Orion O2 Battery Management System - Split Configuration

Orion 02 Split BMS (48S, 72S, 96S)

The Orion 02 Split BMS, available in 48S, 72S, and 96S configurations, is a specialized variant of the industry-leading Orion 02 Battery Management System (BMS) designed to provide maximum flexibility for applications requiring physically separated battery packs or modular configurations. This system ensures precise cell monitoring, balancing, and protection across high-voltage lithium-ion battery systems while offering unique advantages over the standard Orion 02 BMS.

Key Differences from the Standard Orion 02 BMS

Unlike the standard Orion 02 BMS, which operates as a single unified unit, the Orion 02 Split BMS is designed to manage separate battery segments as part of a single BMS ecosystem. This split configuration allows for more adaptable installation in systems where:
✔️ Battery packs are physically distributed (e.g., across different locations in a vehicle or system)
✔️ Space constraints prevent housing a single, large BMS in one location
✔️ Wiring complexity needs to be reduced for better weight distribution and system integration
✔️ High-voltage isolation is required between different sections of the pack

*Note:  The Orion 02 Split BMS uses 24-cell tap harnesses for each 36-cell tap input on the BMS chassis.  This means that the 48S will use the standard 24-72 cell chassis size, the 72S come in the 84-108 cell chassis size, and the 96S will come in the 120-180 cell chassis size.

Applications for the Orion 02 Split BMS

The Orion 02 Split BMS is ideal for a range of demanding applications where standard BMS configurations are impractical due to space, modularity, or voltage requirements:

🔋 Electric Vehicles (EVs) – Optimized for modular battery architectures in cars, buses, motorcycles, and off-road EVs. Essential for distributed battery systems in large-format commercial EVs.

🔋 Energy Storage Systems (ESS) – Perfect for containerized battery storage solutions, enabling independent sections to be monitored and balanced as a single unit.

🔋 Aerospace & UAVs – Supports lightweight, distributed power systems in electric aircraft and drones where space and weight distribution are critical.

🔋 Marine & Industrial Power Systems – Enhances large, compartmentalized battery banks used in maritime vessels and industrial power applications, ensuring safety and reliability.

🔋 Hybrid & Specialty Applications – Ideal for military, off-grid, and hybrid energy systems where separate battery packs must function cohesively.

Why Choose the Orion 02 Split BMS?

✅ Enhanced System Flexibility – Supports multiple battery pack configurations under a single BMS system
✅ Improved Safety & Redundancy – Separating high-voltage sections reduces failure points and increases operational safety
✅ Simplified Wiring & Installation – Reduces long, high-voltage cable runs, minimizing resistance and improving efficiency
✅ Industry-Leading Protection & Monitoring – Retains all the advanced balancing, thermal monitoring, and fault diagnostics of the Orion 02 BMS

At EVolve Electrics, we integrate the Orion 02 Split BMS into high-performance lithium-ion battery systems tailored for advanced energy storage and mobility solutions. Whether you need a custom-built battery system or a modular, turnkey BMS solution, we ensure your power system is optimized for safety, efficiency, and longevity.

Need help selecting the right BMS configuration?
Contact EVolve Electrics today to discuss your specific application and get expert guidance on battery management solutions.

• (1) Main Controller
• (1) BMS Main Input/Output Wiring Harness
• (1) Cell Tap Harness Kit
• (1) CANdapter (Not Included w/ REM Model)
• (1) Current Sensor Harness w/ (8) Thermistors (Not Included w/ REM Model)
• (1) Current Sensor (Not Included w/ REM Model)

Specifications
Wiring and Installation Manual
Operations Manual
Wiring Generator