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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**|Temperature sensor 1 output
132 |**4**|**T_SENS2**|Temperature sensor 2 output
133
134 === X11 – (% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)header for BMS Logic(%%) ===
135
136 Receptacle Housing: Molex 430250400. Terminals: Molex 43030
137
138 [[image:1732198890482-787.png||data-xwiki-image-style-alignment="center" height="77" width="71"]]
139
140 |**Pin**|**Name**|**Description**
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
145
146 === X12 – header for high-voltage bus before contactors (minus) ===
147
148 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
149
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
161 === X13 – header for high-voltage bus after contactors (plus) ===
162
163 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
164
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
176 === X14 – header for high-voltage bus after contactors (minus) ===
177
178 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
179
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
191 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
201 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
210 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
219 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
220
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.
222
223 == Indicators ==
224
225 === DS1 – LED indicating device power ===
226
227 |**State**|**Description**
228 |**Lights up green**|Device power (+5V) is present
229 |**Doesn’t light up**|No device power
230
231 === DS2 – LED indicating device work ===
232
233 |**State**|**Description**
234 |**Blinking green**|Executing the battery management program
235 |**No blinking**|Program execution error
236
237 === DS3 – LED indicating interaction with child devices ===
238
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" %)-
243
244 === DS4 – LED indicating loss of connection with child devices ===
245
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
250
251 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
257 === DS11 – LED indicating the presence of power supply for contactors ===
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
263 == Connection procedure ==
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.
275 * If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
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.