Changes for page 2. Installation and connection
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... ... @@ -1,1 +1,1 @@ 1 - Battery managementsystems.BMS Main3.WebHome1 +drafts.BMS Main 2R.WebHome - Content
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... ... @@ -1,27 +1,42 @@ 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 2 = Installation and connection = 3 3 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 +(% class="box errormessage" %) 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 +((( 17 +The system is not designed to operate with batteries whose total voltage exceeds 3000 V. 18 +))) 19 + 4 4 == Installation procedure == 5 5 6 -The mounting location of the BMS Main 3/ BMS Main 3Xdevice must be protected from mechanical particles (dust, dirt, large objects) and water. The installation location must provide easy access for subsequent connection to the device connectors.22 +The mounting location of the BMS Main 2R device must be protected from mechanical particles (dust, dirt, large objects) and water. The installation location must provide easy access for subsequent connection to the device connectors. 7 7 8 8 Overall and mounting dimensions are shown in figure below. 9 9 10 - (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1733311711953-224.png||data-xwiki-image-style-alignment="center" height="566" width="775"]](% title="Click and drag to resize" %)26 +[[image:1774349658793-888.0b.STEP.JPG||data-xwiki-image-style-alignment="center" height="522" width="450"]](% title="Click and drag to resize" %) 11 11 12 12 |**Parameter**|**Value** 13 -|Overall dimensions (length × width × height), mm|20 0× 123× 1214 -|Mounting dimensions (length × width), mm|1 94 × 11429 +|Overall dimensions (length × width × height), mm|120 × 120 × 16 30 +|Mounting dimensions (length × width), mm|114 × 114 15 15 |Mounting holes|M3 16 -|Connector type|Hirose ZE05 17 17 18 18 == Headers == 19 19 20 -The location and designation of connectors on the BMS Main 3/ BMS Main 3Xdevice are shown below.35 +The location and designation of connectors on the BMS Main 2R device are shown below. 21 21 22 22 (% contenteditable="false" tabindex="-1" %) 23 23 ((( 24 -[[image:17 32119505664-787.png||data-xwiki-image-style-alignment="center"height="417" width="684"]]39 +[[image:1774455018488-627.png||data-xwiki-image-style-alignment="center"]] 25 25 ))) 26 26 27 27 (% class="box warningmessage" %) ... ... @@ -30,191 +30,96 @@ 30 30 All headers are shown from the device side! 31 31 ))) 32 32 33 -=== X1 – header topowerthedevice ===48 +=== X1 – header for discrete inputs and outputs === 34 34 50 +Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF 51 + 35 35 (% class="wikigeneratedid" id="H" %) 36 - (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png||data-xwiki-image-style-alignment="center" height="85" width="200"]]53 +[[image:1732198937514-731.png||data-xwiki-image-style-alignment="center" height="85" width="272"]] 37 37 38 38 |**Pin**|**Name**|**Description** 39 -|**1–2, 5–6**|**GND**|Ground 40 -|**3**|**KEYRUN**|Power-on signal 41 -|**4**|**CHARGE_ON**|Power-on signal (battery charge requirement) 42 -|**7–8**|**VIN**|Power line (9-32V) 56 +|**1–8**|**GND**|Ground 57 +|**9**|**DO_1**|Discrete output 1 (+5V, 20mA) 58 +|**10**|**DO_2**|Discrete output 2 (+5V, 20mA) 59 +|**11**|**DO_3**|Discrete output 3 (+5V, 20mA) 60 +|**12**|**DO_4**|Discrete output 4 (+5V, 20mA) 61 +|**13**|**DI_4**|Discrete input 4 (“dry contact”, +5V) 62 +|**14**|**DI_3**|Discrete input 3 (“dry contact”, +5V) 63 +|**15**|**DI_2**|Discrete input 2 (“dry contact”, +5V) 64 +|**16**|**DI_1**|Discrete input 1 (“dry contact”, +5V) 43 43 44 -Power supply connection diagram: 45 45 46 -(% aria-label="1732120054870-496.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732120054870-496.png||data-xwiki-image-style-alignment="center" height="169" width="327"]] 47 47 48 -=== X2 – headerforcontactors===68 +=== X2 – miniUSB connector === 49 49 50 - (% aria-label="1732121695049-411.pngimage widget" data-widget="image"contenteditable="false" role="region"tabindex="-1"%)[[image:1732121695049-411.png||data-xwiki-image-style-alignment="center"height="87"width="267"]](% title="Clickanddragto resize" %)70 +The miniUSB connector is used to configure the parameters of the BMS Main 2R device. 51 51 52 -|**Pin**|**Name**|**Description** 53 -|**1–4, 8–9**|**GND**|Ground 54 -|**5**|**CONT1_OUT**|Contactor control 1 (plus) 55 -|**6**|**CONT2_OUT**|Contactor control 2 (plus) 56 -|**7**|**CONT3_OUT**|Contactor control 3 (plus) 57 -|**10**|**CONT4_OUT**|Contactor control 4 (plus) 58 -|**11**|**CONT5_OUT**|Contactor control 5 (plus) 59 -|**12**|**CONT6_OUT**|Contactor control 6 (plus) 72 +=== (% title="Click and drag to resize" %)(%%)X3 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for power supply(%%) === 60 60 61 - Contactorconnectiondiagram:74 +Receptacle Housing: Molex 39012020. Terminals: Molex 5556 62 62 63 - (% aria-label="1732121755886-234.