Orion 2 BMS - 72 Cell Battery Management System Kit
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The Orion BMS 2 in a 72 cell kit: the battery management system itself plus the current sensor, the cell tap harnesses, the main I/O harness and the thermistors, so a pack can be wired without sourcing the parts that make the BMS usable.
A lithium pack without management is a pack waiting to fail. Cells drift apart in voltage, one of them hits a limit first, and the whole pack is then governed by its weakest member. The Orion BMS 2 watches every cell individually, balances them, measures pack current through a hall effect sensor, tracks temperature through thermistors, and reports all of it over CAN so the charger, the inverter and the vehicle controller work to the same numbers.
At 72 cells this suits a pack in the 230 to 300 volt class on typical lithium chemistries, which is the range most car conversions end up in.
Buying it as a kit is the point. A bare BMS is a controller with no way to reach the pack. The harnesses and the current sensor are not accessories, they are what turn it into a working system, and sourcing them separately means matching lengths, ranges and connectors yourself.
Key specifications
| Manufacturer part | Orion BMS 2, 72 cell, by Ewert Energy Systems |
|---|---|
| Cells supported | Up to 72 in series |
| Cell voltage range | 0.5 V to 5.0 V per cell |
| Supply voltage | 12 V to 24 V DC |
| Cell voltage accuracy | Plus or minus 0.25 percent across the full temperature range |
| Cell balancing | Passive, up to 200 mA per cell |
| Thermistor inputs | 8, expandable to 800 with expansion modules |
| Operating temperature | -40 °C to +80 °C |
| Communication | Two independent programmable CAN 2.0B interfaces |
| Diagnostics | OBD-II protocol support |
| Charging standards | Direct hardware support for SAE J1772 and CHAdeMO |
| Safety | Isolation fault detection |
| Enclosure size | 181.6 x 170.7 x 60.2 mm, shared by the 24 to 72 cell models |
| Enclosure weight | 1.13 kg |
| Certifications | ISO 7637 Class IV, EN 50498:2010, UNECE Reg 10.05 |
| Current sensor options | 200 A, 500 A, 800 A or 1000 A |
| Cell tap harness options | 6 ft or 12 ft |
Features
- Supplied as a working kit rather than a bare controller, with the harnesses and sensor a 72 cell pack needs
- Measures every cell individually and balances at up to 200 mA, which is what keeps a pack usable over years rather than months
- Two independent CAN interfaces, so the charger and the vehicle controller can be on separate buses
- Isolation fault detection, which watches for insulation breakdown between the pack and the chassis
- Direct support for J1772 and CHAdeMO charging
- Certified to ISO 7637 Class IV, EN 50498 and UNECE Reg 10.05, which matters if the vehicle has to be approved
- State of charge and state of health calculated from the measured data rather than estimated from voltage
Compatibility
For packs of up to 72 cells in series. Count cell groups, not cells: a pack of parallel groups counts as one cell per group.
The range runs from 24 to 180 cells. Smaller packs use the 24 to 48 cell models; larger ones the 96, 108, 120, 144 or 180. Two remote cell tap expansion modules can be added for larger systems.
Choose the current sensor to match your pack. A sensor is most accurate across the middle of its range, so pick the smallest option that comfortably covers your worst case, including regenerative braking and fast charging.
Choose the harness length before ordering. Cell tap harnesses come in 6 ft and 12 ft, and running out at the far corner of a pack is an annoying way to find out.
Configuration is done over CAN from a laptop, which needs a Peak compatible CAN interface.
In the box
- 1 x Orion BMS 2 main unit, 72 cell
- Main I/O wiring harness
- Cell tap wiring harnesses, 6 ft or 12 ft
- Dual range current sensor
- Thermistors
Downloads
Orion's manuals, wiring drawings and specifications are in the Documents tab.
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