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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 It is not recommended to use the system in batteries formed by several series of cells connected in parallel. To increase capacity, it is recommended to connect several cells in parallel groups, and then connect the groups in series.
11
12 (% class="box warningmessage" %)
13 (((
14 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.
15 )))
16
17 (% class="box errormessage" %)
18 (((
19 **The system is not designed to operate with batteries whose total voltage exceeds 3000 V.**
20 )))
21
22 == Installation procedure ==
23
24 The mounting location of the BMS Main 3 / BMS Main 3X 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.
25
26 Overall and mounting dimensions are shown in figure below.
27
28 (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1733311711953-224.png||data-xwiki-image-style-alignment="center" height="566" width="775"]](% title="Click and drag to resize" %)​
29
30 |**Parameter**|**Value**
31 |Overall dimensions (length × width × height), mm|200 × 123 × 12
32 |Mounting dimensions (length × width), mm|194 × 114
33 |Mounting holes|M3
34
35 == Headers ==
36
37 The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
38
39 (% contenteditable="false" tabindex="-1" %)
40 (((
41 [[image:1732119505664-787.png||data-xwiki-image-style-alignment="center" height="417" width="684"]]
42 )))
43
44 (% class="box warningmessage" %)
45 (((
46 **Attention!**
47 All headers are shown from the device side!
48 )))
49
50 === X1 – header to power the device ===
51
52 Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
53
54 (% class="wikigeneratedid" id="H" %)
55 (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png||data-xwiki-image-style-alignment="center" height="85" width="200"]]
56
57 |**Pin**|**Name**|**Description**
58 |**1–2, 5–6**|**GND**|Ground
59 |**3**|**KEYRUN**|Power-on signal
60 |**4**|**CHARGE_ON**|Power-on signal (battery charge requirement)
61 |**7–8**|**VIN**|Power line (9-32V)
62
63 Power supply connection diagram:
64
65 (% aria-label="1732120054870-496.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732120054870-496.png||data-xwiki-image-style-alignment="center" height="169" width="327"]]
66
67 === X2 – header for contactors ===
68
69 Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
70
71 (% aria-label="1732121695049-411.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121695049-411.png||data-xwiki-image-style-alignment="center" height="87" width="267"]](% title="Click and drag to resize" %)​
72
73 |**Pin**|**Name**|**Description**
74 |**1–4, 8–9**|**GND**|Ground
75 |**5**|**CONT1_OUT**|Contactor control 1 (plus)
76 |**6**|**CONT2_OUT**|Contactor control 2 (plus)
77 |**7**|**CONT3_OUT**|Contactor control 3 (plus)
78 |**10**|**CONT4_OUT**|Contactor control 4 (plus)
79 |**11**|**CONT5_OUT**|Contactor control 5 (plus)
80 |**12**|**CONT6_OUT**|Contactor control 6 (plus)
81
82 Contactor connection diagram:
83
84 (% aria-label="1732121755886-234.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121755886-234.png||data-xwiki-image-style-alignment="center" height="82" width="260"]]
85
86 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
87
88 Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
89
90 (% aria-label="1732121811285-182.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121811285-182.png||data-xwiki-image-style-alignment="center" height="94" width="531"]]
91
92 |**Pin**|**Name**|**Description**
93 |**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals
94 |**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact”
95 |**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact”
96 |**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact”
97 |**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact”
98 |**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact”
99 |**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact”
100 |**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
101 |**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
102 |**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
103 |**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A)
104 |**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A)
105 |**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A)
106
107 Connection diagram of a discrete input to a dry contact output:
108
109 (% aria-label="1732121887401-555.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121887401-555.png||data-xwiki-image-style-alignment="center" height="63" width="196"]](% title="Click and drag to resize" %)​(%%)Connection diagram of a discrete input to an open collector output:
110
111 (% aria-label="1732122137116-973.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732122137116-973.png||data-xwiki-image-style-alignment="center" height="100" width="274"]](% title="Click and drag to resize" %)​(%%)Connection diagram for a discrete input for detecting a 9-32V signal:
112
113 (% aria-label="1732121926812-202.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121926812-202.png||data-xwiki-image-style-alignment="center" height="76" width="242"]](% title="Click and drag to resize" %)​(%%)Connection diagram for discrete output:
114
115 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
116
117 === X4 – header for HVIL ===
118
119 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
120
121 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
122
123 |**Pin**|**Name**|**Description**
124 |**1**|**-**|Not used
125 |**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
126 |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
127 |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
128
129 If the BMS Main 3 / BMS Main 3X device generates current in a current loop, the current loop must be connected to the **HVIL_PWR** and **HVIL_IN** pins. If BMS Main 3 / BMS Main 3X is a passive current loop meter, then the current loop must be connected to the **HVIL_IN** and **HVIL_OUT** pins.
