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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**|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)
65
66
67
68 === X2 – miniUSB connector ===
69
70 The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
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(%%) ===
73
74 Receptacle Housing: Molex 39012020. Terminals: Molex 5556
75
76 [[image:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]]
77
78 |**Pin**|**Name**|**Description**
79 |**1**|**GND**|Ground
80 |**2**|**V+**|Supply voltage (9-32V)
81
82
83
84 === X4, X5, X6, X7 – header of relay 1, 2, 3 and 4 ===
85
86 Receptacle Housing: Molex 39012020. Terminals: Molex 5556
87
88 [[image:https://docs.movicomelectric.com/bin/download/Battery%20management%20systems/BMS%20Main%202.1/2.%20Installation%20and%20connection/WebHome/1732198827034-560.png?width=41&height=78&rev=1.1||alt="1732198827034-560.png" height="78" width="41"]]
89
90 By default, relay 1 is used to control the discharging contactor.
91
92 |**Pin**|**Name**|**Description**
93 |**1**|**V+**|Switching voltage (up to 55V, max 3A)
94 |**2**|**NO**|Normally open contact
95
96 Contactor connection example for all relays:
97
98 [[image:https://docs.movicomelectric.com/bin/download/Battery%20management%20systems/BMS%20Main%202.1/2.%20Installation%20and%20connection/WebHome/1741619814065-850.png?width=252&height=189&rev=1.1||alt="1741619814065-850.png" height="189" width="252"]]
99
100 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
101
102 === X4 – header for HVIL ===
103
104 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
105
106 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
107
108 |**Pin**|**Name**|**Description**
109 |**1**|**-**|Not used
110 |**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
111 |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
112 |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
113
114 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.
115
116 Connection diagram to the current loop:
117
118 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
119
120 === X5 – header for current and temperature sensors ===
121
122 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
123
124 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
125
126 (% style="width:539px" %)
127 |**Pin**|**Name**|(% style="width:402px" %)**Description**
128 |**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
129 |**2–6**|**GND**|(% style="width:402px" %)Ground
130 |**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
131 |**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
132 |**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
133 |**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
134 |**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
135 |**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
136 |**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
137 |**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
138 |**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
139 |**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
140
141 Current sensor connection diagram (using the example of LEM HASS 100-S):
142
143 [[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
144
145 Current sensor connection diagram (using the example of LEM DHAB S/118):
146
147 [[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
148
149 NTC-thermistor connection diagram:
150
151 [[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
152
153 === X6 – header for CAN1 and RS-485-1 (external buses) ===
154
155 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
156
157 [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
158
159 |**Pin**|**Name**|**Description**
160 |**1**|**CAN1_H**|CAN1 line H for communication with external equipment
161 |**2**|**CAN1_L**|CAN1 line L for communication with external equipment
162 |**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
163 |**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
164 |**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
165
166 Connection diagram to the CAN1 bus:
167
168 [[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
169
170 Connection diagram to the RS-485-1 bus:
171
172 [[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
173
174 === X7 – header for CAN2 (internal bus) ===
175
176 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
177
178 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
179
180 |**Pin**|**Name**|**Description**
181 |**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
182 |**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
183 |**3**|**GND**|Ground
184 |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
185
186 Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
187
188 [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
189
190 === X8 – header for CAN3 ===
191
192 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
193
194 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
195
196 |**Pin**|**Name**|**Description**
197 |**1**|**CAN3_H**|CAN3 line H
198 |**2**|**CAN3_L**|CAN3 line L
199 |**3**|**GND**|Ground
200 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
201
202 (% class="box infomessage" %)
203 (((
204 **Note:**
205 CAN3 operates differently depending on used firmware:
206
207 * **BMS Main 3:** CAN3 bus is reserved;
208 * **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:
209
210 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
211 )))
212
213 === X9 – header for BMS Logic (RS-485-2) ===
214
215 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
216
217 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
218
219 |**Pin**|**Name**|**Description**
220 |**1**|**LOGIC_B**|RS-485 line B for communication with BMS Logic
221 |**2**|**LOGIC_A**|RS-485 line A for communication with BMS Logic
222 |**3**|**GND**|Ground
223 |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
224
225 (% class="box infomessage" %)
226 (((
227 **Note:**
228 RS-485-2 operates differently depending on used firmware:
229
230 * **BMS Main 3X:** RS-485-2 bus is reserved;
231 * **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
232
233 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
234 )))
235
236 === X10 – ===
237
238 === X11 – header for high-voltage bus before contactors (plus) ===
239
240 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
241
242 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
243
244 |**Pin**|**Name**|**Description**
245 |**1**|**IN1+**|Plus of the high-voltage bus (before contactors)
246 |**2**|**IN1+**|Plus of the high-voltage bus (before contactors)
247
248 (% class="box warningmessage" %)
