Tools

Recommended tools to install and operate the BMS

Installation

Some of the tools used in installing a BMS

• Professsional 24 AWG open barrel crimper, required
  • Eclipse Tools P/N 300-009 (~ $ 40 from stores), or
  • Paladin Tools P/N 1645, or
  • Molex P/N 11-01-0208, or
  • NAPA P/N NW 726603 (non racheting)
• Exacto knife
• Soldering iron
• Needle nose pliers
• Wire stripper for 24 AWG wire
• Extraction tools:
  • For MiniFit Jr sockets

An improperly crimped socket, done using the wrong tools and incorrect stripping length.

Programming

Some of the tools used in programming a BMS

• USB-RS232 serial dongle, required to program the Lithiumate™ BMS controller if your computer doesn't already have a serial port:
  • USB Gear USB serial adapter, compatible with Windows, Linux, Mac
  • UC232A USB serial adapter, compatible with Windows, Linux, Mac
  • Do not use Prolific type adapters with Vista computers: they crash the computer
• PIC programmer, optional, allows you to back-up and / or duplicate the settings from / to a Lithiumate™ BMS controller:
  • PicKit II programmer
  • Download the software

Pgm adapter

Hardware rev F and up

Materials:

• 0.1" pitch pin strip, 0.26" on each end, breakable: Digikey

Construction:

• Break off a group of 6 pins
• Clip one of the pins off, just on one side

Programmer adapter

For your reference, the pin out is:

1. Vpp (this is the pin closest to the white Control connector)
2. Vdd (5 V)
3. Vss (Gnd)
4. PDAT (data)
5. PCLK (clock)

Up to hardware rev E

Materials:

• 0.1" pitch pin strip, 5 pins
• 0.1" pitch pin strip, 6 pins
• Five wires, 4" length, yellow, red, black, white, green
• 1/8" heat shrink tubing

Construction:

• Solder the wires to the 6 pin connector:
  1. yellow
  2. red
  3. black
  4. white
  5. green
  6. none
• Install 10 pieces of 3/8" long heat shrink tubing on the 5 wires, two per wire
• Solder the wires to the 5 pin connector:
  1. red
  2. white
  3. green
  4. yellow
  5. black
• Slip the heat shrink tubing on the soldered ends of the pins, and heat shrink

Programmer adapter diagram

Programmer adapter cable

• Connect the programmer to the BMS controller with the adapter cable
  • programmer side: 6 pin connector, yellow wire on pin marked by a triangle
  • BMS controlelr side: 5 pin connector, red wire in pin 1 (closest to white connector)

PICKit 2 programmer connected