Install - Cable mount current sensors

Installations and wiring instructions for the 2CS0xx0K series, 50 to 600 A, bidirectional, cable mounted current sensors

Unfortunately, we do not have the resources to teach all of our clients proper assembly procedures, which are essential for a succesful project. What we can do is to pass along this info to you:

• Proper tools
• Proper crimping technique from Molex

Because the desired cable length is not known a priori, the sensor comes with an unterminated cable and a connector kit. Use these instructions to terminate the cable in the field.

• Install the current sensor and the BMS controller in their final positions
• Measure and cut the current sensor's cable to an appropriate length
• Unclad the cable end 1 inch, careful not to nick the wires
• Remove the shield foil
• Strip all 4 wires 1/8 inch
• Crimp 4 C-Grid female sockets to the wires
• Slip the sockets in the 4-conductor C-Grid connector, until they snap in place
  1. Red
  2. Green
  3. White
  4. Black and shield bleed wire (uninsulated)

For replacement parts, see the parts list

• Slip the battery power cable through the opening in the current sensor, so that, when discharging, current flows into the side that has the signal cable (note that the arrow printed on the label is the direction of discharging current)
  • If installed backwards, you will need to toggle the "Direction" when programming the controller.
• Connect the signal cable to the BMS controller (4-pin, black connector)

For your reference, current flow is:

• On positive lead, charging: towards battery
• On positive lead, discharging: away from battery
• On negative lead, charging: away from battery
• On negative lead, discharging: towards battery

The biggest wire that fits in the opening in the cable mounted current sensor can carry far more current than the sensor can detect. So, if your cable doen't fit, either the current sensor is undersized for your application (e.g.: you're using a 500 A current sensor in a 200 A application), or the wire is oversized for the application (e.g.: you're using a wire for 2000 A average when it only carries 100 A average).

Regardless, if the cable is too large for the opening on the sensor, you may:

• Install the current sensor on a copper bus bar, and connect the battery cable to the bus bar, or
• Strip the cable, run the copper strands inside the sensor, isolate the strands with heat shrink tubing, or
• Buy your own current sensor with a larger opening

Yes, current sensors with a larger opening are available, but they cost at least 8 times more than these, and we're sure you wouldn't want to pay for it.

Configuration instructions for a load current sensor.
Configuration parameters for our standard cable mounted current sensors (middle section of the table).

It is possible to use two cable mounted current sensors: one for the source current, one for the load current.

• Connect each of the 3 sets of power leads (black, red green) from both sensors directly in parallel, and to the 4-pin EXT current connector
• Connect the signal wire (white) of one current sensor (usually the load current sensor) to the 4-pin EXT current connector
• Connect the signal wire (white) of the other current sensor (usually the source current sensor) to the White Control connector, SRC pin (pin 6)
• Configure the BMS to work with the two current sensors: one from the EXT input, one from the SRC input, for the appropriate offset and gain