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121755886-234.png||data-xwiki-image-style-alignment="center" height="82" width="260"]]76 +[[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]] 64 64 65 -=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs === 66 - 67 -(% aria-label="1732121811285-182.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121811285-182.png||data-xwiki-image-style-alignment="center" height="94" width="531"]] 68 - 69 69 |**Pin**|**Name**|**Description** 70 -|**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals 71 -|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact” 72 -|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact” 73 -|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact” 74 -|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact” 75 -|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact” 76 -|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact” 77 -|**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V) 78 -|**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V) 79 -|**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A) 80 -|**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A) 81 -|**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A) 82 -|**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A) 79 +|**1**|**GND**|Ground 80 +|**2**|**V+**|Supply voltage (9-32V) 83 83 84 -Connection diagram of a discrete input to a dry contact output: 85 85 86 -(% aria-label="1732121887401-555.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121887401-555.png||data-xwiki-image-style-alignment="center" height="63" width="196"]](% title="Click and drag to resize" %)(%%)Connection diagram of a discrete input to an open collector output: 87 87 88 - (% aria-label="1732122137116-973.png image widget" data-widget="image" contenteditable="false"role="region"tabindex="-1"%)[[image:1732122137116-973.png||data-xwiki-image-style-alignment="center"height="100" width="274"]](% title="Clickanddragto resize" %)(%%)Connection diagramforadiscreteinput fordetectinga9-32V signal:84 +=== X4, X5, X6, X7 – header of relay 1, 2, 3 and 4 === 89 89 90 - (% aria-label="1732121926812-202.png image widget" data-widget="image"contenteditable="false"role="region"tabindex="-1"%)[[image:1732121926812-202.png||data-xwiki-image-style-alignment="center"height="76" width="242"]](% title="Click and drag to resize" %)(%%)Connectiondiagram for discrete output:86 +Receptacle Housing: Molex 39012020. Terminals: Molex 5556 91 91 92 - === X4– headerforHVIL===88 +[[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]] 93 93 94 -[[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]] 95 - 96 96 |**Pin**|**Name**|**Description** 97 -|**1**|**-**|Not used 98 -|**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output) 99 -|**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input) 100 -|**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA) 91 +|**1**|**V+**|Switching voltage (up to 55V, max 3A) 92 +|**2**|**NO**|Normally open contact 101 101 102 - If the BMS Main3 / BMS Main 3X device generates current inacurrentloop, the currentloop must beconnected tothe**HVIL_PWR**and **HVIL_IN**pins. If BMS Main 3 / BMS Main 3X is a passivecurrentloopmeter, then the currentloop must be connected to the **HVIL_IN**and **HVIL_OUT** pins.94 +Contactor connection example for all relays: 103 103 104 - Connectiondiagramtothecurrentloop:96 +[[image:1774456661980-866.png||data-xwiki-image-style-alignment="center" height="211" width="282"]] 105 105 106 -=== X5 – header for current and temperature sensors === 107 107 108 - [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center"height="83"width="349"]]99 +=== X8 – header for current sensor 1 === 109 109 110 -(% style="width:539px" %) 111 -|**Pin**|**Name**|(% style="width:402px" %)**Description** 112 -|**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA) 113 -|**2–6**|**GND**|(% style="width:402px" %)Ground 114 -|**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output) 115 -|**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output) 116 -|**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA) 117 -|**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output) 118 -|**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output) 119 -|**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA) 120 -|**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output) 