Orion Replacement Harnesses

OEM-grade Orion BMS harnesses for Standard (legacy) and Orion 02 controllers. Choose Main I/O, Current Sensor + Thermistors, or Cell Tap harnesses in 6' and 12' lengths.

Automotive-grade terminals
Correct pinouts
Labeled leads
Stocked lengths

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.

Orion BMS 02 - Replacement Harnesses