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Last modified by Admin on 2026/04/02 13:49
From version 55.1
edited by Admin
on 2025/02/12 12:15
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To version 86.2
edited by Admin
on 2026/03/25 16:38
Change comment: There is no comment for this version

Summary

Details

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Parent
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1 -Battery management systems.BMS Main 3.WebHome
1 +drafts.BMS Main 2R.WebHome
Content
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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 3X 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.
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|200 × 123 × 12
14 -|Mounting dimensions (length × width), mm|194 × 114
29 +|Overall dimensions (length × width × height), mm|120 × 120 × 16
30 +|Mounting dimensions (length × width), mm|114 × 114
15 15  |Mounting holes|M3
16 -|Headers X1-X9 type|Hirose ZE05
17 -|Headers X11-X14 type|Molex series Micro-Fit
18 18  
19 19  == Headers ==
20 20  
21 -The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
35 +The location and designation of connectors on the BMS Main 2R device are shown below.
22 22  
23 23  (% contenteditable="false" tabindex="-1" %)
24 24  (((
25 -[[image:1732119505664-787.png||data-xwiki-image-style-alignment="center" height="417" width="684"]]
39 +[[image:1774455018488-627.png||data-xwiki-image-style-alignment="center"]]
26 26  )))
27 27  
28 28  (% class="box warningmessage" %)
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31 31  All headers are shown from the device side!
32 32  )))
33 33  
34 -=== X1 – header to power the device ===
48 +=== X1 – header for discrete inputs and outputs ===
35 35  
50 +Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
51 +
36 36  (% class="wikigeneratedid" id="H" %)
37 -(% 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"]]
38 38  
39 39  |**Pin**|**Name**|**Description**
40 -|**1–2, 5–6**|**GND**|Ground
41 -|**3**|**KEYRUN**|Power-on signal
42 -|**4**|**CHARGE_ON**|Power-on signal (battery charge requirement)
43 -|**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)
44 44  
45 -Power supply connection diagram:
46 46  
47 -(% 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"]]
48 48  
49 -=== X2 – header for contactors ===
68 +=== X2 – miniUSB connector ===
50 50  
51 -(% aria-label="1732121695049-411.png image 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="Click and drag to resize" %)​
70 +The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
52 52  
53 -|**Pin**|**Name**|**Description**
54 -|**1–4, 8–9**|**GND**|Ground
55 -|**5**|**CONT1_OUT**|Contactor control 1 (plus)
56 -|**6**|**CONT2_OUT**|Contactor control 2 (plus)
57 -|**7**|**CONT3_OUT**|Contactor control 3 (plus)
58 -|**10**|**CONT4_OUT**|Contactor control 4 (plus)
59 -|**11**|**CONT5_OUT**|Contactor control 5 (plus)
60 -|**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(%%) ===
61 61  
62 - Contactor connection diagram:
74 +Receptacle Housing: Molex 39012020. Terminals: Molex 5556
63 63  
64 -(% 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"]]
65 65  
66 -=== (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
67 -
68 -(% 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"]]
69 -
70 70  |**Pin**|**Name**|**Description**
71 -|**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals
72 -|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact”
73 -|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact”
74 -|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact”
75 -|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact”
76 -|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact”
77 -|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact”
78 -|**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
79 -|**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
80 -|**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
81 -|**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A)
82 -|**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A)
83 -|**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A)
79 +|**1**|**GND**|Ground
80 +|**2**|**V+**|Supply voltage (9-32V)
84 84  
85 -Connection diagram of a discrete input to a dry contact output:
86 86  
87 -(% 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:
88 88  
89 -(% 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="Click and drag to resize" %)​(%%)Connection diagram for a discrete input for detecting a 9-32V signal:
84 +=== X4, X5, X6, X7 – header of relay 1, 2, 3 and 4 ===
90 90  
91 -(% 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" %)​(%%)Connection diagram for discrete output:
86 +Receptacle Housing: Molex 39012020. Terminals: Molex 5556
92 92  
93 -[[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
88 +[[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]]
94 94  
95 -=== X4 – header for HVIL ===
96 -
97 -[[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
98 -
99 99  |**Pin**|**Name**|**Description**
100 -|**1**|**-**|Not used
101 -|**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
102 -|**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
103 -|**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
104 104  
105 - If the BMS Main 3 / BMS Main 3X device generates current in a current loop, the current loop must be connected to the **HVIL_PWR** and **HVIL_IN** pins. If BMS Main 3 / BMS Main 3X is a passive current loop meter, then the current loop must be connected to the **HVIL_IN** and **HVIL_OUT** pins.
94 +Contactor connection example for all relays:
106 106  
107 -Connection diagram to the current loop:
96 +[[image:1774456661980-866.png||data-xwiki-image-style-alignment="center" height="211" width="282"]]
108 108  
109 -[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
110 110  
111 -=== X5 – header for current and temperature sensors ===
99 +=== X8 – header for current sensor ===
112 112  
113 -[[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
101 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
114 114  