130
131 Connection diagram to the current loop:
132
133 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
134
135 === X5 – header for current and temperature sensors ===
136
137 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
138
139 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
140
141 (% style="width:539px" %)
142 |**Pin**|**Name**|(% style="width:402px" %)**Description**
143 |**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
144 |**2–6**|**GND**|(% style="width:402px" %)Ground
145 |**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
146 |**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
147 |**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
148 |**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
149 |**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
150 |**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
151 |**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
152 |**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
153 |**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
154 |**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
155
156 Current sensor connection diagram (using the example of LEM HASS 100-S):
157
158 [[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
159
160 Current sensor connection diagram (using the example of LEM DHAB S/118):
161
162 [[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
163
164 NTC-thermistor connection diagram:
165
166 [[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
167
168 === X6 – header for CAN1 and RS-485-1 (external buses) ===
169
170 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
171
172 [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
173
174 |**Pin**|**Name**|**Description**
175 |**1**|**CAN1_H**|CAN1 line H for communication with external equipment
176 |**2**|**CAN1_L**|CAN1 line L for communication with external equipment
177 |**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
178 |**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
179 |**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
180
181 Connection diagram to the CAN1 bus:
182
183 [[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
184
185 Connection diagram to the RS-485-1 bus:
186
187 [[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
188
189 === X7 – header for CAN2 (internal bus) ===
190
191 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
192
193 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
194
195 |**Pin**|**Name**|**Description**
196 |**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
197 |**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
198 |**3**|**GND**|Ground
199 |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
200
201 Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
202
203 [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
204
205 === X8 – header for CAN3 ===
206
207 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
208
209 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
210
211 |**Pin**|**Name**|**Description**
212 |**1**|**CAN3_H**|CAN3 line H
213 |**2**|**CAN3_L**|CAN3 line L
214 |**3**|**GND**|Ground
215 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
216
217 (% class="box infomessage" %)
218 (((
219 **Note:**
220 CAN3 operates differently depending on used firmware:
221
222 * **BMS Main 3:** CAN3 bus is reserved;
223 * **BMS Main 3X:** CAN3 bus is used to connect with BMS Main 3 inside parallel strings. Diagram for connecting battery modules to the CAN3 bus:
224
225 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
226 )))
227
228 === X9 – header for BMS Logic (RS-485-2) ===
229
230 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
231
232 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
233
234 |**Pin**|**Name**|**Description**
235 |**1**|**LOGIC_B**|RS-485 line B for communication with BMS Logic
236 |**2**|**LOGIC_A**|RS-485 line A for communication with BMS Logic
237 |**3**|**GND**|Ground
238 |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
239
240 (% class="box infomessage" %)
241 (((
242 **Note:**
243 RS-485-2 operates differently depending on used firmware:
244
245 * **BMS Main 3X:** RS-485-2 bus is reserved;
246 * **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
247
248 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
249 )))
250
251 === X10 – miniUSB connector ===
252
253 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
254
255 === X11 – header for high-voltage bus before contactors (plus) ===
256
257 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
258
259 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
260
261 |**Pin**|**Name**|**Description**
262 |**1**|**IN1+**|Plus of the high-voltage bus (before contactors)
263 |**2**|**IN1+**|Plus of the high-voltage bus (before contactors)
264
265 (% class="box warningmessage" %)
266 (((
267 The connected voltage must not exceed 1000V.
268 )))
269
270 === X12 – header for high-voltage bus before contactors (minus) ===
271
272 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
273
274 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
275
276 |**Pin**|**Name**|**Description**
277 |**1**|**IN1-**|Minus of the high-voltage bus (before contactors)
278 |**2**|**IN1-**|Minus of the high-voltage bus (before contactors)
279
280 (% class="box warningmessage" %)
