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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 1 ===
100
101 Receptacle Housing: Molex 430250400. Terminals: Molex 43030
102
103 [[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]]
104
105 |**Pin**|**Name**|**Description**
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
110
111 === X9 – header for BMS Logic (RS-485-2) ===
112
113 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
114
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
123 (% class="box infomessage" %)
124 (((
125 **Note:**
126 RS-485-2 operates differently depending on used firmware:
127
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:
130
131 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
132 )))
133
134 === X10 – ===
135
136 === X11 – header for high-voltage bus before contactors (plus) ===
137
138 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
139
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
151 === X12 – header for high-voltage bus before contactors (minus) ===
152
153 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
154
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
166 === X13 – header for high-voltage bus after contactors (plus) ===
167
168 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
169
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
181 === X14 – header for high-voltage bus after contactors (minus) ===
182
183 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
184
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
196 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
206 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
215 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
224 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
225
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.
227
228 == Indicators ==
229
230 === DS1 – LED indicating device power ===
231
232 |**State**|**Description**
233 |**Lights up green**|Device power (+5V) is present
234 |**Doesn’t light up**|No device power
235
236 === DS2 – LED indicating device work ===
237
238 |**State**|**Description**
239 |**Blinking green**|Executing the battery management program
240 |**No blinking**|Program execution error
241
242 === DS3 – LED indicating interaction with child devices ===
243
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" %)-
248
249 === DS4 – LED indicating loss of connection with child devices ===
250
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
255
256 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
262 === DS11 – LED indicating the presence of power supply for contactors ===
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
268 == Connection procedure ==
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.
280 * If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
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.