Wiki source code of 2. Installation and connection

Version 67.1 by Admin on 2025/07/15 17:30

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
65.1	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.
63.1	7
	8	Before use, configure the system. Proper operation of the BMS is possible only if it is correctly configured.
	9
66.1	10	(% class="box errormessage" %)
63.1	11	(((
	12	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.
	13	)))
	14
	15	(% class="box errormessage" %)
	16	(((
66.1	17	The system is not designed to operate with batteries whose total voltage exceeds 1200 V.
63.1	18	)))
	19
49.1	20	== Installation procedure ==
	21
45.1	22	Overall and mounting dimensions of the BMS Main 2.1 are shown below.
26.2	23
	24
49.3	25	(% style="width:494px" %)
	26	\|Parameter\|(% style="width:178px" %)Value
67.1	27	\|Overall dimensions (length × width × height), mm\|(% style="width:178px" %)120 × 120 × 17
49.3	28	\|Mounting dimensions (length × width), mm\|(% style="width:178px" %)114 × 114
	29	\|Mounting holes\|(% style="width:178px" %)M3
26.2	30
49.1	31	== Connection procedure ==
26.2	32
20.3	33	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	34
20.3	35	1. Connect the charging and discharging contactors to the P6-P9 headers.
	36	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.
	37	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.
	38	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.
	39
49.1	40	== Headers description ==
20.3	41
1.2	42	The BMS Main 2.1 headers are shown in figure below.
	43
44.1	44	[[image:1731516393377-928.jpeg\|\|alt="1731517946345-632.png" data-xwiki-image-style-alignment="center" height="417" width="451"]]
1.2	45
48.1	46	(% class="box warningmessage" %)
	47	(((
	48	Attention!
	49	All headers are shown from the device side!
	50	)))
20.3	51
49.1	52	=== P1 – header for power supply ===
2.2	53
55.1	54	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	55
47.1	56	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
2.2	57
46.1	58	\|Pin\|Name\|Description
	59	\|1\|GND\|Ground
	60	\|2\|V+\|Supply voltage 9-30V
4.2	61
49.1	62	=== P15 – header for BMS Logic ===
4.2	63
55.1	64	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
	65
47.1	66	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
4.2	67
46.1	68	\|Pin\|Name\|Description
	69	\|1\|RS485_A\|RS-485 line A for communication with BMS Logic
	70	\|2\|RS485_B\|RS-485 line B for communication with BMS Logic
	71	\|3\|+5V\|Supply voltage for BMS Logic
	72	\|4\|GND\|Ground
44.1	73
49.1	74	=== P12 – header for current sensor ===
5.2	75
55.1	76	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
	77
47.1	78	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
5.3	79
46.1	80	\|Pin\|Name\|Description
	81	\|1\|+5V\|Supply voltage for the current sensor 5V, max 50 mA
	82	\|2\|GND\|Ground
	83	\|3\|Vcs\|ADC input (current sensor output)
	84	\|4\|Vref\|ADC input (current sensor reference signal)
5.3	85
49.1	86	=== P13 – header for humidity sensor ===
5.3	87
55.1	88	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
	89
47.1	90	[[image:1732198896526-660.png\|\|data-xwiki-image-style-alignment="center" height="70" width="64"]]
6.2	91
46.1	92	\|Pin\|Name\|Description
	93	\|1\|+5V\|Supply voltage 5 V, max 50 mA
	94	\|2\|GND\|Ground
	95	\|3\|Vhs\|ADC input (humidity sensor output)
	96	\|4\|Vts\|ADC input (temperature sensor output)
6.2	97
49.1	98	=== P8 – header of relay 1 ===
6.2	99
55.1	100	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	101
47.1	102	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
6.2	103
	104	By default, relay 1 is used to control the discharging contactor.
	105
46.1	106	\|Pin\|Name\|Description
56.2	107	\|1\|V+\|Switching voltage (up to 55V, max 3A)
46.1	108	\|2\|NO\|Normally open contact
6.2	109
60.2	110	Contactor connection example for all relays:
58.2	111
60.2	112	[[image:1741619814065-850.png\|\|height="189" width="252"]]
59.2	113
49.1	114	=== P9 – header of relay 2 ===
11.2	115
55.1	116	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	117
47.1	118	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
11.2	119
	120	By default, relay 2 is used to output the “Allow charging” signal.
	121
46.1	122	\|Pin\|Name\|Description
56.2	123	\|1\|V+\|Switching voltage (up to 55V, max 3A)
46.1	124	\|2\|NO\|Normally open contact
6.2	125
61.1	126	Contactor connection example: see relay 1.
	127
49.1	128	=== P6 – header of relay 3 ===
6.2	129
55.1	130	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	131
47.1	132	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
6.2	133
11.2	134	By default, relay 3 is used to control the charging contactor.
6.2	135
46.1	136	\|Pin\|Name\|Description
56.2	137	\|1\|V+\|Switching voltage up to 55V,
	138	up to 8A (board rev. 2.1b), up to 3A (board rev. 2.1c)
46.1	139	\|2\|NO\|Normally open contact
6.2	140
