Wiki source code of 2. Installation and connection

Version 63.1 by Admin on 2025/03/18 12:17

version	line-number	content
49.1	1	(% data-numbered-headings-start="2" style="--numbered-headings-start: 1;font-size: 0px;color: rgba(0, 0, 0, 0.0);margin-bottom: 0px; margin-top: 0px;" %)
	2	= Installation and connection =
25.4	3
63.1	4	== Safety rules ==
	5
	6	To perform the protection functions, the BMS must be able to disconnect the battery from the load and charger. To do this, at least one contactor able to break the load and charge circuits must be connected to the BMS.
	7
	8	Before use, configure the system. Proper operation of the BMS is possible only if it is correctly configured.
	9
	10	It is not recommended to use the system in batteries formed by several series of cells connected in parallel. To increase capacity, it is recommended to connect several cells in parallel groups, and then connect the groups in series.
	11
	12	(% class="box warningmessage" %)
	13	(((
	14	The BMS can be connected to batteries with life-threatening and health-hazardous voltage levels. When working with high-voltage batteries, observe electrical safety regulations, use safety glasses, protective clothing, insulated tools and appliances. To prevent the damage of device avoid electrostatic discharges while working with the battery.
	15	)))
	16
	17	(% class="box errormessage" %)
	18	(((
	19	The system is not designed to operate with batteries whose total voltage exceeds 1200 V.
	20	)))
	21
49.1	22	== Installation procedure ==
	23
45.1	24	Overall and mounting dimensions of the BMS Main 2.1 are shown below.
26.2	25
44.1	26	[[image:1732198397369-222.png\|\|data-xwiki-image-style-alignment="center" height="393" width="556"]]
26.2	27
49.3	28	(% style="width:494px" %)
	29	\|Parameter\|(% style="width:178px" %)Value
	30	\|Overall dimensions (length × width × height), mm\|(% style="width:178px" %)120 × 120 × 32
	31	\|Mounting dimensions (length × width), mm\|(% style="width:178px" %)114 × 114
	32	\|Mounting holes\|(% style="width:178px" %)M3
26.2	33
49.1	34	== Connection procedure ==
26.2	35
20.3	36	The mounting area of the BMS Main 2.1 must be protected from mechanical particles (dust, dirt, large objects) and water. The installation site must provide convenient access for subsequent connection to the device’s headers.
1.2	37
20.3	38	1. Connect the charging and discharging contactors to the P6-P9 headers.
	39	1. Connect a current sensor to the P12 header according to its documentation. The positive current direction (indicated by an arrow on the sensor) corresponds to the battery charging. It is recommended to use a shielded cable to connect the current sensor, the shield should be grounded on the side of the current sensor. The cable should be positioned as far as possible from the high current circuits. If the current sensor has a reference voltage line, connect it to pin 4 of the P12 header.
	40	1. Connect the BMS Main 2.1 to the on-board CAN network. Observe the rules for connecting CAN devices. If the BMS Main 2.1 is the last device on a bus, close pins 1-2 on the P21 jumper, otherwise leave the jumper on pins 2-3.
	41	1. Connect a power supply to the P1 header. It is not recommended to power the BMS Main 2.1 from the battery only, since at a critical discharge of the battery, it is not possible to turn on the BMS and close the charging contactor.
	42
49.1	43	== Headers description ==
20.3	44
1.2	45	The BMS Main 2.1 headers are shown in figure below.
	46
44.1	47	[[image:1731516393377-928.jpeg\|\|alt="1731517946345-632.png" data-xwiki-image-style-alignment="center" height="417" width="451"]]
1.2	48
48.1	49	(% class="box warningmessage" %)
