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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 |**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**|Power-on signal
63 |**15**|**DI_2**|Power-on signal (battery charge requirement)
64 |**16**|**DI_1**|Power line (9-32V)
65
66 Power supply connection diagram:
67
68 (% 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"]]
69
70 === X2 – header for contactors ===
71
72 Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
73
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
76 |**Pin**|**Name**|**Description**
77 |**1–4, 8–9**|**GND**|Ground
78 |**5**|**CONT1_OUT**|Contactor control 1 (plus)
79 |**6**|**CONT2_OUT**|Contactor control 2 (plus)
80 |**7**|**CONT3_OUT**|Contactor control 3 (plus)
81 |**10**|**CONT4_OUT**|Contactor control 4 (plus)
82 |**11**|**CONT5_OUT**|Contactor control 5 (plus)
83 |**12**|**CONT6_OUT**|Contactor control 6 (plus)
84
85 Contactor connection diagram:
86
87 (% 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"]]
88
89 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
90
91 Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
92
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
95 |**Pin**|**Name**|**Description**
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”
103 |**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
104 |**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
105 |**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
106 |**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A)
107 |**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A)
108 |**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A)
109
110 Connection diagram of a discrete input to a dry contact output:
111
112 (% 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:
113
114 (% 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:
115
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
118 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
119
120 === X4 – header for HVIL ===
121
122 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
123
124 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
125
126 |**Pin**|**Name**|**Description**
127 |**1**|**-**|Not used
128 |**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
129 |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
130 |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
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.
133
134 Connection diagram to the current loop:
135
136 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
137
138 === X5 – header for current and temperature sensors ===
139
140 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
141
142 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
143
144 (% style="width:539px" %)
145 |**Pin**|**Name**|(% style="width:402px" %)**Description**
146 |**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
147 |**2–6**|**GND**|(% style="width:402px" %)Ground
148 |**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
149 |**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
150 |**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
151 |**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
152 |**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
153 |**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
154 |**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
155 |**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
156 |**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
157 |**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
158
159 Current sensor connection diagram (using the example of LEM HASS 100-S):
160
161 [[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
162
163 Current sensor connection diagram (using the example of LEM DHAB S/118):
164
165 [[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
166
167 NTC-thermistor connection diagram:
168
169 [[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
170
171 === X6 – header for CAN1 and RS-485-1 (external buses) ===
172
173 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
174
175 [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
176
177 |**Pin**|**Name**|**Description**
178 |**1**|**CAN1_H**|CAN1 line H for communication with external equipment
179 |**2**|**CAN1_L**|CAN1 line L for communication with external equipment
180 |**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
181 |**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
182 |**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
183
184 Connection diagram to the CAN1 bus:
185
186 [[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
187
188 Connection diagram to the RS-485-1 bus:
189
190 [[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
191
192 === X7 – header for CAN2 (internal bus) ===
193
194 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
195
196 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
197
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
201 |**3**|**GND**|Ground
202 |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
203
204 Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
205
206 [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
207
208 === X8 – header for CAN3 ===
209
210 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
211
212 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
213
214 |**Pin**|**Name**|**Description**
215 |**1**|**CAN3_H**|CAN3 line H
216 |**2**|**CAN3_L**|CAN3 line L
217 |**3**|**GND**|Ground
218 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
219
220 (% class="box infomessage" %)
221 (((
222 **Note:**
223 CAN3 operates differently depending on used firmware:
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:
227
228 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
229 )))
230
231 === X9 – header for BMS Logic (RS-485-2) ===
232
233 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
234
235 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
236
237 |**Pin**|**Name**|**Description**
238 |**1**|**LOGIC_B**|RS-485 line B for communication with BMS Logic
239 |**2**|**LOGIC_A**|RS-485 line A for communication with BMS Logic
240 |**3**|**GND**|Ground
241 |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
242
243 (% class="box infomessage" %)
244 (((
245 **Note:**
246 RS-485-2 operates differently depending on used firmware:
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:
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 === X10 – miniUSB connector ===
255
256 The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
257
258 === X11 – header for high-voltage bus before contactors (plus) ===
259
260 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
261
262 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
263
264 |**Pin**|**Name**|**Description**
265 |**1**|**IN1+**|Plus of the high-voltage bus (before contactors)
266 |**2**|**IN1+**|Plus of the high-voltage bus (before contactors)
267
268 (% class="box warningmessage" %)
