Wiki source code of 2. Installation and connection

Version 81.2 by Admin on 2026/03/25 16:31

version	line-number	content
31.1	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	= Installation and connection =
30.1	3
57.1	4	== Safety rules ==
	5
61.1	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.
57.1	7
59.1	8	Before use, configure the system. Proper operation of the BMS is possible only if it is correctly configured.
57.1	9
62.1	10	(% class="box errormessage" %)
56.2	11	(((
57.1	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.
56.2	13	)))
	14
	15	(% class="box errormessage" %)
	16	(((
62.1	17	The system is not designed to operate with batteries whose total voltage exceeds 3000 V.
56.2	18	)))
	19
28.1	20	== Installation procedure ==
27.1	21
78.2	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.
27.1	23
	24	Overall and mounting dimensions are shown in figure below.
	25
81.2	26	[[image:1774349658793-888.0b.STEP.JPG\|\|data-xwiki-image-style-alignment="center" height="522" width="450"]](% title="Click and drag to resize" %)
27.1	27
	28	\|Parameter\|Value
81.2	29	\|Overall dimensions (length × width × height), mm\|120 × 120 × 16
	30	\|Mounting dimensions (length × width), mm\|114 × 114
27.1	31	\|Mounting holes\|M3
	32
30.1	33	== Headers ==
27.1	34
78.2	35	The location and designation of connectors on the BMS Main 2R device are shown below.
27.1	36
	37	(% contenteditable="false" tabindex="-1" %)
	38	(((
81.2	39	[[image:1774455018488-627.png\|\|data-xwiki-image-style-alignment="center"]]
27.1	40	)))
	41
	42	(% class="box warningmessage" %)
	43	(((
	44	Attention!
	45	All headers are shown from the device side!
	46	)))
	47
81.2	48	=== X1 – header for discrete inputs and outputs ===
27.1	49
55.3	50	Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
	51
27.1	52	(% class="wikigeneratedid" id="H" %)
81.2	53	[[image:1732198937514-731.png\|\|data-xwiki-image-style-alignment="center" height="85" width="272"]]
27.1	54
	55	\|Pin\|Name\|Description
81.2	56	\|1–8\|GND\|Ground
	57	\| \| \|
27.1	58	\|3\|KEYRUN\|Power-on signal
	59	\|4\|CHARGE_ON\|Power-on signal (battery charge requirement)
	60	\|7–8\|VIN\|Power line (9-32V)
	61
	62	Power supply connection diagram:
	63
	64	(% 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"]]
	65
30.1	66	=== X2 – header for contactors ===
27.1	67
55.3	68	Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
	69
27.1	70	(% 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
	72	\|Pin\|Name\|Description
	73	\|1–4, 8–9\|GND\|Ground
	74	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	75	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	76	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	77	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	78	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	79	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	80
	81	Contactor connection diagram:
	82
	83	(% 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"]]
	84
30.1	85	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	86
55.3	87	Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
	88
27.1	89	(% 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"]]
	90
	91	\|Pin\|Name\|Description
	92	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	93	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	94	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	95	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	96	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	97	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	98	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	99	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	100	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	101	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	102	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	103	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	104	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	105
	106	Connection diagram of a discrete input to a dry contact output:
	107
	108	(% 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:
	109
	110	(% 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:
	111
	112	(% 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:
	113
51.1	114	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	115
30.1	116	=== X4 – header for HVIL ===
27.1	117
55.3	118	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	119
30.1	120	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	121
	122	\|Pin\|Name\|Description
	123	\|1\|-\|Not used
	124	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	125	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	126	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	127
78.2	128	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.
27.1	129
	130	Connection diagram to the current loop:
	131
54.1	132	[[image:1739361367866-742.png\|\|data-xwiki-image-style-alignment="center" height="210" width="281"]]
	133
31.1	134	=== X5 – header for current and temperature sensors ===
27.1	135
55.3	136	Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
	137
30.1	138	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	139
	140	(% style="width:539px" %)
	141	\|Pin\|Name\|(% style="width:402px" %)Description
	142	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	143	\|2–6\|GND\|(% style="width:402px" %)Ground
	144	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	145	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	146	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	147	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	148	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	149	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	150	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	151	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	152	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	153	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	154
	155	Current sensor connection diagram (using the example of LEM HASS 100-S):
	156
	157	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	158
	159	Current sensor connection diagram (using the example of LEM DHAB S/118):
	160
	161	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	162
	163	NTC-thermistor connection diagram:
	164
	165	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	166
30.1	167	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	168
55.3	169	Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
	170
27.1	171	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	172
	173	\|Pin\|Name\|Description
	174	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	175	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	176	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	177	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	178	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	179
	180	Connection diagram to the CAN1 bus:
	181
	182	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	183
	184	Connection diagram to the RS-485-1 bus:
	185
	186	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	187
30.1	188	=== X7 – header for CAN2 (internal bus) ===
27.1	189
55.3	190	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	191
27.1	192	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	193
	194	\|Pin\|Name\|Description
38.1	195	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	196	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	197	\|3\|GND\|Ground
