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Orion BMS JR2 - Replacement Harnesses
Orion JR2 Replacement Harnesses
OEM-grade replacement harnesses and interfaces for the Orion JR2 (48 V class, 1β16S). Choose Main I/O, Cell Tap, Current Sensor + Thermistors, and optional PC interfaces for programming and CAN diagnostics.
- JR2 Controller compatible
- Automotive-grade connectors
- Correct pinouts & labels
- Built for EMI hygiene
Quick selector
Main I/O Harness
Primary I/O harness for Orion JR2 controllers.
| Part | SKU | Use | Compatibility |
|---|---|---|---|
| Main I/O Harness | CWHJRMC2 |
Controller power, contactors, inputs/outputs | Orion JR2 only |
Cell Tap Harness
Connects JR2 cell-sense inputs to your 1β16S pack.
| Part | SKU | Series Range | Compatibility |
|---|---|---|---|
| Cell Tap Harness | CWHJ2166 |
1β16 cells (JR2 header) | Orion JR2 only |
Current Sensor Harness w/ Thermistors
Pre-terminated current-sensor connector with thermistor leads for pack temperature sensing.
| Part | SKU | Included | Compatibility |
|---|---|---|---|
| Current Sensor Harness w/ Thermistors | CWHJ2CUR |
Thermistor tails (pre-wired) | Orion JR2 only |
Pair with the appropriate Hall-effect sensor (e.g., CS118200, CS124500B, CS133800B, CS1371KB) to match your current range.
Programming & PC Interfaces
Cables/adapters for configuration and diagnostics with a laptop.
| Part | SKU | Use | Compatibility |
|---|---|---|---|
| RS232 β USB Programming Adapter | β | Direct PC programming/config (JR2 RS232 port) | Orion JR2 |
| CANdapter (USB-to-CAN Interface) | β | CAN diagnostics/logging, live telemetry | Orion JR2 (also Orion O2 family) |
Selection & installation tips
- Match to JR2: These harnesses are designed for Orion JR2 (48 V class, 1β16S).
- Programming: Use RS232βUSB for configuration/firmware with the Orion utility.
- Diagnostics: Use CANdapter for live CAN telemetry, logging, and service tools.
- Routing & EMI: Keep tap leads away from HV busbars/traction cabling; avoid long parallel runs with high dI/dt conductors.
- Strain relief: Support harness weight near connectors; avoid tight radii and torsion at the shell.
- Thermistors: Bond probes to representative cells/modules; log temps over CAN (if equipped) during commissioning.
Helpful add-ons
- Cell Wiring Validator β Confirms tap order before first power-on.
- SOC Display w/ Data Logging β CAN logging (100 ms to 10 s) to removable media.
- Thermistor Expansion Module β Add more temperature channels over CAN.
FAQs
Are JR2 harnesses compatible with Standard/Orion 02 controllers?
No. CWHJRMC2, CWHJ2166, and CWHJ2CUR are for Orion JR2. Use controller-specific harnesses for Standard/Orion 02.
How do I verify the cell tap sequence?
Use a validator or meter the tap ladder end-to-end before connecting to JR2. Confirm ascending voltages per the wiring manual.
Which interface should I use for setup vs. diagnostics?
RS232βUSB for programming/configuration; CANdapter for live CAN telemetry, logging, and diagnostics.
Can I extend these harnesses?
Keep extensions minimal; use shielded cable where appropriate. Excess length increases noise pickup and voltage drop.
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Couldn't load pickup availability
Pickup available at EVolve Electrics Office
Usually ready in 24 hoursPairs well with

Orion BMS JR2 - Replacement Harnesses
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