Flipsky BMS 24S 120A 120V Lithium Ion Battery Protection Circuit Board User Manual

1. Introduction

This manual provides essential information for the safe and effective use of your Flipsky BMS (Battery Management System) 24S 120A 120V Lithium Ion Battery Protection Circuit Board. This BMS is designed to protect lithium-ion battery packs in various applications, including e-scooters, e-cars, e-bikes, and e-skateboards. Please read this manual thoroughly before installation and operation.

2. Product Specifications

2.1. 24S BMS Specifications

2.2. 12S BMS Specifications (for reference)

2.3. Key Features

• Compact layout and mini design with aluminum alloy shell for better heat dissipation.
• Automotive-grade design with locking connectors for enhanced reliability.
• Configurable and firmware upgradable via USB using MAXKGO-BMS-TOOL and ENNOID-BMS-TOOL.
• Automotive-grade monitoring & balancing IC with separate power supply.
• Voltage measurements for load, charger, and battery pack.
• Bi-directional current monitoring.
• State of Charge (SOC) based on coulomb counting.
• Humidity sensor & board temperature monitoring.
• Charger detection circuit and integrated precharge circuit.
• Power button, USB-C, UART, I2C & isolated CAN bus interface.
• On-board High-Efficiency 3.3V regulator powered from the main battery pack.
• High current capacity automotive-grade screw connectors for main power connections.
• Buzzer & status LED for indications.
• Supports overcharge/discharge/over current/temperature protection, thermal management, and active/passive balance.
• Compatible with almost all lithium batteries (Li-ion, Li-Po, LiFePO4, etc.).

3. Package Contents

Before proceeding with installation, please verify that all components are present in your package:

• Flipsky BMS Board (24S or 12S variant)
• M5*8 Stainless Steel Round Head Screws (4 pcs)
• M5 Copper Gaskets (4 pcs)
• 90 Degree Angle Terminal Block T90-6/5 (Red Copper) (4 pcs)
• GH1.25 Single Head 5P Cable (2 pcs)
• GH1.25-5P to Dupont Line (1 pc)
• 2.0MM Jumper Cap (1 pc)
• XT30 (Female) Connector (1 pc)
• 1.3 inch OLED Display LCD Screen Module (1 pc)
• USB Cable Type-C Data Cable (1 pc)
• 12mm 3-6V Key Switch (1 pc)
• HY2.0 Single Head 13P Line (1 pc)
• HY2.0 Single Head 10P Line (1 pc)

4. Setup and Wiring

Proper wiring is crucial for the safe and correct operation of the BMS. Refer to the diagram below for connection points.

4.1. Main Power Connections

• PACK+ / PACK-: Connect the main positive and negative terminals of your battery pack to these screw terminals. Ensure correct polarity.
• LOAD+: Connect the positive terminal of your load (e.g., motor controller) here.
• -Charge +: Connect the positive terminal of your charger here. The negative terminal of the charger should connect to PACK-.
• COMMON: This is a common ground point.

4.2. Cell Balance Connections

• Cell (1-24): Connect the individual cell balance wires from your battery pack to the designated cell connectors on the BMS. Start from cell 1 (lowest voltage) and connect sequentially up to cell 24 (highest voltage). Double-check each connection for correct order and polarity.

4.3. Accessory Connections

• Temp Sensor (T1, T2, GND): Connect external temperature sensors if desired.
• OLED: Connect the 1.3-inch OLED display module using the provided cable for real-time data display.
• Button: Connect the 12mm 3-6V key switch to this port to control the BMS power.
• Type-C: Use the USB Type-C cable to connect the BMS to a computer for configuration and firmware updates.
• SERIAL, CAN, DEBUG: These ports are for communication and debugging purposes. Refer to advanced documentation for their specific use.

Safety Warning: Always ensure all connections are secure and correct before applying power to avoid damage to the BMS or battery pack. Incorrect wiring can lead to severe damage or fire.

5. Operation

5.1. Powering On/Off

Use the connected 12mm 3-6V key switch to power the BMS on or off. The status LED and buzzer will provide feedback on the BMS's state.

