Wiki source code of 2. Installation and connection

Version 87.2 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
87.2	99	=== X8 – header for current sensor 1 ===
27.1	100
87.2	101	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
55.3	102
87.2	103	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
27.1	104
	105	\|Pin\|Name\|Description
87.2	106	\|1\|+5V\|Supply voltage for the current sensor 5V, max 50 mA
	107	\|2\|GND\|Ground
	108	\|3\|CS1_OUT\|Current sensor 1 output
	109	\|4\|CS1_REF\|Current sensor 1 reference signal
27.1	110
30.1	111	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	112
55.3	113	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	114
27.1	115	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	116
	117	\|Pin\|Name\|Description
	118	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	119	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	120	\|3\|GND\|Ground
	121	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	122
40.1	123	(% class="box infomessage" %)
	124	(((
	125	Note:
	126	RS-485-2 operates differently depending on used firmware:
27.1	127
40.1	128	* BMS Main 3X: RS-485-2 bus is reserved;
	129	* 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	130
40.1	131	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	132	)))
	133
82.2	134	=== X10 – ===
27.1	135
30.1	136	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	137
55.3	138	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	139
27.1	140	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	141
	142	\|Pin\|Name\|Description
	143	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	144	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	145
	146	(% class="box warningmessage" %)
	147	(((
	148	The connected voltage must not exceed 1000V.
	149	)))
	150
30.1	151	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	152
55.3	153	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	154
27.1	155	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	156
	157	\|Pin\|Name\|Description
	158	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	159	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	160
	161	(% class="box warningmessage" %)
	162	(((
	163	The connected voltage must not exceed 1000V.
	164	)))
	165
30.1	166	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	167
55.3	168	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	169
27.1	170	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	171
	172	\|Pin\|Name\|Description
	173	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	174	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	175
	176	(% class="box warningmessage" %)
	177	(((
	178	The connected voltage must not exceed 1000V.
	179	)))
	180
30.1	181	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	182
55.3	183	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	184
27.1	185	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	186
	187	\|Pin\|Name\|Description
	188	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	189	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	190
	191	(% class="box warningmessage" %)
	192	(((
	193	The connected voltage must not exceed 1000V.
	194	)))
	195
30.1	196	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	197
	198	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	199
	200	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:
	201
	202	\|Pin\|Name\|Description
	203	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	204	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	205
30.1	206	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	207
	208
	209	[[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:
	210
	211	\|Pin\|Name\|Description
	212	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	213	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	214
30.1	215	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	216
	217
	218	[[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:
	219
	220	\|Pin\|Name\|Description
	221	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	222	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	223
30.1	224	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	225
78.2	226	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	227
30.1	228	== Indicators ==
27.1	229
30.1	230	=== DS1 – LED indicating device power ===
27.1	231
	232	\|State\|Description
	233	\|Lights up green\|Device power (+5V) is present
	234	\|Doesn’t light up\|No device power
	235
30.1	236	=== DS2 – LED indicating device work ===
27.1	237
	238	\|State\|Description
	239	\|Blinking green\|Executing the battery management program
	240	\|No blinking\|Program execution error
	241
54.2	242	=== DS3 – LED indicating interaction with child devices ===
27.1	243
54.2	244	(% style="width:447px" %)
	245	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	246	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	247	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	248
54.2	249	=== DS4 – LED indicating loss of connection with child devices ===
27.1	250
54.4	251	(% style="width:601px" %)
	252	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	253	\|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
	254	\|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	255
30.1	256	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	257
	258	\|State\|Description
	259	\|Lights up green\|The switch supplies voltage to the contactor winding
	260	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	261
30.1	262	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	263
	264	\|State\|Description
	265	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	266	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	267
30.1	268	== Connection procedure ==
27.1	269
	270	All operations to connect the device must be carried out with the supply voltage removed.
	271
	272	* Connect the power contactors to header X2.
	273	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	274	* Connect BMS Logic devices to header X9.
	275	* Connect digital inputs and outputs (if necessary) to header X3.
	276	* Connect the high voltage bus (if necessary) to headers X11-X14.
	277	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	278	* Connect external devices (if necessary) to header X6.
	279	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
78.2	280	* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
27.1	281	* 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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