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Last modified by Admin on 2026/04/02 13:49
From version 81.3
edited by Admin
on 2026/03/25 16:32
Change comment: There is no comment for this version
To version 33.2
edited by Admin
on 2024/12/11 11:33
Change comment: Update document after refactoring.

Summary

Details

Page properties
Parent
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1 -drafts.BMS Main 2R.WebHome
1 +Battery management systems.BMS Main 3.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 -
20 20  == Installation procedure ==
21 21  
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.
6 +The mounting location of the BMS Main 3.0 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.
23 23  
24 24  Overall and mounting dimensions are shown in figure below.
25 25  
26 -[[image:1774349658793-888.0b.STEP.JPG||data-xwiki-image-style-alignment="center" height="522" width="450"]](% title="Click and drag to resize" %)​
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" %)​
27 27  
28 28  |**Parameter**|**Value**
29 -|Overall dimensions (length × width × height), mm|120 × 120 × 16
30 -|Mounting dimensions (length × width), mm|114 × 114
13 +|Overall dimensions (length × width × height), mm|200 × 123 × 12
14 +|Mounting dimensions (length × width), mm|194 × 114
31 31  |Mounting holes|M3
32 32  
33 33  == Headers ==
34 34  
35 -The location and designation of connectors on the BMS Main 2R device are shown below.
19 +The location and designation of connectors on the BMS Main 3.0 device are shown below.
36 36  
37 37  (% contenteditable="false" tabindex="-1" %)
38 38  (((
39 -[[image:1774455018488-627.png||data-xwiki-image-style-alignment="center"]]
23 +[[image:1732119505664-787.png||data-xwiki-image-style-alignment="center" height="417" width="684"]]
40 40  )))
41 41  
42 42  (% class="box warningmessage" %)
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45 45  All headers are shown from the device side!
46 46  )))
47 47  
48 -=== X1 – header for discrete inputs and outputs ===
32 +=== X1 – header to power the device ===
49 49  
50 -Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
51 -
52 52  (% class="wikigeneratedid" id="H" %)
53 -[[image:1732198937514-731.png||data-xwiki-image-style-alignment="center" height="85" width="272"]]
35 +(% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png||data-xwiki-image-style-alignment="center" height="85" width="200"]]
54 54  
55 55  |**Pin**|**Name**|**Description**
56 -|**1–8**|**GND**|Ground
57 -|**9**|**DO_1**|Discrete output 1 “open drain” (5V
58 -|**10**|**DO_2**|Discrete output 2 “open drain” (60 V, 1A)
59 -|**11**|**DO_3**|Discrete output 3 “open drain” (60 V, 1A)
60 -|**12**|**DO_4**|Discrete output 4 “open drain” (60 V, 1A)
61 -|**13**|**DI_4**|
62 -|**14**|**DI_3**|Power-on signal
63 -|**15**|**DI_2**|Power-on signal (battery charge requirement)
64 -|**16**|**DI_1**|Power line (9-32V)
38 +|**1–2, 5–6**|**GND**|Ground
39 +|**3**|**KEYRUN**|Power-on signal
40 +|**4**|**CHARGE_ON**|Power-on signal (battery charge requirement)
41 +|**7–8**|**VIN**|Power line (9-32V)
65 65  
66 66  Power supply connection diagram:
67 67  
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69 69  
70 70  === X2 – header for contactors ===
71 71  
72 -Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
73 -
74 74  (% 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" %)​
75 75  
76 76  |**Pin**|**Name**|**Description**
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88 88  
89 89  === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
90 90  
91 -Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
92 -
93 93  (% 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"]]
94 94  
95 95  |**Pin**|**Name**|**Description**
96 96  |**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals
97 -|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact”
98 -|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact”
99 -|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact”
100 -|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact”
101 -|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact”
102 -|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact”
70 +|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact” (+5 V)
71 +|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact” (+5 V)
72 +|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact” (+5 V)
73 +|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact” (+5 V)
74 +|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact” (+5 V)
75 +|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact” (+5 V)
103 103  |**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
104 104  |**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
105 105  |**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
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115 115  
116 116  (% 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:
117 117  
118 -[[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
119 -
120 120  === X4 – header for HVIL ===
121 121  
122 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
123 -
124 124  [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
125 125  
126 126  |**Pin**|**Name**|**Description**
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129 129  |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
130 130  |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
131 131  
132 - If the BMS Main 2R device generates current in a current loop, the current loop must be connected to the **HVIL_PWR** and **HVIL_IN** pins. If BMS Main 2R is a passive current loop meter, then the current loop must be connected to the **HVIL_IN** and **HVIL_OUT** pins.
101 + If the BMS Main 3 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 is a passive current loop meter, then the current loop must be connected to the **HVIL_IN** and **HVIL_OUT** pins.
133 133  
134 134  Connection diagram to the current loop:
135 135  
136 -[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
137 -
138 138  === X5 – header for current and temperature sensors ===
139 139  
140 -Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
141 -
142 142  [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
143 143  
144 144  (% style="width:539px" %)
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170 170  
171 171  === X6 – header for CAN1 and RS-485-1 (external buses) ===
172 172  
173 -Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
174 -
175 175  [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
176 176  
177 177  |**Pin**|**Name**|**Description**
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191 191  
192 192  === X7 – header for CAN2 (internal bus) ===
193 193  
194 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
195 -
196 196  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
197 197  
198 198  |**Pin**|**Name**|**Description**
199 -|**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
