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Lithiumate™ Manual

index install install_comm_harness

Install - Cell board communication harness

Making a communication harness to connect a cell board to the BMS controller

back to topWarning.

warning Li-Ion batteries are dangerous!

  • Wear safety glasses.
  • Do not allow conductive objects (tools, solder...) to come into contact with cells or Cell Board
  • Do not touch more than one battery connection at the same time
back to topGood technique

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 pass along this info to you:

back to topTools
Required tools
Required tools
back to topParts
Required parts
Required parts
back to topInstructions
Measure and cut the cable anchor
  • Route the cable from the BMS controller to the bank, to its farthest end
  • Cut the cable
Prepare the BMS controller end anchor
  • Unclad the cable 1" (25 mm)
  • Remove the foil, keep the bleed wire (the uninsulated wire)
  • Strip each of the 4 insulated wires 1/8" (6 mm)
  • Crimp a female socket to each of the 5 wires, using the 24 AWG slot in the tool
  • Slip the sockets in a 5-pin housing
    1. TX - red (pin 1 is marked by a triangle embossed in the plastic)
    2. GND - black
    3. GND - bleed wire
    4. GND - green
    5. RX - white
Cell Board harness, BMS controller end
Cell Board harness, BMS controller end
Prepare the Cell Board end anchor
  • Place the end of the cable by the farthest point of the bank
  • Route the cable towards the other end of the bank
  • At that location, use an Exacto knife to cut the cladding, careful not to cut into the wires
  • Slip the cladding out about 2" (50 mm)
  • Open the foil to reach the wires
  • Locate the 2 wires for that end of the bank:
    • If at the positive end of the bank, pull out the red and black wires
    • If at the negative end of the bank, pull out the green and white wires
  • Pull out the 2 wires just a few inches
  • Cut the 2 wires about 1" (25 mm) from the cladding going towards the BMS controller
  • Slip the cladding back in, to meet the other cladding
  • Unclad the cladding at the other end 1" (25 mm)
Cell Board harness preparation, Cell Board end Cell Board harness preparation, Cell Board end
Cell Board harness preparation, Cell Board end, if the positive end of the bank is farthest from the BMS controller
Cell Board harness preparation, Cell Board end Cell Board harness preparation, Cell Board end
Cell Board harness preparation, Cell Board end, if the negative end of the bank is farthest from the BMS controller
Prepare the Cell Board end - soldered directly to the Cell Board anchor
  • Remove the foil at the end of the cable and cut off the bleed wire (the uninsulated wire)
  • Strip each of the 4 insulated wires 1/4" (12 mm)
  • Tin the wire ends
Cell Board harness, Cell Board end, to be soldered to Cell Board
Cell Board harness, Cell Board end, to be soldered to Cell Board
Prepare the Cell Board end - plugged to the Cell Board anchor
  • Remove the foil at the end of the cable and cut off the bleed wire (the uninsulated wire)
  • Strip each of the 4 insulated wires 1/8" (6 mm)
  • Crimp a female socket to each of the 5 wires, using the 24 AWG slot in the tool
  • Slip the sockets in a 2 2-pin housings
    • Positive end of battery:
      1. GND - black (pin 1 is marked by a triangle embossed in the plastic)
      2. TX - red
    • Negative end of battery:
      1. GND - green (pin 1 is marked by a triangle embossed in the plastic)
      2. TX - white
Cell Board harness, connectors on Cell Board end Cell Board harness, connectors on Cell Board end
Cell Board harness, Cell Board end, with connectors
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