121 -|**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output) 122 -|**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm) 123 -|**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm) 101 +Receptacle Housing: Molex 430250400. Terminals: Molex 43030 124 124 125 - Currentsensor connectiondiagram(using the example of LEM HASS100-S):103 +[[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]] 126 126 127 -[[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]] 128 - 129 -Current sensor connection diagram (using the example of LEM DHAB S/118): 130 - 131 -[[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]] 132 - 133 -NTC-thermistor connection diagram: 134 - 135 -[[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]] 136 - 137 -=== X6 – header for CAN1 and RS-485-1 (external buses) === 138 - 139 -[[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]] 140 - 141 141 |**Pin**|**Name**|**Description** 142 -|**1**|**CAN1_H**|CAN1 line H for communication with external equipment 143 -|**2**|**CAN1_L**|CAN1 line L for communication with external equipment 144 -|**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1 145 -|**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment 146 -|**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment 106 +|**1**|**+5V**|Supply voltage for the current sensor 5V, max 50 mA 107 +|**2**|**GND**|Ground 108 +|**3**|**CS1_OUT**|Current sensor 1 output 109 +|**4**|**CS1_REF**|Current sensor 1 reference signal 147 147 148 - ConnectiondiagramtotheCAN1bus:111 +=== X9 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for current sensor 2(%%) === 149 149 150 - [[image:1733316241362-843.png||data-xwiki-image-style-alignment="center"height="153" width="410"]]113 +Receptacle Housing: Molex 430250400. Terminals: Molex 43030 151 151 152 - ConnectiondiagramtotheRS-485-1bus:115 +[[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]] 153 153 154 -[[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]] 155 - 156 -=== X7 – header for CAN2 (internal bus) === 157 - 158 -[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]] 159 - 160 160 |**Pin**|**Name**|**Description** 161 -|**1**|** CAN2_H**|CAN2lineHfor communicationwith otherBMSdevices162 -|**2**|** CAN2_L**|CAN2 line L forcommunication with other BMSdevices163 -|**3**|** GND**|Ground164 -|**4**|**C AN2_5V**|CAN2powerline(5 V, max 400 mA)118 +|**1**|**+5V**|Supply voltage for the current sensor 5V, max 50 mA 119 +|**2**|**GND**|Ground 120 +|**3**|**CS2_OUT**|Current sensor 2 output 121 +|**4**|**CS2_REF**|Current sensor 2 reference signal 165 165 166 - ConnectiondiagramtotheCAN2bus(usingtheexampleofconnectingBMS Display1.2):123 +=== X10 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for temperature sensors(%%) === 167 167 168 - [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center"height="158"width="392"]]125 +Receptacle Housing: Molex 430250400. Terminals: Molex 43030 169 169 170 - === X8– headerforCAN3===127 +[[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]] 171 171 172 -[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]] 173 - 174 174 |**Pin**|**Name**|**Description** 175 -|**1**|**CAN3_H**|CAN3 line H 176 -|**2**|**CAN3_L**|CAN3 line L 177 -|**3**|**GND**|Ground 178 -|**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA) 130 +|**1, 2**|**GND**|Ground 131 +|**3**|**T_SENS1**|Ground 132 +|**4**|**T_SENS2**|Current sensor 2 output 179 179 180 -(% class="box infomessage" %) 181 -((( 182 -**Note:** 183 -CAN3 operates differently depending on used firmware: 184 - 185 -* **BMS Main 3:** CAN3 bus is reserved; 186 -* **BMS Main 3X:** CAN3 bus is used to connect with BMS Main 3 inside parallel strings. Diagram for connecting battery modules to the CAN3 bus: 187 - 188 -[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]] 189 -))) 190 - 191 -=== X9 – header for BMS Logic (RS-485-2) === 192 - 193 -[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]] 194 - 195 -|**Pin**|**Name**|**Description** 196 -|**1**|**LOGIC_B**|RS-485 line B for communication with BMS Logic 197 -|**2**|**LOGIC_A**|RS-485 line A for communication with BMS Logic 198 -|**3**|**GND**|Ground 199 -|**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA) 200 - 201 -(% class="box infomessage" %) 202 -((( 203 -**Note:** 204 -RS-485-2 operates differently depending on used firmware: 205 - 206 -* **BMS Main 3X:** RS-485-2 bus is reserved; 207 -* **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices: 208 - 209 -[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]] 210 -))) 211 - 212 -=== X10 – miniUSB connector === 213 - 214 -The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device. 