200 -|**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
160 +|**1**|**CAN2_H**|CAN2 line H for communication with BMS devices
161 +|**2**|**CAN2_L**|CAN2 line L for communication with BMS devices
201 201  |**3**|**GND**|Ground
202 202  |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
203 203  
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207 207  
208 208  === X8 – header for CAN3 ===
209 209  
210 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
211 -
212 212  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
213 213  
214 214  |**Pin**|**Name**|**Description**
215 -|**1**|**CAN3_H**|CAN3 line H
216 -|**2**|**CAN3_L**|CAN3 line L
174 +|**1**|**CAN3_H**|CAN3 line H for communication with battery modules (for BMS Main 3X)
175 +|**2**|**CAN3_L**|CAN3 line L for communication with battery modules (for BMS Main 3X)
217 217  |**3**|**GND**|Ground
218 218  |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
219 219  
220 220  (% class="box infomessage" %)
221 221  (((
222 -**Note:**
223 -CAN3 operates differently depending on used firmware:
181 +If the BMS Main 3 device acts as a controller for a battery system consisting of several battery modules connected in parallel, then the parallel battery BMS must be connected to the CAN3 bus.
182 +)))
224 224  
225 -* **BMS Main 3:** CAN3 bus is reserved;
226 -* **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:
184 +Diagram for connecting battery modules to the CAN3 bus:
227 227  
228 -[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
229 -)))
186 +[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" height="153" width="417"]]
230 230  
231 231  === X9 – header for BMS Logic (RS-485-2) ===
232 232  
233 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
234 -
235 235  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
236 236  
237 237  |**Pin**|**Name**|**Description**
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240 240  |**3**|**GND**|Ground
241 241  |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
242 242  
243 -(% class="box infomessage" %)
244 -(((
245 -**Note:**
246 -RS-485-2 operates differently depending on used firmware:
198 +Connection diagram for BMS Logic devices:
247 247  
248 -* **BMS Main 3X:** RS-485-2 bus is reserved;
249 -* **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
200 +[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" height="163" width="400"]]
250 250  
251 -[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
252 -)))
253 -
254 254  === X10 – miniUSB connector ===
255 255  
256 -The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
204 +The miniUSB connector is used to configure the parameters of the BMS Main 3.0 device.
257 257  
258 258  === X11 – header for high-voltage bus before contactors (plus) ===
259 259  
260 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
261 -
262 262  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
263 263  
264 264  |**Pin**|**Name**|**Description**
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272 272  
273 273  === X12 – header for high-voltage bus before contactors (minus) ===
274 274  
275 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
276 -
277 277  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
278 278  
279 279  |**Pin**|**Name**|**Description**
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287 287  
288 288  === X13 – header for high-voltage bus after contactors (plus) ===
289 289  
290 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
291 -
292 292  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
293 293  
294 294  |**Pin**|**Name**|**Description**
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302 302  
303 303  === X14 – header for high-voltage bus after contactors (minus) ===
304 304  
305 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
306 -
307 307  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
308 308  
309 309  |**Pin**|**Name**|**Description**
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345 345  
346 346  === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
347 347  
348 -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.
288 +The BMS Main 3 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.
349 349  
350 350  == Indicators ==
351 351  
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361 361  |**Blinking green**|Executing the battery management program
362 362  |**No blinking**|Program execution error
363 363  
364 -=== DS3 – LED indicating interaction with child devices ===
304 +=== DS3 – LED indicating interaction with BMS Logic ===
365 365  
366 -(% style="width:447px" %)
367 -|**State**|(% style="width:166px" %)**Description (Main 3)**|(% style="width:168px" %)**Description (Main 3X)**
368 -|**Blinking yellow**|(% style="width:166px" %)The device interacts with BMS Logic devices|(% style="width:168px" %)The device interacts with BMS Main 3 devices
369 -|**No blinking**|(% style="width:166px" %)-|(% style="width:168px" %)-
306 +|**State**|**Description**
307 +|**Blinking yellow**|The device interacts with BMS Logic devices
308 +|**No blinking**|-
370 370  
371 -=== DS4 – LED indicating loss of connection with child devices ===
310 +=== DS4 – LED indicating loss of connection with BMS Logic ===
372 372  
373 -(% style="width:601px" %)
374 -|**State**|(% style="width:220px" %)**Description (Main 3)**|(% style="width:218px" %)**Description (Main 3X)**
375 -|**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
376 -|**No blinking**|(% style="width:220px" %)Communication with BMS Logic devices is stable|(% style="width:218px" %)Communication with BMS Main 3 devices is stable
312 +|**State**|**Description**
313 +|**Blinking/lights up red**|Communication with one or more BMS Logic devices is lost
314 +|**No blinking**|Communication with BMS Logic is stable
377 377  
378 378  === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
379 379  
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389 389  
390 390  == Connection procedure ==
391 391  
330 +(% class="box warningmessage" %)
331 +(((
332 +Before connection, configure the device (see [[3. Settings>>doc:drafts.BMS Main 3.3\. Settings.WebHome]]). Correct operation of the BMS system is only possible with correct configuration.
333 +)))
334 +
392 392  All operations to connect the device must be carried out with the supply voltage removed.
393 393  
394 394  * Connect the power contactors to header X2.
... ... @@ -399,5 +399,5 @@
399 399  * Connect the high-voltage network integrity circuit (if necessary) to header X4.
400 400  * Connect external devices (if necessary) to header X6.
401 401  * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
402 -* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
345 +* If the BMS Main 3.0 is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
403 403  * 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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