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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:1732198827034-560.png||data-xwiki-image-style-alignment="center" height="78" width="41"]]
89
90 |**Pin**|**Name**|**Description**
91 |**1**|**V+**|Switching voltage (up to 55V, max 3A)
92 |**2**|**NO**|Normally open contact
93
94 Contactor connection example for all relays:
95
96 [[image:1774456661980-866.png||data-xwiki-image-style-alignment="center" height="211" width="282"]]
97
98
99 === X8 – header for current sensor ===
100
101 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
102
103 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
104
105 |**Pin**|**Name**|**Description**
106 |**1**|**CAN3_H**|CAN3 line H
107 |**2**|**CAN3_L**|CAN3 line L
108 |**3**|**GND**|Ground
109 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
110
111 (% class="box infomessage" %)
112 (((
113 **Note:**
114 CAN3 operates differently depending on used firmware:
115
116 * **BMS Main 3:** CAN3 bus is reserved;
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:
118
119 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
120 )))
121
122 === X9 – header for BMS Logic (RS-485-2) ===
123
124 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
125
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
134 (% class="box infomessage" %)
135 (((
136 **Note:**
137 RS-485-2 operates differently depending on used firmware:
138
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:
141
142 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
143 )))
144
145 === X10 – ===
146
147 === X11 – header for high-voltage bus before contactors (plus) ===
148
149 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
150
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
162 === X12 – header for high-voltage bus before contactors (minus) ===
163
164 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
165
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
177 === X13 – header for high-voltage bus after contactors (plus) ===
178
179 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
180
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
192 === X14 – header for high-voltage bus after contactors (minus) ===
193
194 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
195
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
207 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
217 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
226 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
235 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
236
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.
238
239 == Indicators ==
240
241 === DS1 – LED indicating device power ===
242
243 |**State**|**Description**
244 |**Lights up green**|Device power (+5V) is present
245 |**Doesn’t light up**|No device power
246
247 === DS2 – LED indicating device work ===
248
249 |**State**|**Description**
250 |**Blinking green**|Executing the battery management program
251 |**No blinking**|Program execution error
252
253 === DS3 – LED indicating interaction with child devices ===
254
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" %)-
259
260 === DS4 – LED indicating loss of connection with child devices ===
261
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
266
267 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
273 === DS11 – LED indicating the presence of power supply for contactors ===
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
279 == Connection procedure ==
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.
291 * If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
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.