	50	(((
	51	Attention!
	52	All headers are shown from the device side!
	53	)))
20.3	54
49.1	55	=== P1 – header for power supply ===
2.2	56
55.1	57	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	58
47.1	59	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
2.2	60
46.1	61	\|Pin\|Name\|Description
	62	\|1\|GND\|Ground
	63	\|2\|V+\|Supply voltage 9-30V
4.2	64
49.1	65	=== P15 – header for BMS Logic ===
4.2	66
55.1	67	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
	68
47.1	69	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
4.2	70
46.1	71	\|Pin\|Name\|Description
	72	\|1\|RS485_A\|RS-485 line A for communication with BMS Logic
	73	\|2\|RS485_B\|RS-485 line B for communication with BMS Logic
	74	\|3\|+5V\|Supply voltage for BMS Logic
	75	\|4\|GND\|Ground
44.1	76
49.1	77	=== P12 – header for current sensor ===
5.2	78
55.1	79	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
	80
47.1	81	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
5.3	82
46.1	83	\|Pin\|Name\|Description
	84	\|1\|+5V\|Supply voltage for the current sensor 5V, max 50 mA
	85	\|2\|GND\|Ground
	86	\|3\|Vcs\|ADC input (current sensor output)
	87	\|4\|Vref\|ADC input (current sensor reference signal)
5.3	88
49.1	89	=== P13 – header for humidity sensor ===
5.3	90
55.1	91	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
	92
47.1	93	[[image:1732198896526-660.png\|\|data-xwiki-image-style-alignment="center" height="70" width="64"]]
6.2	94
46.1	95	\|Pin\|Name\|Description
	96	\|1\|+5V\|Supply voltage 5 V, max 50 mA
	97	\|2\|GND\|Ground
	98	\|3\|Vhs\|ADC input (humidity sensor output)
	99	\|4\|Vts\|ADC input (temperature sensor output)
6.2	100
49.1	101	=== P8 – header of relay 1 ===
6.2	102
55.1	103	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	104
47.1	105	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
6.2	106
	107	By default, relay 1 is used to control the discharging contactor.
	108
46.1	109	\|Pin\|Name\|Description
56.2	110	\|1\|V+\|Switching voltage (up to 55V, max 3A)
46.1	111	\|2\|NO\|Normally open contact
6.2	112
60.2	113	Contactor connection example for all relays:
58.2	114
60.2	115	[[image:1741619814065-850.png\|\|height="189" width="252"]]
59.2	116
49.1	117	=== P9 – header of relay 2 ===
11.2	118
55.1	119	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	120
47.1	121	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
11.2	122
	123	By default, relay 2 is used to output the “Allow charging” signal.
	124
46.1	125	\|Pin\|Name\|Description
56.2	126	\|1\|V+\|Switching voltage (up to 55V, max 3A)
46.1	127	\|2\|NO\|Normally open contact
6.2	128
61.1	129	Contactor connection example: see relay 1.
	130
49.1	131	=== P6 – header of relay 3 ===
6.2	132
55.1	133	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	134
47.1	135	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
6.2	136
11.2	137	By default, relay 3 is used to control the charging contactor.
6.2	138
46.1	139	\|Pin\|Name\|Description
56.2	140	\|1\|V+\|Switching voltage up to 55V,
	141	up to 8A (board rev. 2.1b), up to 3A (board rev. 2.1c)
46.1	142	\|2\|NO\|Normally open contact
6.2	143
61.1	144	Contactor connection example: see relay 1.
	145
49.1	146	=== P7 – header of relay 4 ===
6.2	147
55.1	148	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	149
47.1	150	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
11.2	151
	152	By default, relay 4 is used to control the heater.
	153
46.1	154	\|Pin\|Name\|Description
56.2	155	\|1\|V+\|Switching voltage up to 55V,
	156	up to 8A (board rev. 2.1b), up to 3A (board rev. 2.1c)
46.1	157	\|2\|NO\|Normally open contact
6.2	158
61.1	159	Contactor connection example: see relay 1.