	198	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	199
	200	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	201
	202	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	203
30.1	204	=== X8 – header for CAN3 ===
27.1	205
55.3	206	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	207
27.1	208	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	209
	210	\|Pin\|Name\|Description
38.1	211	\|1\|CAN3_H\|CAN3 line H
	212	\|2\|CAN3_L\|CAN3 line L
27.1	213	\|3\|GND\|Ground
	214	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	215
	216	(% class="box infomessage" %)
	217	(((
38.1	218	Note:
	219	CAN3 operates differently depending on used firmware:
27.1	220
38.1	221	* BMS Main 3: CAN3 bus is reserved;
39.1	222	* 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:
38.1	223
	224	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	225	)))
27.1	226
30.1	227	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	228
55.3	229	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	230
27.1	231	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	232
	233	\|Pin\|Name\|Description
	234	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	235	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	236	\|3\|GND\|Ground
	237	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	238
40.1	239	(% class="box infomessage" %)
	240	(((
	241	Note:
	242	RS-485-2 operates differently depending on used firmware:
27.1	243
40.1	244	* BMS Main 3X: RS-485-2 bus is reserved;
	245	* BMS Main 3: RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
27.1	246
40.1	247	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	248	)))
	249
30.1	250	=== X10 – miniUSB connector ===
27.1	251
78.2	252	The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
27.1	253
30.1	254	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	255
55.3	256	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	257
27.1	258	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	259
	260	\|Pin\|Name\|Description
	261	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	262	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	263
	264	(% class="box warningmessage" %)
	265	(((
	266	The connected voltage must not exceed 1000V.
	267	)))
	268
30.1	269	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	270
55.3	271	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	272
27.1	273	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	274
	275	\|Pin\|Name\|Description
	276	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	277	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	278
	279	(% class="box warningmessage" %)
	280	(((
	281	The connected voltage must not exceed 1000V.
	282	)))
	283
30.1	284	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	285
55.3	286	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	287
27.1	288	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	289
	290	\|Pin\|Name\|Description
	291	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	292	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	293
	294	(% class="box warningmessage" %)
	295	(((
	296	The connected voltage must not exceed 1000V.
	297	)))
	298
30.1	299	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	300
55.3	301	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	302
27.1	303	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	304
	305	\|Pin\|Name\|Description
	306	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	307	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	308
	309	(% class="box warningmessage" %)
	310	(((
	311	The connected voltage must not exceed 1000V.
	312	)))
	313
30.1	314	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	315
	316	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	317
	318	To connect a terminal resistor between the RS485_1_A and RS485_1_B lines, install a jumper. The jumper is installed according to the table:
	319
	320	\|Pin\|Name\|Description
	321	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	322	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	323
30.1	324	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	325
	326
	327	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]To connect a terminal resistor between the CAN1_H and CAN1_L lines, install a jumper. The jumper is installed according to the table:
	328
	329	\|Pin\|Name\|Description
	330	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	331	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	332
30.1	333	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	334
	335
	336	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]To connect a terminal resistor between the CAN2_H and CAN2_L lines, install a jumper. The jumper is installed according to the table:
	337
	338	\|Pin\|Name\|Description
	339	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	340	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	341
30.1	342	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	343
78.2	344	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.
27.1	345
30.1	346	== Indicators ==
27.1	347
30.1	348	=== DS1 – LED indicating device power ===
27.1	349
	350	\|State\|Description
	351	\|Lights up green\|Device power (+5V) is present
	352	\|Doesn’t light up\|No device power
	353
30.1	354	=== DS2 – LED indicating device work ===
27.1	355
	356	\|State\|Description
	357	\|Blinking green\|Executing the battery management program
	358	\|No blinking\|Program execution error
	359
54.2	360	=== DS3 – LED indicating interaction with child devices ===
27.1	361
54.2	362	(% style="width:447px" %)
	363	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	364	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	365	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	366
54.2	367	=== DS4 – LED indicating loss of connection with child devices ===
27.1	368
54.4	369	(% style="width:601px" %)
	370	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	371	\|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
	372	\|No blinking\|(% style="width:220px" %)Communication with BMS Logic devices is stable\|(% style="width:218px" %)Communication with BMS Main 3 devices is stable
27.1	373
30.1	374	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	375
	376	\|State\|Description
	377	\|Lights up green\|The switch supplies voltage to the contactor winding
	378	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	379
30.1	380	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	381
	382	\|State\|Description
	383	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	384	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	385
30.1	386	== Connection procedure ==
27.1	387
	388	All operations to connect the device must be carried out with the supply voltage removed.
	389
	390	* Connect the power contactors to header X2.
	391	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	392	* Connect BMS Logic devices to header X9.
	393	* Connect digital inputs and outputs (if necessary) to header X3.
	394	* Connect the high voltage bus (if necessary) to headers X11-X14.
	395	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	396	* Connect external devices (if necessary) to header X6.
	397	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
78.2	398	* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
27.1	399	* 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.

Wiki source code of 2. Installation and connection

Applications

Navigation

Table of Contents