249 (((
250 The connected voltage must not exceed 1000V.
251 )))
252
253 === X12 – header for high-voltage bus before contactors (minus) ===
254
255 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
256
257 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
258
259 |**Pin**|**Name**|**Description**
260 |**1**|**IN1-**|Minus of the high-voltage bus (before contactors)
261 |**2**|**IN1-**|Minus of the high-voltage bus (before contactors)
262
263 (% class="box warningmessage" %)
264 (((
265 The connected voltage must not exceed 1000V.
266 )))
267
268 === X13 – header for high-voltage bus after contactors (plus) ===
269
270 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
271
272 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
273
274 |**Pin**|**Name**|**Description**
275 |**1**|**IN2+**|Plus of the high-voltage bus (after contactors)
276 |**2**|**IN2+**|Plus of the high-voltage bus (after contactors)
277
278 (% class="box warningmessage" %)
279 (((
280 The connected voltage must not exceed 1000V.
281 )))
282
283 === X14 – header for high-voltage bus after contactors (minus) ===
284
285 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
286
287 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
288
289 |**Pin**|**Name**|**Description**
290 |**1**|**IN2-**|Minus of the high-voltage bus (after contactors)
291 |**2**|**IN2-**|Minus of the high-voltage bus (after contactors)
292
293 (% class="box warningmessage" %)
294 (((
295 The connected voltage must not exceed 1000V.
296 )))
297
298 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
299
300 [[image:1733316982359-759.png||data-xwiki-image-style-alignment="center" height="77" width="148"]]
301
302 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:
303
304 |**Pin**|**Name**|**Description**
305 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
306 |**2-3**|**-**|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
307
308 === J2 – jumper for switching CAN1 bus terminal resistor ===
309
310
311 [[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:
312
313 |**Pin**|**Name**|**Description**
314 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN1 bus is connected
315 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
316
317 === J3 – jumper for switching CAN2 bus terminal resistor ===
318
319
320 [[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:
321
322 |**Pin**|**Name**|**Description**
323 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN2 bus is connected
324 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
325
326 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
327
328 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.
329
330 == Indicators ==
331
332 === DS1 – LED indicating device power ===
333
334 |**State**|**Description**
335 |**Lights up green**|Device power (+5V) is present
336 |**Doesn’t light up**|No device power
337
338 === DS2 – LED indicating device work ===
339
340 |**State**|**Description**
341 |**Blinking green**|Executing the battery management program
342 |**No blinking**|Program execution error
343
344 === DS3 – LED indicating interaction with child devices ===
345
346 (% style="width:447px" %)
347 |**State**|(% style="width:166px" %)**Description (Main 3)**|(% style="width:168px" %)**Description (Main 3X)**
348 |**Blinking yellow**|(% style="width:166px" %)The device interacts with BMS Logic devices|(% style="width:168px" %)The device interacts with BMS Main 3 devices
349 |**No blinking**|(% style="width:166px" %)-|(% style="width:168px" %)-
350
351 === DS4 – LED indicating loss of connection with child devices ===
352
353 (% style="width:601px" %)
354 |**State**|(% style="width:220px" %)**Description (Main 3)**|(% style="width:218px" %)**Description (Main 3X)**
355 |**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
356 |**No blinking**|(% style="width:220px" %)Communication with BMS Logic devices is stable|(% style="width:218px" %)Communication with BMS Main 3 devices is stable
357
358 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
359
360 |**State**|**Description**
361 |**Lights up green**|The switch supplies voltage to the contactor winding
362 |**Doesn’t light up**|The switch doesn’t supply voltage to the contactor winding
363
364 === DS11 – LED indicating the presence of power supply for contactors ===
365
366 |**State**|**Description**
367 |**Lights up green**|Power supply for contactor switches (9-32V) is present
368 |**Doesn’t light up**|Power supply for contactor switches (9-32V) is not present
369
370 == Connection procedure ==
371
372 All operations to connect the device must be carried out with the supply voltage removed.
373
374 * Connect the power contactors to header X2.
375 * Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
376 * Connect BMS Logic devices to header X9.
377 * Connect digital inputs and outputs (if necessary) to header X3.
378 * Connect the high voltage bus (if necessary) to headers X11-X14.
379 * Connect the high-voltage network integrity circuit (if necessary) to header X4.
380 * Connect external devices (if necessary) to header X6.
381 * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
382 * If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
383 * 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.