	160
49.1	161	=== P14 – header for CAN and RS-485 interfaces ===
6.2	162
55.1	163	Receptacle Housing: Molex 430250600. Terminals: Molex 43030
	164
47.1	165	[[image:1731517180930-597.png\|\|data-xwiki-image-style-alignment="center" height="81" width="113"]]
6.2	166
21.3	167	(% style="width:641px" %)
46.1	168	\|Pin\|Name\|Description
	169	\|1\|EXT_RS485_A\|RS-485 line A for communication with external equipment
	170	\|2\|CAN_H\|CAN H line for communication with external equipment
	171	\|3\|+5V_CAN\|Supply voltage 5V for external devices, max 200 mA
	172	\|4\|EXT_RS485_B\|RS-485 line B for communication with external equipment
	173	\|5\|CAN_L\|CAN L line for communication with external equipment
	174	\|6\|GND_CAN\|Ground
11.2	175
49.1	176	=== P21 – CAN termination resistor jumper ===
11.2	177
47.1	178	[[image:1731517188900-976.png\|\|data-xwiki-image-style-alignment="center" height="78" width="149"]]
11.2	179
	180	To connect the termination resistor between the lines CAN_H and CAN_L, install a jumper, according to the P21 pinout:
	181
46.1	182	\|Pin\|Name\|Description
	183	\|1-2\|120 Ohm\|Termination resistor 120 Ohm is connected
	184	\|2-3\|-\|Termination resistor 120 Ohm is not connected
11.2	185
49.1	186	=== P22 - RS-485 termination resistor jumper ===
11.2	187
47.1	188	[[image:1731517195672-298.png\|\|data-xwiki-image-style-alignment="center" height="81" width="155"]]
11.2	189
	190	To connect the termination resistor between the EXT_RS485_A and EXT_RS485_B lines, install a jumper according to the P22 pinout:
	191
46.1	192	\|Pin\|Name\|Description
	193	\|1-2\|120 Ohm\|Terminating resistor 120 Ohm is connected
	194	\|2-3\|-\|Terminating resistor 120 Ohm is not connected
11.2	195
49.1	196	=== P11 – header for discrete inputs/outputs ===
11.2	197
55.1	198	Receptacle Housing: Molex 430251600. Terminals: Molex 43030
	199
47.1	200	[[image:1732198937514-731.png\|\|data-xwiki-image-style-alignment="center" height="85" width="272"]]
11.2	201
46.1	202	\|Pin\|Name\|Description
	203	\|16\|IN_1\|Discrete input #1 “dry contact” (+5V)
	204	\|8\|GND_1\|Discrete input #1 “dry contact” (ground)
	205	\|15\|IN_2\|Discrete input #2 “dry contact” (+5V)
	206	\|7\|GND_2\|Discrete input #2 “dry contact” (ground)
	207	\|14\|IN_3\|Discrete input #3 “dry contact” (+5V)
	208	\|6\|GND_3\|Discrete input #3 “dry contact” (ground)
	209	\|13\|IN_4\|Discrete input #4 “dry contact” (+5V)
	210	\|5\|GND_4\|Discrete input #4 “dry contact” (ground)
	211	\|12\|OUT_4\|Discrete output #4 (+5V, 20mA)
	212	\|4\|GND_OUT_4\|Discrete output #4 (ground)
	213	\|11\|OUT_3\|Discrete output #3 (+5V, 20mA)
	214	\|3\|GND_OUT_3\|Discrete output #3 (ground)
	215	\|10\|OUT_2\|Discrete output #2 (+5V, 20mA)
	216	\|2\|GND_OUT_2\|Discrete output #2 (ground)
	217	\|9\|OUT_1\|Discrete output #1 (+5V, 20mA)
	218	\|1\|GND_OUT_1\|Discrete output #1 (ground)
11.2	219
49.1	220	== Indicators ==
11.2	221
49.1	222	=== DS1 – power indicator ===
13.1	223
46.1	224	\|State\|Description
	225	\|Lights red\|The device is powered
	226	\|Off\|The device is not powered
11.2	227
49.1	228	=== DS2 – operation indicator ===
11.2	229
46.1	230	\|State\|Description
	231	\|Blinking green\|The BMS firmware is running
	232	\|Off\|The BMS firmware is not running
11.2	233
49.1	234	=== DS3 – communication indicator ===
11.2	235
46.1	236	\|State\|Description
	237	\|Blinking yellow (2Hz)\|Initializing communication with BMS Logic boards
	238	\|Blinking yellow (25Hz)\|Communication with BMS Logic is established
11.2	239
49.1	240	=== DS4 – error indicator ===
11.2	241
	242
46.1	243	\|(State\|Description
	244	\|(Blinking red\|Errors in communication with BMS Logic
	245
49.1	246	=== DS7 – relay 1 indicator ===
11.2	247
46.1	248	\|State\|Description
	249	\|Lights green\|Relay #1 is closed
	250	\|Off\|Relay #1 is opened
11.2	251
49.1	252	=== DS8 – relay 2 indicator ===
11.2	253
46.1	254	\|State\|Description
	255	\|Lights green\|Relay #2 is closed
	256	\|Off\|Relay #2 is opened
19.1	257
49.1	258	=== DS5 – relay 3 indicator ===
11.2	259
46.1	260	\|State\|Description
	261	\|Lights green\|Relay #3 is closed
	262	\|Off\|Relay #3 is opened
11.2	263
49.1	264	=== DS6 – relay 4 indicator ===
11.2	265
46.1	266	\|State\|Description
	267	\|Lights green\|Relay #4 is closed
	268	\|Off\|Relay #4 is opened
11.2	269
5.3	270

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