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Wiki source code of 2. Installation and connection

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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 =
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 == Installation procedure ==
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.
23
24 Overall and mounting dimensions are shown in figure below.
25
26 [[image:1774349658793-888.0b.STEP.JPG||data-xwiki-image-style-alignment="center" height="522" width="450"]](% title="Click and drag to resize" %)​
27
28 |**Parameter**|**Value**
29 |Overall dimensions (length × width × height), mm|120 × 120 × 16
30 |Mounting dimensions (length × width), mm|114 × 114
31 |Mounting holes|M3
32
33 == Headers ==
34
35 The location and designation of connectors on the BMS Main 2R device are shown below.
36
37 (% contenteditable="false" tabindex="-1" %)
38 (((
39 [[image:1774455018488-627.png||data-xwiki-image-style-alignment="center"]]
40 )))
41
42 (% class="box warningmessage" %)
43 (((
44 **Attention!**
45 All headers are shown from the device side!
46 )))
47
48 === X1 – header for discrete inputs and outputs ===
49
50 Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
51
52 (% class="wikigeneratedid" id="H" %)
53 [[image:1732198937514-731.png||data-xwiki-image-style-alignment="center" height="85" width="272"]]
54
55 |**Pin**|**Name**|**Description**
56 |**1–8**|**GND**|Ground
57 | | |
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
66 === X2 – header for contactors ===
67
68 Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
69
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
85 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
86
87 Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
88
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
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”
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
114 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
115
116 === X4 – header for HVIL ===
117
118 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
119
120 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
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
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.
129
130 Connection diagram to the current loop:
131
132 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
133
134 === X5 – header for current and temperature sensors ===
135
136 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
137
138 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
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
167 === X6 – header for CAN1 and RS-485-1 (external buses) ===
168
169 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
170
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
188 === X7 – header for CAN2 (internal bus) ===
189
190 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
191
192 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
193
194 |**Pin**|**Name**|**Description**
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
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
204 === X8 – header for CAN3 ===
205
206 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
207
208 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
209
210 |**Pin**|**Name**|**Description**
211 |**1**|**CAN3_H**|CAN3 line H
212 |**2**|**CAN3_L**|CAN3 line L
213 |**3**|**GND**|Ground
214 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
215
216 (% class="box infomessage" %)
217 (((
218 **Note:**
219 CAN3 operates differently depending on used firmware:
220
221 * **BMS Main 3:** CAN3 bus is reserved;
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:
223
224 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
225 )))
226
227 === X9 – header for BMS Logic (RS-485-2) ===
228
229 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
230
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
239 (% class="box infomessage" %)
240 (((
241 **Note:**
242 RS-485-2 operates differently depending on used firmware:
243
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:
246
247 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
248 )))
249
250 === X10 – miniUSB connector ===
251
252 The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
253
254 === X11 – header for high-voltage bus before contactors (plus) ===
255
256 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
257
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
269 === X12 – header for high-voltage bus before contactors (minus) ===
270
271 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
272
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
284 === X13 – header for high-voltage bus after contactors (plus) ===
285
286 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
287
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
299 === X14 – header for high-voltage bus after contactors (minus) ===
300
301 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
302
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
314 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
324 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
333 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
342 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
343
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.
345
346 == Indicators ==
347
348 === DS1 – LED indicating device power ===
349
350 |**State**|**Description**
351 |**Lights up green**|Device power (+5V) is present
352 |**Doesn’t light up**|No device power
353
354 === DS2 – LED indicating device work ===
355
356 |**State**|**Description**
357 |**Blinking green**|Executing the battery management program
358 |**No blinking**|Program execution error
359
360 === DS3 – LED indicating interaction with child devices ===
361
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" %)-
366
367 === DS4 – LED indicating loss of connection with child devices ===
368
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
373
374 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
380 === DS11 – LED indicating the presence of power supply for contactors ===
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
386 == Connection procedure ==
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.
398 * If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
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.