215 - 216 216 === X11 – header for high-voltage bus before contactors (plus) === 217 217 136 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 137 + 218 218 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]] 219 219 220 220 |**Pin**|**Name**|**Description** ... ... @@ -228,6 +228,8 @@ 228 228 229 229 === X12 – header for high-voltage bus before contactors (minus) === 230 230 151 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 152 + 231 231 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]] 232 232 233 233 |**Pin**|**Name**|**Description** ... ... @@ -241,6 +241,8 @@ 241 241 242 242 === X13 – header for high-voltage bus after contactors (plus) === 243 243 166 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 167 + 244 244 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]] 245 245 246 246 |**Pin**|**Name**|**Description** ... ... @@ -254,6 +254,8 @@ 254 254 255 255 === X14 – header for high-voltage bus after contactors (minus) === 256 256 181 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 182 + 257 257 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]] 258 258 259 259 |**Pin**|**Name**|**Description** ... ... @@ -295,7 +295,7 @@ 295 295 296 296 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 === 297 297 298 -The BMS Main 3/ BMS Main 3Xdevice implements a circuit for hardware opening of power contactors when the discrete input signal DIN7 and/or DIN8 (voltage level 9-32V) is removed. To enable this function, jumper J5 and/or J6 must be installed.224 +The BMS Main 2R device implements a circuit for hardware opening of power contactors when the discrete input signal DIN7 and/or DIN8 (voltage level 9-32V) is removed. To enable this function, jumper J5 and/or J6 must be installed. 299 299 300 300 == Indicators == 301 301 ... ... @@ -311,17 +311,19 @@ 311 311 |**Blinking green**|Executing the battery management program 312 312 |**No blinking**|Program execution error 313 313 314 -=== DS3 – LED indicating interaction with BMSLogic ===240 +=== DS3 – LED indicating interaction with child devices === 315 315 316 -|**State**|**Description** 317 -|**Blinking yellow**|The device interacts with BMS Logic devices 318 -|**No blinking**|- 242 +(% style="width:447px" %) 243 +|**State**|(% style="width:166px" %)**Description (Main 3)**|(% style="width:168px" %)**Description (Main 3X)** 244 +|**Blinking yellow**|(% style="width:166px" %)The device interacts with BMS Logic devices|(% style="width:168px" %)The device interacts with BMS Main 3 devices 245 +|**No blinking**|(% style="width:166px" %)-|(% style="width:168px" %)- 319 319 320 -=== DS4 – LED indicating loss of connection with BMS Logic ===247 +=== DS4 – LED indicating loss of connection with child devices === 321 321 322 -|**State**|**Description** 323 -|**Blinking/lights up red**|Communication with one or more BMS Logic devices is lost 324 -|**No blinking**|Communication with BMS Logic is stable 249 +(% style="width:601px" %) 250 +|**State**|(% style="width:220px" %)**Description (Main 3)**|(% style="width:218px" %)**Description (Main 3X)** 251 +|**Blinking/lights up red**|(% style="width:220px" %)Communication with one or more BMS Logic devices is lost|(% style="width:218px" %)Communication with one or more BMS Main 3 devices is lost 252 +|**No blinking**|(% style="width:220px" %)Communication with BMS Logic devices is stable|(% style="width:218px" %)Communication with BMS Main 3 devices is stable 325 325 326 326 === DS5-DS10 – LEDs indicating contactor switches 1-6 === 327 327 ... ... @@ -337,11 +337,6 @@ 337 337 338 338 == Connection procedure == 339 339 340 -(% class="box warningmessage" %) 341 -((( 342 -Before connection, configure the device (see [[Settings>>doc:Battery management systems.BMS Main 3.3\. Configuration.WebHome]]). Correct operation of the BMS system is only possible with correct configuration. 343 -))) 344 - 345 345 All operations to connect the device must be carried out with the supply voltage removed. 346 346 347 347 * Connect the power contactors to header X2. ... ... @@ -352,5 +352,5 @@ 352 352 * Connect the high-voltage network integrity circuit (if necessary) to header X4. 353 353 * Connect external devices (if necessary) to header X6. 354 354 * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7. 355 -* If the BMS Main 3/ BMS Main 3X is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.278 +* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3. 356 356 * Connect an external power supply to header X1. The device will start when there is a 9-32V power supply and one of the KEYRUN or CHARGE_ON signals with a voltage of more than 8.5V is supplied.
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