells SKU Length Compatibility 12-cell tap CWH1212G 12 ft Orion 02 only 24-cell tap CWH2412G 12 ft Orion 02 only 36-cell tap CWH3612G 12 ft Orion 02 only Tip: Keep tap leads tidy and away from HV cabling; follow Orion routing/strain-relief guidelines for best EMI performance. Selection & installation tips Match your controller: Main I/O fits legacy Orion and Orion 02; Current Sensor + 8 Thermistors and Cell Tap harnesses are Orion 02 only. Length matters: Use the shortest length that reaches cleanly; avoid tight bends near connectors. EMI hygiene: Separate tap harnesses from HV busbars and traction cabling; maintain shielding/grounds per manual. Labeling: Verify tap order before connection; a Cell Wiring Validator can save hours. Helpful Orion accessories SOC Display w/ Data Logging — CAN logging 100 ms to 10 s. Cell Wiring Validator — Confirms correct tap order before first power-on. Thermistor Expansion Module — Add up to 80 thermistors per module. Orion BMS Connect — Remote monitoring and diagnostics. FAQs Are these harnesses compatible with the legacy Orion (pre-O2)? Main I/O (CWHMIO3) is compatible with both legacy Orion and Orion 02. CWHCRTH8 and all Cell Tap harnesses listed are Orion 02 only. How do I choose 12/24/36-cell tap harnesses? Match the harness to the tap header count on your Orion 02 and the segment size (12/24/36 cells). Use multiple harnesses to cover the full series count. Can I mix 6' and 12' harnesses in one pack? Yes. Keep lengths consistent per segment for neat routing and even slack management; avoid unnecessary excess length. Do you offer custom lengths or assemblies? Contact EVolve Engineering for custom harnessing, breakouts, and labeling.