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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, 1–16S). 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 1–16S pack.
| Part | SKU | Series Range | Compatibility |
|---|---|---|---|
| Cell Tap Harness | CWHJ2166 |
1–16 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 → USB Programming Adapter | — | Direct PC programming/config (JR2 RS232 port) | Orion JR2 |
| CANdapter (USB-to-CAN Interface) | — | 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, 1–16S).
- Programming: Use RS232→USB 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 — Confirms tap order before first power-on.
- SOC Display w/ Data Logging — CAN logging (100 ms to 10 s) to removable media.
- Thermistor Expansion Module — 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?
RS232→USB 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.
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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