269 (((
270 The connected voltage must not exceed 1000V.
271 )))
272
273 === X12 – header for high-voltage bus before contactors (minus) ===
274
275 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
276
277 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
278
279 |**Pin**|**Name**|**Description**
280 |**1**|**IN1-**|Minus of the high-voltage bus (before contactors)
281 |**2**|**IN1-**|Minus of the high-voltage bus (before contactors)
282
283 (% class="box warningmessage" %)
284 (((
285 The connected voltage must not exceed 1000V.
286 )))
287
288 === X13 – header for high-voltage bus after contactors (plus) ===
289
290 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
291
292 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
293
294 |**Pin**|**Name**|**Description**
295 |**1**|**IN2+**|Plus of the high-voltage bus (after contactors)
296 |**2**|**IN2+**|Plus of the high-voltage bus (after contactors)
297
298 (% class="box warningmessage" %)
299 (((
300 The connected voltage must not exceed 1000V.
301 )))
302
303 === X14 – header for high-voltage bus after contactors (minus) ===
304
305 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
306
307 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
308
309 |**Pin**|**Name**|**Description**
310 |**1**|**IN2-**|Minus of the high-voltage bus (after contactors)
311 |**2**|**IN2-**|Minus of the high-voltage bus (after contactors)
312
313 (% class="box warningmessage" %)
314 (((
315 The connected voltage must not exceed 1000V.
316 )))
317
318 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
319
320 [[image:1733316982359-759.png||data-xwiki-image-style-alignment="center" height="77" width="148"]]
321
322 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:
323
324 |**Pin**|**Name**|**Description**
325 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
326 |**2-3**|**-**|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
327
328 === J2 – jumper for switching CAN1 bus terminal resistor ===
329
330
331 [[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:
332
333 |**Pin**|**Name**|**Description**
334 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN1 bus is connected
335 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
336
337 === J3 – jumper for switching CAN2 bus terminal resistor ===
338
339
340 [[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:
341
342 |**Pin**|**Name**|**Description**
343 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN2 bus is connected
344 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
345
346 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
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.
349
350 == Indicators ==
351
352 === DS1 – LED indicating device power ===
353
354 |**State**|**Description**
355 |**Lights up green**|Device power (+5V) is present
356 |**Doesn’t light up**|No device power
357
358 === DS2 – LED indicating device work ===
359
360 |**State**|**Description**
361 |**Blinking green**|Executing the battery management program
362 |**No blinking**|Program execution error
363
364 === DS3 – LED indicating interaction with child devices ===
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" %)-
370
371 === DS4 – LED indicating loss of connection with child devices ===
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
377
378 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
379
380 |**State**|**Description**
381 |**Lights up green**|The switch supplies voltage to the contactor winding
382 |**Doesn’t light up**|The switch doesn’t supply voltage to the contactor winding
383
384 === DS11 – LED indicating the presence of power supply for contactors ===
385
386 |**State**|**Description**
387 |**Lights up green**|Power supply for contactor switches (9-32V) is present
388 |**Doesn’t light up**|Power supply for contactor switches (9-32V) is not present
389
390 == Connection procedure ==
391
392 All operations to connect the device must be carried out with the supply voltage removed.
393
394 * Connect the power contactors to header X2.
395 * Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
396 * Connect BMS Logic devices to header X9.
397 * Connect digital inputs and outputs (if necessary) to header X3.
398 * Connect the high voltage bus (if necessary) to headers X11-X14.
399 * Connect the high-voltage network integrity circuit (if necessary) to header X4.
400 * Connect external devices (if necessary) to header X6.
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.
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.