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Last modified by Admin on 2026/04/02 13:49
From version 55.3
edited by Admin
on 2025/02/20 13:10
Change comment: There is no comment for this version
To version 87.2
edited by Admin
on 2026/03/25 16:39
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 16  
17 17  == Headers ==
18 18  
19 -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.
20 20  
21 21  (% contenteditable="false" tabindex="-1" %)
22 22  (((
23 -[[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"]]
24 24  )))
25 25  
26 26  (% class="box warningmessage" %)
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29 29  All headers are shown from the device side!
30 30  )))
31 31  
32 -=== X1 – header to power the device ===
48 +=== X1 – header for discrete inputs and outputs ===
33 33  
34 34  Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
35 35  
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 -Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
70 +The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
52 52  
53 -(% 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" %)​
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(%%) ===
54 54  
55 -|**Pin**|**Name**|**Description**
56 -|**1–4, 8–9**|**GND**|Ground
57 -|**5**|**CONT1_OUT**|Contactor control 1 (plus)
58 -|**6**|**CONT2_OUT**|Contactor control 2 (plus)
59 -|**7**|**CONT3_OUT**|Contactor control 3 (plus)
60 -|**10**|**CONT4_OUT**|Contactor control 4 (plus)
61 -|**11**|**CONT5_OUT**|Contactor control 5 (plus)
62 -|**12**|**CONT6_OUT**|Contactor control 6 (plus)
74 +Receptacle Housing: Molex 39012020. Terminals: Molex 5556
63 63  
64 - Contactor connection diagram:
76 +[[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]]
65 65  
66 -(% 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"]]
67 -
68 -=== (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
69 -
70 -Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
71 -
72 -(% 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"]]
73 -
74 74  |**Pin**|**Name**|**Description**
75 -|**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals
76 -|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact”
77 -|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact”
78 -|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact”
79 -|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact”
80 -|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact”
81 -|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact”
82 -|**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
83 -|**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
84 -|**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
85 -|**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A)
86 -|**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A)
87 -|**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A)
79 +|**1**|**GND**|Ground
80 +|**2**|**V+**|Supply voltage (9-32V)
88 88  
89 -Connection diagram of a discrete input to a dry contact output:
90 90  
91 -(% 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:
92 92  
93 -(% 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 ===
94 94  
95 -(% 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
96 96  
97 -[[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"]]
98 98  
99 -=== X4 – header for HVIL ===
100 -
101 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
102 -
103 -[[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
104 -
105 105  |**Pin**|**Name**|**Description**
106 -|**1**|**-**|Not used
107 -|**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
108 -|**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
109 -|**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
110 110  
111 - 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:
112 112  
113 -Connection diagram to the current loop:
96 +[[image:1774456661980-866.png||data-xwiki-image-style-alignment="center" height="211" width="282"]]
114 114  
115 -[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
116 116  
117 -=== X5 – header for current and temperature sensors ===
99 +=== X8 – header for current sensor 1 ===
118 118  
119 -Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
101 +Receptacle Housing: Molex 430250400. Terminals: Molex 43030
120 120  
121 -[[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
103 +[[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]]
122 122  
123 -(% style="width:539px" %)
124 -|**Pin**|**Name**|(% style="width:402px" %)**Description**
125 -|**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
126 -|**2–6**|**GND**|(% style="width:402px" %)Ground
127 -|**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
128 -|**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
129 -|**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
130 -|**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
131 -|**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
132 -|**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
133 -|**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
134 -|**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
135 -|**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
136 -|**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
137 -
138 -Current sensor connection diagram (using the example of LEM HASS 100-S):
139 -
140 -[[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
141 -
142 -Current sensor connection diagram (using the example of LEM DHAB S/118):
143 -
144 -[[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
145 -
146 -NTC-thermistor connection diagram:
147 -
148 -[[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
149 -
150 -=== X6 – header for CAN1 and RS-485-1 (external buses) ===
151 -
152 -Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
153 -
154 -[[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
155 -
156 156  |**Pin**|**Name**|**Description**
157 -|**1**|**CAN1_H**|CAN1 line H for communication with external equipment
158 -|**2**|**CAN1_L**|CAN1 line L for communication with external equipment
159 -|**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
160 -|**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
161 -|**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
162 162  
163 -Connection diagram to the CAN1 bus:
164 -
165 -[[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
166 -
167 -Connection diagram to the RS-485-1 bus:
168 -
169 -[[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
170 -
171 -=== X7 – header for CAN2 (internal bus) ===
172 -
173 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
174 -
175 -[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
176 -
177 -|**Pin**|**Name**|**Description**
178 -|**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
179 -|**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
180 -|**3**|**GND**|Ground
181 -|**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
182 -
183 -Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
184 -
185 -[[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
186 -
187 -=== X8 – header for CAN3 ===
188 -
189 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
190 -
191 -[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
192 -
193 -|**Pin**|**Name**|**Description**
194 -|**1**|**CAN3_H**|CAN3 line H
195 -|**2**|**CAN3_L**|CAN3 line L
196 -|**3**|**GND**|Ground
197 -|**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
198 -
199 -(% class="box infomessage" %)
200 -(((
201 -**Note:**
202 -CAN3 operates differently depending on used firmware:
203 -
204 -* **BMS Main 3:** CAN3 bus is reserved;
205 -* **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:
206 -
207 -[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
208 -)))
209 -
210 210  === X9 – header for BMS Logic (RS-485-2) ===
211 211  
212 212  Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
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230 230  [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
231 231  )))
232 232  
233 -=== X10 – miniUSB connector ===
134 +=== X10 – ===
234 234  
235 -The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
236 -
237 237  === X11 – header for high-voltage bus before contactors (plus) ===
238 238  
239 239  Receptacle Housing: Molex 436450200. Terminals: Molex 43030
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324 324  
325 325  === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
326 326  
327 -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.
226 +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.
328 328  
329 329  == Indicators ==
330 330  
... ... @@ -368,18 +368,6 @@
368 368  
369 369  == Connection procedure ==
370 370  
371 -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.
372 -
373 -(% class="box errormessage" %)
374 -(((
375 -**The system is not designed to operate with batteries with total voltage more than 3000V.**
376 -)))
377 -
378 -(% class="box warningmessage" %)
379 -(((
380 -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.
381 -)))
382 -
383 383  All operations to connect the device must be carried out with the supply voltage removed.
384 384  
385 385  * Connect the power contactors to header X2.
... ... @@ -390,5 +390,5 @@
390 390  * Connect the high-voltage network integrity circuit (if necessary) to header X4.
391 391  * Connect external devices (if necessary) to header X6.
392 392  * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
393 -* 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.
280 +* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
394 394  * 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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