281 (((
282 The connected voltage must not exceed 1000V.
283 )))
284
285 === X13 – header for high-voltage bus after contactors (plus) ===
286
287 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
288
289 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
290
291 |**Pin**|**Name**|**Description**
292 |**1**|**IN2+**|Plus of the high-voltage bus (after contactors)
293 |**2**|**IN2+**|Plus of the high-voltage bus (after contactors)
294
295 (% class="box warningmessage" %)
296 (((
297 The connected voltage must not exceed 1000V.
298 )))
299
300 === X14 – header for high-voltage bus after contactors (minus) ===
301
302 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
303
304 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
305
306 |**Pin**|**Name**|**Description**
307 |**1**|**IN2-**|Minus of the high-voltage bus (after contactors)
308 |**2**|**IN2-**|Minus of the high-voltage bus (after contactors)
309
310 (% class="box warningmessage" %)
311 (((
312 The connected voltage must not exceed 1000V.
313 )))
314
315 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
316
317 [[image:1733316982359-759.png||data-xwiki-image-style-alignment="center" height="77" width="148"]]
318
319 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:
320
321 |**Pin**|**Name**|**Description**
322 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
323 |**2-3**|**-**|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
324
325 === J2 – jumper for switching CAN1 bus terminal resistor ===
326
327
328 [[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:
329
330 |**Pin**|**Name**|**Description**
331 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN1 bus is connected
332 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
333
334 === J3 – jumper for switching CAN2 bus terminal resistor ===
335
336
337 [[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:
338
339 |**Pin**|**Name**|**Description**
340 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN2 bus is connected
341 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
342
343 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
344
345 The BMS Main 3 / BMS Main 3X 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.
346
347 == Indicators ==
348
349 === DS1 – LED indicating device power ===
350
351 |**State**|**Description**
352 |**Lights up green**|Device power (+5V) is present
353 |**Doesn’t light up**|No device power
354
355 === DS2 – LED indicating device work ===
356
357 |**State**|**Description**
358 |**Blinking green**|Executing the battery management program
359 |**No blinking**|Program execution error
360
361 === DS3 – LED indicating interaction with child devices ===
362
363 (% style="width:447px" %)
364 |**State**|(% style="width:166px" %)**Description (Main 3)**|(% style="width:168px" %)**Description (Main 3X)**
365 |**Blinking yellow**|(% style="width:166px" %)The device interacts with BMS Logic devices|(% style="width:168px" %)The device interacts with BMS Main 3 devices
366 |**No blinking**|(% style="width:166px" %)-|(% style="width:168px" %)-
367
368 === DS4 – LED indicating loss of connection with child devices ===
369
370 (% style="width:601px" %)
371 |**State**|(% style="width:220px" %)**Description (Main 3)**|(% style="width:218px" %)**Description (Main 3X)**
372 |**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
373 |**No blinking**|(% style="width:220px" %)Communication with BMS Logic devices is stable|(% style="width:218px" %)Communication with BMS Main 3 devices is stable
374
375 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
376
377 |**State**|**Description**
378 |**Lights up green**|The switch supplies voltage to the contactor winding
379 |**Doesn’t light up**|The switch doesn’t supply voltage to the contactor winding
380
381 === DS11 – LED indicating the presence of power supply for contactors ===
382
383 |**State**|**Description**
384 |**Lights up green**|Power supply for contactor switches (9-32V) is present
385 |**Doesn’t light up**|Power supply for contactor switches (9-32V) is not present
386
387 == Connection procedure ==
388
389 All operations to connect the device must be carried out with the supply voltage removed.
390
391 * Connect the power contactors to header X2.
392 * Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
393 * Connect BMS Logic devices to header X9.
394 * Connect digital inputs and outputs (if necessary) to header X3.
395 * Connect the high voltage bus (if necessary) to headers X11-X14.
396 * Connect the high-voltage network integrity circuit (if necessary) to header X4.
397 * Connect external devices (if necessary) to header X6.
398 * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
399 * If the BMS Main 3 / BMS Main 3X is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
400 * 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.