Description

JKBMS Relay BMS Split Port BMS + 2 x 500A Relays

Included components

1 x JKBMS Relay BMS Split Port BMS for 24v, 36v, 48v, 60v, 72v and 80v Battery packs

2 x TE Connectivity EVC 500 Main Contactors (TE Connectivity AMP+ EVC 500, Mfr. Part No. 2299223-1  or equivalent)
External 500 A, 12 V-coil relays driven by the BMS’s CHG+ and DCH+ wires—one to interrupt charging and one to interrupt discharging for full fault isolation
1 x 100A EV4010A Relay for PreCharge resistor
1 x 48-12v DC Converter (48V-72V to 13.8V 20A 240W DC DC Step Down Converter Voltage Regulator)

Key Specifications

• Battery String Configuration: 7- to 25-series (7S–25S)

• Continuous Current Rating: 500 A (via 2 x  external relay, (1 charge/1 x discharge)

• Power Supply Mode: Self-powered by battery pack

• Single-Cell Voltage Monitoring: 0–5 V range; maximum error < 10 mV (typical < 5 mV)

• Cell Dropout Detection: Yes

• Active Balancing Current: 2A (full-state on)

• Wiring Configuration: Common-port connection

• Short-Circuit Protection: Yes

Communications & Monitoring

• Bluetooth Connectivity: Built-in; compatible with Android and iOS devices

• Temperature Sensing: –40 °C to 125 °C

System-Level Measurements

• Total Voltage Detection: 0–100 V; accuracy within 0.5 % of full scale

• Current Sensing (Shunt): –150 A to 300 A; accuracy within 0.5 % of full scale

• State-of-Charge (SoC) Estimation: ± 8 % error under typical operating conditions

• Remaining Capacity Display: Error ± 8 %

• Cumulative Ampere-Hour Counter: Tracks half of total charge/discharge value

Power Consumption

• Active Operating Current: < 5 mA (idle); 15 mA (with RS-485 or CAN communication)

• Standby Current: < 2 mA

Environmental Ratings

• Operating Temperature: –40 °C to 85 °C

• Storage Temperature: –40 °C to 95 °C

Installation Guide: Forklift BMS 500A

Please follow these steps carefully to ensure a safe and reliable installation of your Forklift BMS 500A.

Installation Instructions

1. Unpack and Inspect

• Open the package and visually inspect the BMS module and current shunt for any damage.

• Observe basic anti-static precautions: handle the electronics by their edges and avoid touching exposed circuitry.

2. Mount the BMS Module

• Select a clean, dry location inside your battery enclosure.

• Secure the BMS by its mounting holes on an insulated, vibration-resistant surface.

3. Install the Current Shunt

• Place the shunt adjacent to the pack’s negative busbar.

• Tighten the M8 power terminals to the manufacturer’s torque specification for accurate current sensing.

4. Wire the Cell-String Leads

• Connect each cell-string lead in sequence (from B– up through B1, B2… to B+), matching the markings on the BMS.

• Double-check polarity and order with a multimeter before moving on.

5. Attach Temperature Sensors

• Plug in up to three temperature probes into the BMS sensor ports.

• Secure the probes to representative cells or busbars to monitor pack temperature.

6. Connect Charge and Discharge Outputs

• Wire the “C+” and “C–” terminals to the charge contactor coil.

• Wire the “D+” and “D–” terminals to the discharge contactor coil.

• Tie both coil-negative lines to the pack’s negative (ground).

7. Power the BMS Electronics

• Apply your pack voltage (40–60 V) to the BMS power input terminals.

• Ensure any accessory or ignition-sense inputs are wired as required for your application.

8. Initial Power-Up and Inspection

• With all wiring secured, switch on pack power.

• Confirm the BMS powers up (power LED on) and shows no active fault indicators.

9. Pair with the Mobile App

• Download the BMS app on Android or iOS.
  JK BMS App Android                Apple iOS

• Enable Bluetooth on your phone, open the app, and connect to the BMS (default password 1234).

• Configure cell count, pack capacity, and protection thresholds using the app’s guided setup.

10. Calibrate and Test

• In the app, calibrate voltage and current readings against your pack’s terminals.

• Perform a controlled test of both charge and discharge outputs and verify cell balancing functionality before full-load operation.

Key Considerations:

• Always follow torque specs on all terminals.

• Ensure a reliable 12 V supply for your contactor coils (via DC–DC converter or auxiliary battery).

• Verify proper function in a safe test environment before returning the forklift to service.

This installation procedure ensures optimal performance, safety, and longevity for your 51.2 V LiFePO₄ forklift battery system.