Wiki source code of 2. Installation and connection

Version 88.2 by Admin on 2026/03/25 16:42

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
88.2	131	\|3\|T_SENS1\|Temperature sensor 1 output
	132	\|4\|T_SENS2\|Temperature sensor 2 output
27.1	133
88.2	134	=== X11 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for BMS Logic(%%) ===
27.1	135
88.2	136	Receptacle Housing: Molex 430250400. Terminals: Molex 43030
55.3	137
88.2	138	[[image:1732198890482-787.png\|\|data-xwiki-image-style-alignment="center" height="77" width="71"]]
27.1	139
	140	\|Pin\|Name\|Description
88.2	141	\|1\|RS485_A\|RS-485 line A for communication with BMS Logic
	142	\|2\|RS485_B\|RS-485 line B for communication with BMS Logic
	143	\|3\|+5V\|Supply voltage for BMS Logic
	144	\|4\|GND\|Ground
27.1	145
30.1	146	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	147
55.3	148	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	149
27.1	150	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	151
	152	\|Pin\|Name\|Description
	153	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	154	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	155
	156	(% class="box warningmessage" %)
	157	(((
	158	The connected voltage must not exceed 1000V.
	159	)))
	160
30.1	161	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	162
55.3	163	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	164
27.1	165	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	166
	167	\|Pin\|Name\|Description
	168	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	169	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	170
	171	(% class="box warningmessage" %)
	172	(((
	173	The connected voltage must not exceed 1000V.
	174	)))
	175
30.1	176	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	177
55.3	178	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	179
27.1	180	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	181
	182	\|Pin\|Name\|Description
	183	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	184	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	185
	186	(% class="box warningmessage" %)
	187	(((
	188	The connected voltage must not exceed 1000V.
	189	)))
	190
30.1	191	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	192
	193	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	194
	195	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:
	196
	197	\|Pin\|Name\|Description
	198	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	199	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	200
30.1	201	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	202
	203
	204	[[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:
	205
	206	\|Pin\|Name\|Description
	207	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	208	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	209
30.1	210	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	211
	212
	213	[[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:
	214
	215	\|Pin\|Name\|Description
	216	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	217	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	218
30.1	219	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	220
78.2	221	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	222
30.1	223	== Indicators ==
27.1	224
30.1	225	=== DS1 – LED indicating device power ===
27.1	226
	227	\|State\|Description
	228	\|Lights up green\|Device power (+5V) is present
	229	\|Doesn’t light up\|No device power
	230
30.1	231	=== DS2 – LED indicating device work ===
27.1	232
	233	\|State\|Description
	234	\|Blinking green\|Executing the battery management program
	235	\|No blinking\|Program execution error
	236
54.2	237	=== DS3 – LED indicating interaction with child devices ===
27.1	238
54.2	239	(% style="width:447px" %)
	240	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	241	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	242	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	243
54.2	244	=== DS4 – LED indicating loss of connection with child devices ===
27.1	245
54.4	246	(% style="width:601px" %)
	247	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	248	\|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
	249	\|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	250
30.1	251	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	252
	253	\|State\|Description
	254	\|Lights up green\|The switch supplies voltage to the contactor winding
	255	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	256
30.1	257	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	258
	259	\|State\|Description
	260	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	261	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	262
30.1	263	== Connection procedure ==
27.1	264
	265	All operations to connect the device must be carried out with the supply voltage removed.
	266
	267	* Connect the power contactors to header X2.
	268	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	269	* Connect BMS Logic devices to header X9.
	270	* Connect digital inputs and outputs (if necessary) to header X3.
	271	* Connect the high voltage bus (if necessary) to headers X11-X14.
	272	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	273	* Connect external devices (if necessary) to header X6.
	274	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
78.2	275	* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
27.1	276	* 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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