115 -(% style="width:539px" %)
116 -|**Pin**|**Name**|(% style="width:402px" %)**Description**
117 -|**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
118 -|**2–6**|**GND**|(% style="width:402px" %)Ground
119 -|**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
120 -|**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
121 -|**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
122 -|**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
123 -|**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
124 -|**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
125 -|**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
126 -|**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
127 -|**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
128 -|**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
129 -
130 -Current sensor connection diagram (using the example of LEM HASS 100-S):
131 -
132 -[[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
133 -
134 -Current sensor connection diagram (using the example of LEM DHAB S/118):
135 -
136 -[[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
137 -
138 -NTC-thermistor connection diagram:
139 -
140 -[[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
141 -
142 -=== X6 – header for CAN1 and RS-485-1 (external buses) ===
143 -
144 -[[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
145 -
146 -|**Pin**|**Name**|**Description**
147 -|**1**|**CAN1_H**|CAN1 line H for communication with external equipment
148 -|**2**|**CAN1_L**|CAN1 line L for communication with external equipment
149 -|**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
150 -|**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
151 -|**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
152 -
153 -Connection diagram to the CAN1 bus:
154 -
155 -[[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
156 -
157 -Connection diagram to the RS-485-1 bus:
158 -
159 -[[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
160 -
161 -=== X7 – header for CAN2 (internal bus) ===
162 -
163 163  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
164 164  
165 165  |**Pin**|**Name**|**Description**
166 -|**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
167 -|**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
168 -|**3**|**GND**|Ground
169 -|**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
170 -
171 -Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
172 -
173 -[[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
174 -
175 -=== X8 – header for CAN3 ===
176 -
177 -[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
178 -
179 -|**Pin**|**Name**|**Description**
180 180  |**1**|**CAN3_H**|CAN3 line H
181 181  |**2**|**CAN3_L**|CAN3 line L
182 182  |**3**|**GND**|Ground
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195 195  
196 196  === X9 – header for BMS Logic (RS-485-2) ===
197 197  
124 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
125 +
198 198  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
199 199  
200 200  |**Pin**|**Name**|**Description**
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214 214  [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
215 215  )))
216 216  
217 -=== X10 – miniUSB connector ===
145 +=== X10 – ===
218 218  
219 -The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
220 -
221 221  === X11 – header for high-voltage bus before contactors (plus) ===
222 222  
149 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
150 +
223 223  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
224 224  
225 225  |**Pin**|**Name**|**Description**
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233 233  
234 234  === X12 – header for high-voltage bus before contactors (minus) ===
235 235  
164 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
165 +
236 236  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
237 237  
238 238  |**Pin**|**Name**|**Description**
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246 246  
247 247  === X13 – header for high-voltage bus after contactors (plus) ===
248 248  
179 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
180 +
249 249  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
250 250  
251 251  |**Pin**|**Name**|**Description**
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259 259  
260 260  === X14 – header for high-voltage bus after contactors (minus) ===
261 261  
194 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
195 +
262 262  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
263 263  
264 264  |**Pin**|**Name**|**Description**
... ... @@ -300,7 +300,7 @@
300 300  
301 301  === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
302 302  
303 -The BMS Main 3 / BMS Main 3X 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.
237 +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.
304 304  
305 305  == Indicators ==
306 306  
... ... @@ -344,18 +344,6 @@
344 344  
345 345  == Connection procedure ==
346 346  
347 -The BMS can connect to batteries with voltage levels dangerous to life and health. When working with high voltage batteries, follow electrical safety rules, use safety glasses, protective clothing, insulated tools and devices.
348 -
349 -(% class="box errormessage" %)
350 -(((
351 -**The system is not designed to operate with batteries with total voltage more than 3000V.**
352 -)))
353 -
354 -(% class="box warningmessage" %)
355 -(((
356 -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.
357 -)))
358 -
359 359  All operations to connect the device must be carried out with the supply voltage removed.
360 360  
361 361  * Connect the power contactors to header X2.
... ... @@ -366,5 +366,5 @@
366 366  * Connect the high-voltage network integrity circuit (if necessary) to header X4.
367 367  * Connect external devices (if necessary) to header X6.
368 368  * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
369 -* 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.
291 +* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
370 370  * 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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