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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 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for current sensor 2(%%) ===
112
113 Receptacle Housing: Molex 430250400. Terminals: Molex 43030
114
115 [[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]]
116
117 |**Pin**|**Name**|**Description**
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
122
123 === X10 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for temperature sensors(%%) ===
124
125 Receptacle Housing: Molex 430250400. Terminals: Molex 43030
126
127 [[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]]
128
129 |**Pin**|**Name**|**Description**
130 |**1, 2**|**GND**|Ground
131 |**3**|**T_SENS1**|Ground
132 |**4**|**T_SENS2**|Current sensor 2 output
133
134 === X11 – header for high-voltage bus before contactors (plus) ===
135
136 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
137
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
149 === X12 – header for high-voltage bus before contactors (minus) ===
150
151 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
152
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
164 === X13 – header for high-voltage bus after contactors (plus) ===
165
166 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
167
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
179 === X14 – header for high-voltage bus after contactors (minus) ===
180
181 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
182
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
194 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
204 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
213 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
222 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
223
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.
225
226 == Indicators ==
227
228 === DS1 – LED indicating device power ===
229
230 |**State**|**Description**
231 |**Lights up green**|Device power (+5V) is present
232 |**Doesn’t light up**|No device power
233
234 === DS2 – LED indicating device work ===
235
236 |**State**|**Description**
237 |**Blinking green**|Executing the battery management program
238 |**No blinking**|Program execution error
239
240 === DS3 – LED indicating interaction with child devices ===
241
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" %)-
246
247 === DS4 – LED indicating loss of connection with child devices ===
248
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
253
254 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
260 === DS11 – LED indicating the presence of power supply for contactors ===
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
266 == Connection procedure ==
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.
278 * If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
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.