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Last modified by Admin on 2026/04/02 13:49
From version 86.2
edited by Admin
on 2026/03/25 16:38
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To version 55.2
edited by Admin
on 2025/02/20 13:07
Change comment: There is no comment for this version

Summary

Details

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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 / 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.
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 / BMS Main 3X 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 (+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)
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  
43 +Power supply connection diagram:
66 66  
45 +(% 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"]]
67 67  
68 -=== X2 – miniUSB connector ===
47 +=== X2 – header for contactors ===
69 69  
70 -The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
49 +(% 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" %)​
71 71  
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(%%) ===
51 +|**Pin**|**Name**|**Description**
52 +|**1–4, 8–9**|**GND**|Ground
53 +|**5**|**CONT1_OUT**|Contactor control 1 (plus)
54 +|**6**|**CONT2_OUT**|Contactor control 2 (plus)
55 +|**7**|**CONT3_OUT**|Contactor control 3 (plus)
56 +|**10**|**CONT4_OUT**|Contactor control 4 (plus)
57 +|**11**|**CONT5_OUT**|Contactor control 5 (plus)
58 +|**12**|**CONT6_OUT**|Contactor control 6 (plus)
73 73  
74 -Receptacle Housing: Molex 39012020. Terminals: Molex 5556
60 + Contactor connection diagram:
75 75  
76 -[[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]]
62 +(% 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"]]
77 77  
64 +=== (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
65 +
66 +(% 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"]]
67 +
78 78  |**Pin**|**Name**|**Description**
79 -|**1**|**GND**|Ground
80 -|**2**|**V+**|Supply voltage (9-32V)
69 +|**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals
70 +|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact”
71 +|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact”
72 +|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact”
73 +|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact”
74 +|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact”
75 +|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact”
76 +|**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
77 +|**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
78 +|**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
79 +|**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A)
80 +|**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A)
81 +|**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A)
81 81  
83 +Connection diagram of a discrete input to a dry contact output:
82 82  
85 +(% 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:
83 83  
84 -=== X4, X5, X6, X7 – header of relay 1, 2, 3 and 4 ===
87 +(% 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:
85 85  
86 -Receptacle Housing: Molex 39012020. Terminals: Molex 5556
89 +(% 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:
87 87  
88 -[[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]]
91 +[[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
89 89  
93 +=== X4 – header for HVIL ===
94 +
95 +[[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
96 +
90 90  |**Pin**|**Name**|**Description**
91 -|**1**|**V+**|Switching voltage (up to 55V, max 3A)
92 -|**2**|**NO**|Normally open contact
98 +|**1**|**-**|Not used
99 +|**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
100 +|**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
101 +|**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
93 93  
94 -Contactor connection example for all relays:
103 + 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.
95 95  
96 -[[image:1774456661980-866.png||data-xwiki-image-style-alignment="center" height="211" width="282"]]
105 +Connection diagram to the current loop:
97 97  
107 +[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
98 98  
99 -=== X8 – header for current sensor ===
109 +=== X5 – header for current and temperature sensors ===
100 100  
101 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
111 +[[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
102 102  
113 +(% style="width:539px" %)
114 +|**Pin**|**Name**|(% style="width:402px" %)**Description**
115 +|**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
116 +|**2–6**|**GND**|(% style="width:402px" %)Ground
117 +|**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
118 +|**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
119 +|**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
120 +|**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
121 +|**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
122 +|**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
123 +|**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
124 +|**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
125 +|**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
126 +|**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
127 +
128 +Current sensor connection diagram (using the example of LEM HASS 100-S):
129 +
130 +[[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
131 +
132 +Current sensor connection diagram (using the example of LEM DHAB S/118):
133 +
134 +[[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
135 +
136 +NTC-thermistor connection diagram:
137 +
138 +[[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
139 +
140 +=== X6 – header for CAN1 and RS-485-1 (external buses) ===
141 +
142 +[[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
143 +
144 +|**Pin**|**Name**|**Description**
145 +|**1**|**CAN1_H**|CAN1 line H for communication with external equipment
146 +|**2**|**CAN1_L**|CAN1 line L for communication with external equipment
147 +|**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
148 +|**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
149 +|**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
150 +
151 +Connection diagram to the CAN1 bus:
152 +
153 +[[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
154 +
155 +Connection diagram to the RS-485-1 bus:
156 +
157 +[[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
158 +
159 +=== X7 – header for CAN2 (internal bus) ===
160 +
103 103  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
104 104  
105 105  |**Pin**|**Name**|**Description**
164 +|**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
165 +|**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
166 +|**3**|**GND**|Ground
167 +|**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
168 +
169 +Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
170 +
171 +[[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
172 +
173 +=== X8 – header for CAN3 ===
174 +
175 +[[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
176 +
177 +|**Pin**|**Name**|**Description**
106 106  |**1**|**CAN3_H**|CAN3 line H
107 107  |**2**|**CAN3_L**|CAN3 line L
108 108  |**3**|**GND**|Ground
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121 121  
122 122  === X9 – header for BMS Logic (RS-485-2) ===
123 123  
124 -Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
125 -
126 126  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
127 127  
128 128  |**Pin**|**Name**|**Description**
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142 142  [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
143 143  )))
144 144  
145 -=== X10 – ===
215 +=== X10 – miniUSB connector ===
146 146  
217 +The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
218 +
147 147  === X11 – header for high-voltage bus before contactors (plus) ===
148 148  
149 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
150 -
151 151  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
152 152  
153 153  |**Pin**|**Name**|**Description**
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161 161  
162 162  === X12 – header for high-voltage bus before contactors (minus) ===
163 163  
164 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
165 -
166 166  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
167 167  
168 168  |**Pin**|**Name**|**Description**
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176 176  
177 177  === X13 – header for high-voltage bus after contactors (plus) ===
178 178  
179 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
180 -
181 181  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
182 182  
183 183  |**Pin**|**Name**|**Description**
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191 191  
192 192  === X14 – header for high-voltage bus after contactors (minus) ===
193 193  
194 -Receptacle Housing: Molex 436450200. Terminals: Molex 43030
195 -
196 196  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
197 197  
198 198  |**Pin**|**Name**|**Description**
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234 234  
235 235  === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
236 236  
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.
301 +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.
238 238  
239 239  == Indicators ==
240 240  
... ... @@ -278,6 +278,18 @@
278 278  
279 279  == Connection procedure ==
280 280  
345 +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.
346 +
347 +(% class="box errormessage" %)
348 +(((
349 +**The system is not designed to operate with batteries with total voltage more than 3000V.**
350 +)))
351 +
352 +(% class="box warningmessage" %)
353 +(((
354 +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.
355 +)))
356 +
281 281  All operations to connect the device must be carried out with the supply voltage removed.
282 282  
283 283  * Connect the power contactors to header X2.
... ... @@ -288,5 +288,5 @@
288 288  * Connect the high-voltage network integrity circuit (if necessary) to header X4.
289 289  * Connect external devices (if necessary) to header X6.
290 290  * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
291 -* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
367 +* 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.
292 292  * 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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