5.2. Monitoring

The 1.3-inch OLED display module provides real-time information about your battery pack, including cell voltages, total pack voltage, current, and State of Charge (SOC).

5.3. Configuration and Firmware

The BMS can be configured and its firmware updated via the USB Type-C port. Download the latest MAXKGO-BMS-TOOL or ENNOID-BMS-TOOL software from the official Flipsky website. Connect the BMS to your computer using the provided USB cable and follow the software instructions for advanced settings and diagnostics.

5.4. Protection Functions

The BMS continuously monitors the battery pack for various conditions and activates protection mechanisms as needed:

• Overcharge Protection: Prevents cells from being charged beyond their safe voltage limit.
• Over-discharge Protection: Prevents cells from being discharged below their safe voltage limit.
• Overcurrent Protection: Limits current during discharge to prevent damage to cells or components.
• Short Circuit Protection: Immediately cuts off power in case of a short circuit.
• Temperature Protection: Monitors board and battery temperature (with external sensors) to prevent operation outside safe temperature ranges.
• Cell Balancing: Actively or passively balances cell voltages to ensure longevity and performance of the battery pack.

6. Maintenance

• Regular Inspection: Periodically check all wiring connections for tightness and signs of wear or corrosion.
• Cleanliness: Keep the BMS clean and free from dust, dirt, and moisture. Use a soft, dry cloth for cleaning.
• Temperature Management: Ensure the BMS operates within its specified working temperature range (-20℃ to +80℃). Avoid exposing it to extreme heat or cold.
• Storage: If storing the battery pack and BMS for an extended period, ensure they are kept within the storage temperature range (-20℃ to +100℃) and at a recommended State of Charge (e.g., 50%).
• Firmware Updates: Check the Flipsky website periodically for firmware updates that may improve performance or add new features.

7. Troubleshooting

• BMS Not Powering On: Check the key switch connection and functionality. Verify the main battery pack voltage is within the minimum operating voltage.
• No Display on OLED: Ensure the OLED module is correctly connected to the BMS. Check the cable for damage.
• Battery Not Charging/Discharging: Verify all main power connections (PACK+, PACK-, LOAD+, -Charge +). Check for any active protection (e.g., over-discharge, overcurrent) indicated by the BMS software or LED/buzzer.
• Cell Imbalance: If the OLED or software indicates significant cell voltage differences, ensure all cell balance wires are correctly and securely connected. The BMS will attempt to balance cells, but severe imbalance may require manual intervention or professional service.
• Overheating: If the BMS or battery pack becomes excessively hot, immediately disconnect power. Check for short circuits, excessive load, or poor ventilation. Ensure the operating temperature range is respected.
• Communication Issues (USB/CAN/UART): Verify cable connections. Ensure the correct drivers are installed on your computer for USB communication. Check software settings.

8. Warranty and Support

Flipsky products are tested before shipment. For warranty claims or technical support, please contact Flipsky service at flipsky_service@outlook.com. Please provide your original order number and purchase details when contacting support.

The warranty period for consumable electronic products (e.g., ESC/Motor/Battery) is generally 2 months from the 7th day after shipment. For non-electronic products, the warranty period is typically 2 months from the 7th day after shipment. Specific conditions may apply based on the product type and purchase date. Please refer to the seller's detailed warranty policy for the most accurate and up-to-date information.

9. User Tips

• Pre-charge Circuit: The integrated precharge circuit helps to prevent large inrush currents when connecting the BMS to a discharged load, protecting components.
• Software Tools: Familiarize yourself with the MAXKGO-BMS-TOOL or ENNOID-BMS-TOOL software. These tools offer advanced monitoring, logging, and customization options that can significantly enhance your experience and help diagnose issues.
• Battery Compatibility: While the BMS supports various lithium battery types, always ensure your battery chemistry and cell count (S-number) match the BMS specifications to prevent damage.
• Ventilation: Ensure adequate airflow around the BMS, especially in high-current applications, to aid in heat dissipation.