61.1	141	Contactor connection example: see relay 1.
	142
49.1	143	=== P7 – header of relay 4 ===
6.2	144
55.1	145	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
	146
47.1	147	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
11.2	148
	149	By default, relay 4 is used to control the heater.
	150
46.1	151	\|Pin\|Name\|Description
56.2	152	\|1\|V+\|Switching voltage up to 55V,
	153	up to 8A (board rev. 2.1b), up to 3A (board rev. 2.1c)
46.1	154	\|2\|NO\|Normally open contact
6.2	155
61.1	156	Contactor connection example: see relay 1.
	157
49.1	158	=== P14 – header for CAN and RS-485 interfaces ===
6.2	159
55.1	160	Receptacle Housing: Molex 430250600. Terminals: Molex 43030
	161
47.1	162	[[image:1731517180930-597.png\|\|data-xwiki-image-style-alignment="center" height="81" width="113"]]
6.2	163
21.3	164	(% style="width:641px" %)
46.1	165	\|Pin\|Name\|Description
	166	\|1\|EXT_RS485_A\|RS-485 line A for communication with external equipment
	167	\|2\|CAN_H\|CAN H line for communication with external equipment
	168	\|3\|+5V_CAN\|Supply voltage 5V for external devices, max 200 mA
	169	\|4\|EXT_RS485_B\|RS-485 line B for communication with external equipment
	170	\|5\|CAN_L\|CAN L line for communication with external equipment
	171	\|6\|GND_CAN\|Ground
11.2	172
49.1	173	=== P21 – CAN termination resistor jumper ===
11.2	174
47.1	175	[[image:1731517188900-976.png\|\|data-xwiki-image-style-alignment="center" height="78" width="149"]]
11.2	176
	177	To connect the termination resistor between the lines CAN_H and CAN_L, install a jumper, according to the P21 pinout:
	178
46.1	179	\|Pin\|Name\|Description
	180	\|1-2\|120 Ohm\|Termination resistor 120 Ohm is connected
	181	\|2-3\|-\|Termination resistor 120 Ohm is not connected
11.2	182
49.1	183	=== P22 - RS-485 termination resistor jumper ===
11.2	184
47.1	185	[[image:1731517195672-298.png\|\|data-xwiki-image-style-alignment="center" height="81" width="155"]]
11.2	186
	187	To connect the termination resistor between the EXT_RS485_A and EXT_RS485_B lines, install a jumper according to the P22 pinout:
	188
46.1	189	\|Pin\|Name\|Description
	190	\|1-2\|120 Ohm\|Terminating resistor 120 Ohm is connected
	191	\|2-3\|-\|Terminating resistor 120 Ohm is not connected
11.2	192
49.1	193	=== P11 – header for discrete inputs/outputs ===
11.2	194
55.1	195	Receptacle Housing: Molex 430251600. Terminals: Molex 43030
	196
47.1	197	[[image:1732198937514-731.png\|\|data-xwiki-image-style-alignment="center" height="85" width="272"]]
11.2	198
46.1	199	\|Pin\|Name\|Description
	200	\|16\|IN_1\|Discrete input #1 “dry contact” (+5V)
	201	\|8\|GND_1\|Discrete input #1 “dry contact” (ground)
	202	\|15\|IN_2\|Discrete input #2 “dry contact” (+5V)
	203	\|7\|GND_2\|Discrete input #2 “dry contact” (ground)
	204	\|14\|IN_3\|Discrete input #3 “dry contact” (+5V)
	205	\|6\|GND_3\|Discrete input #3 “dry contact” (ground)
	206	\|13\|IN_4\|Discrete input #4 “dry contact” (+5V)
	207	\|5\|GND_4\|Discrete input #4 “dry contact” (ground)
	208	\|12\|OUT_4\|Discrete output #4 (+5V, 20mA)
	209	\|4\|GND_OUT_4\|Discrete output #4 (ground)
	210	\|11\|OUT_3\|Discrete output #3 (+5V, 20mA)
	211	\|3\|GND_OUT_3\|Discrete output #3 (ground)
	212	\|10\|OUT_2\|Discrete output #2 (+5V, 20mA)
	213	\|2\|GND_OUT_2\|Discrete output #2 (ground)
	214	\|9\|OUT_1\|Discrete output #1 (+5V, 20mA)
	215	\|1\|GND_OUT_1\|Discrete output #1 (ground)
11.2	216
49.1	217	== Indicators ==
11.2	218
49.1	219	=== DS1 – power indicator ===
13.1	220
46.1	221	\|State\|Description
	222	\|Lights red\|The device is powered
	223	\|Off\|The device is not powered
11.2	224
49.1	225	=== DS2 – operation indicator ===
11.2	226
46.1	227	\|State\|Description
	228	\|Blinking green\|The BMS firmware is running
	229	\|Off\|The BMS firmware is not running
11.2	230
49.1	231	=== DS3 – communication indicator ===
11.2	232
46.1	233	\|State\|Description
	234	\|Blinking yellow (2Hz)\|Initializing communication with BMS Logic boards
	235	\|Blinking yellow (25Hz)\|Communication with BMS Logic is established
11.2	236
49.1	237	=== DS4 – error indicator ===
11.2	238
	239
46.1	240	\|(State\|Description
	241	\|(Blinking red\|Errors in communication with BMS Logic
	242
49.1	243	=== DS7 – relay 1 indicator ===
11.2	244
46.1	245	\|State\|Description
	246	\|Lights green\|Relay #1 is closed
	247	\|Off\|Relay #1 is opened
11.2	248
49.1	249	=== DS8 – relay 2 indicator ===
11.2	250
46.1	251	\|State\|Description
	252	\|Lights green\|Relay #2 is closed
	253	\|Off\|Relay #2 is opened
19.1	254
49.1	255	=== DS5 – relay 3 indicator ===
11.2	256
46.1	257	\|State\|Description
	258	\|Lights green\|Relay #3 is closed
	259	\|Off\|Relay #3 is opened
11.2	260
49.1	261	=== DS6 – relay 4 indicator ===
11.2	262
46.1	263	\|State\|Description
	264	\|Lights green\|Relay #4 is closed
	265	\|Off\|Relay #4 is opened
11.2	266
5.3	267

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