Wiki source code of 2. Installation and connection

Version 87.3 by Admin on 2026/03/25 16:41

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
87.3	111	=== X9 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for current sensor 2(%%) ===
27.1	112
87.3	113	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
55.3	114
87.3	115	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
27.1	116
	117	\|Pin\|Name\|Description
87.3	118	\|1\|+5V\|Supply voltage for the current sensor 5V, max 50 mA
	119	\|2\|GND\|Ground
	120	\|3\|CS2_OUT\|Current sensor 2 output
	121	\|4\|CS2_REF\|Current sensor 2 reference signal
27.1	122
87.3	123	=== X10 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for temperature sensors(%%) ===
27.1	124
87.3	125	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
27.1	126
87.3	127	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
40.1	128
87.3	129	\|Pin\|Name\|Description
	130	\|1, 2\|GND\|Ground
	131	\|3\|T_SENS1\|Ground
	132	\|4\|T_SENS2\|Current sensor 2 output
27.1	133
30.1	134	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	135
55.3	136	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	137
27.1	138	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	139
	140	\|Pin\|Name\|Description
	141	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	142	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	143
	144	(% class="box warningmessage" %)
	145	(((
	146	The connected voltage must not exceed 1000V.
	147	)))
	148
30.1	149	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	150
55.3	151	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	152
27.1	153	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	154
	155	\|Pin\|Name\|Description
	156	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	157	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	158
	159	(% class="box warningmessage" %)
	160	(((
	161	The connected voltage must not exceed 1000V.
	162	)))
	163
30.1	164	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	165
55.3	166	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	167
27.1	168	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	169
	170	\|Pin\|Name\|Description
	171	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	172	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	173
	174	(% class="box warningmessage" %)
	175	(((
	176	The connected voltage must not exceed 1000V.
	177	)))
	178
30.1	179	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	180
55.3	181	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	182
27.1	183	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	184
	185	\|Pin\|Name\|Description
	186	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	187	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	188
	189	(% class="box warningmessage" %)
	190	(((
	191	The connected voltage must not exceed 1000V.
	192	)))
	193
30.1	194	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	195
	196	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	197
	198	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:
	199
	200	\|Pin\|Name\|Description
	201	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	202	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	203
30.1	204	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	205
	206
	207	[[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:
	208
	209	\|Pin\|Name\|Description
	210	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	211	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	212
30.1	213	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	214
	215
	216	[[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:
	217
	218	\|Pin\|Name\|Description
	219	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	220	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	221
30.1	222	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	223
78.2	224	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	225
30.1	226	== Indicators ==
27.1	227
30.1	228	=== DS1 – LED indicating device power ===
27.1	229
	230	\|State\|Description
	231	\|Lights up green\|Device power (+5V) is present
	232	\|Doesn’t light up\|No device power
	233
30.1	234	=== DS2 – LED indicating device work ===
27.1	235
	236	\|State\|Description
	237	\|Blinking green\|Executing the battery management program
	238	\|No blinking\|Program execution error
	239
54.2	240	=== DS3 – LED indicating interaction with child devices ===
27.1	241
54.2	242	(% style="width:447px" %)
	243	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	244	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	245	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	246
54.2	247	=== DS4 – LED indicating loss of connection with child devices ===
27.1	248
54.4	249	(% style="width:601px" %)
	250	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	251	\|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
	252	\|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	253
30.1	254	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	255
	256	\|State\|Description
	257	\|Lights up green\|The switch supplies voltage to the contactor winding
	258	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	259
30.1	260	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	261
	262	\|State\|Description
	263	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	264	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	265
30.1	266	== Connection procedure ==
27.1	267
	268	All operations to connect the device must be carried out with the supply voltage removed.
	269
	270	* Connect the power contactors to header X2.
	271	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	272	* Connect BMS Logic devices to header X9.
	273	* Connect digital inputs and outputs (if necessary) to header X3.
	274	* Connect the high voltage bus (if necessary) to headers X11-X14.
	275	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	276	* Connect external devices (if necessary) to header X6.
	277	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
78.2	278	* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
27.1	279	* 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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