Wiki source code of 2. Installation and connection

Version 87.1 by Admin on 2026/03/25 16:39

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
81.4	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)
81.5	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)
27.1	65
	66
	67
82.2	68	=== X2 – miniUSB connector ===
27.1	69
82.2	70	The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
55.3	71
82.2	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
81.5	74	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
27.1	75
82.2	76	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
81.5	77
27.1	78	\|Pin\|Name\|Description
81.5	79	\|1\|GND\|Ground
82.2	80	\|2\|V+\|Supply voltage (9-32V)
27.1	81
	82
	83
83.2	84	=== X4, X5, X6, X7 – header of relay 1, 2, 3 and 4 ===
27.1	85
83.2	86	Receptacle Housing: Molex 39012020. Terminals: Molex 5556
55.3	87
86.2	88	[[image:1732198827034-560.png\|\|data-xwiki-image-style-alignment="center" height="78" width="41"]]
27.1	89
	90	\|Pin\|Name\|Description
83.2	91	\|1\|V+\|Switching voltage (up to 55V, max 3A)
	92	\|2\|NO\|Normally open contact
27.1	93
83.2	94	Contactor connection example for all relays:
27.1	95
86.2	96	[[image:1774456661980-866.png\|\|data-xwiki-image-style-alignment="center" height="211" width="282"]]
27.1	97
51.1	98
86.2	99	=== X8 – header for current sensor ===
27.1	100
55.3	101	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	102
27.1	103	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	104
	105	\|Pin\|Name\|Description
38.1	106	\|1\|CAN3_H\|CAN3 line H
	107	\|2\|CAN3_L\|CAN3 line L
27.1	108	\|3\|GND\|Ground
	109	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	110
	111	(% class="box infomessage" %)
	112	(((
38.1	113	Note:
	114	CAN3 operates differently depending on used firmware:
27.1	115
38.1	116	* BMS Main 3: CAN3 bus is reserved;
39.1	117	* 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	118
	119	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	120	)))
27.1	121
30.1	122	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	123
55.3	124	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	125
27.1	126	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	127
	128	\|Pin\|Name\|Description
	129	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	130	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	131	\|3\|GND\|Ground
	132	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	133
40.1	134	(% class="box infomessage" %)
	135	(((
	136	Note:
	137	RS-485-2 operates differently depending on used firmware:
27.1	138
40.1	139	* BMS Main 3X: RS-485-2 bus is reserved;
	140	* 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	141
40.1	142	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	143	)))
	144
82.2	145	=== X10 – ===
27.1	146
30.1	147	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	148
55.3	149	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	150
27.1	151	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	152
	153	\|Pin\|Name\|Description
	154	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	155	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	156
	157	(% class="box warningmessage" %)
	158	(((
	159	The connected voltage must not exceed 1000V.
	160	)))
	161
30.1	162	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	163
55.3	164	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	165
27.1	166	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	167
	168	\|Pin\|Name\|Description
	169	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	170	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	171
	172	(% class="box warningmessage" %)
	173	(((
	174	The connected voltage must not exceed 1000V.
	175	)))
	176
30.1	177	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	178
55.3	179	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	180
27.1	181	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	182
	183	\|Pin\|Name\|Description
	184	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	185	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	186
	187	(% class="box warningmessage" %)
	188	(((
	189	The connected voltage must not exceed 1000V.
	190	)))
	191
30.1	192	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	193
55.3	194	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	195
27.1	196	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	197
	198	\|Pin\|Name\|Description
	199	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	200	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	201
	202	(% class="box warningmessage" %)
	203	(((
	204	The connected voltage must not exceed 1000V.
	205	)))
	206
30.1	207	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	208
	209	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	210
	211	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:
	212
	213	\|Pin\|Name\|Description
	214	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	215	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	216
30.1	217	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	218
	219
	220	[[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:
	221
	222	\|Pin\|Name\|Description
	223	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	224	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	225
30.1	226	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	227
	228
	229	[[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:
	230
	231	\|Pin\|Name\|Description
	232	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	233	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	234
30.1	235	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	236
78.2	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.
27.1	238
30.1	239	== Indicators ==
27.1	240
30.1	241	=== DS1 – LED indicating device power ===
27.1	242
	243	\|State\|Description
	244	\|Lights up green\|Device power (+5V) is present
	245	\|Doesn’t light up\|No device power
	246
30.1	247	=== DS2 – LED indicating device work ===
27.1	248
	249	\|State\|Description
	250	\|Blinking green\|Executing the battery management program
	251	\|No blinking\|Program execution error
	252
54.2	253	=== DS3 – LED indicating interaction with child devices ===
27.1	254
54.2	255	(% style="width:447px" %)
	256	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	257	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	258	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	259
54.2	260	=== DS4 – LED indicating loss of connection with child devices ===
27.1	261
54.4	262	(% style="width:601px" %)
	263	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	264	\|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
	265	\|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	266
30.1	267	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	268
	269	\|State\|Description
	270	\|Lights up green\|The switch supplies voltage to the contactor winding
	271	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	272
30.1	273	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	274
	275	\|State\|Description
	276	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	277	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	278
30.1	279	== Connection procedure ==
27.1	280
	281	All operations to connect the device must be carried out with the supply voltage removed.
	282
	283	* Connect the power contactors to header X2.
	284	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	285	* Connect BMS Logic devices to header X9.
	286	* Connect digital inputs and outputs (if necessary) to header X3.
	287	* Connect the high voltage bus (if necessary) to headers X11-X14.
	288	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	289	* Connect external devices (if necessary) to header X6.
	290	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
78.2	291	* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
27.1	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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