Changes for page 2. Installation and connection
Last modified by Admin on 2025/03/18 12:51
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... ... @@ -1,1 +1,1 @@ 1 - drafts.bms-main-3.WebHome1 +Battery management systems.BMS Main 3.WebHome - Content
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... ... @@ -1,8 +1,25 @@ 1 -(% data-numbered-headings-start="1" style="--numbered-headings-start: 1;font-size: 0px;color: rgba(0, 0, 0, 0.0)" %) 2 -= = 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 warningmessage" %) 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 + 3 3 == Installation procedure == 4 4 5 -The mounting location of the BMS Main 3 .0device 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.22 +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. 6 6 7 7 Overall and mounting dimensions are shown in figure below. 8 8 ... ... @@ -13,9 +13,9 @@ 13 13 |Mounting dimensions (length × width), mm|194 × 114 14 14 |Mounting holes|M3 15 15 16 -== 2.2Headers ==33 +== Headers == 17 17 18 -The location and designation of connectors on the BMS Main 3 .0device are shown below.35 +The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below. 19 19 20 20 (% contenteditable="false" tabindex="-1" %) 21 21 ((( ... ... @@ -28,8 +28,10 @@ 28 28 All headers are shown from the device side! 29 29 ))) 30 30 31 -=== 2.2.1X1 – header to power the device ===48 +=== X1 – header to power the device === 32 32 50 +Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF 51 + 33 33 (% class="wikigeneratedid" id="H" %) 34 34 (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png||data-xwiki-image-style-alignment="center" height="85" width="200"]] 35 35 ... ... @@ -43,8 +43,10 @@ 43 43 44 44 (% 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"]] 45 45 46 -=== (% title="Click and drag to resize" %)(%%)2.2.2X2 – header for contactors ===65 +=== X2 – header for contactors === 47 47 67 +Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF 68 + 48 48 (% 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" %) 49 49 50 50 |**Pin**|**Name**|**Description** ... ... @@ -60,18 +60,20 @@ 60 60 61 61 (% 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"]] 62 62 63 -=== (% title="Click and drag to resize" %)(%%) 2.2.3X3 – header for discrete inputs and outputs ===84 +=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs === 64 64 86 +Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF 87 + 65 65 (% 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"]] 66 66 67 67 |**Pin**|**Name**|**Description** 68 68 |**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals 69 -|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact” (+5 V)70 -|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact” (+5 V)71 -|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact” (+5 V)72 -|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact” (+5 V)73 -|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact” (+5 V)74 -|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact” (+5 V)92 +|**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact” 93 +|**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact” 94 +|**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact” 95 +|**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact” 96 +|**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact” 97 +|**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact” 75 75 |**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V) 76 76 |**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V) 77 77 |**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A) ... ... @@ -87,10 +87,14 @@ 87 87 88 88 (% 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: 89 89 90 - (% aria-label="1732121942791-517.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121942791-517.png||data-xwiki-image-style-alignment="center" height="90" width="269"]](% title="Click and drag to resize" %)(% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px, 14.4444px + 0.462963vw))" %)2.2.4 X4 – header for HVIL113 +[[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]] 91 91 92 - (% aria-label="1732122015188-642.pngimagewidget" data-widget="image"contenteditable="false" role="region"tabindex="-1"%)[[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]](% title="Click and drag to resize" %)115 +=== X4 – header for HVIL === 93 93 117 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF 118 + 119 +[[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]] 120 + 94 94 |**Pin**|**Name**|**Description** 95 95 |**1**|**-**|Not used 96 96 |**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output) ... ... @@ -97,14 +97,18 @@ 97 97 |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input) 98 98 |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA) 99 99 100 - If the BMS Main 3 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 is a passive current loop meter, then the current loop must be connected to the **HVIL_IN** and **HVIL_OUT** pins. 127 + 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. 101 101 102 102 Connection diagram to the current loop: 103 103 104 - (% aria-label="1732122067418-263.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732122067418-263.png||data-xwiki-image-style-alignment="center" height="264" width="356"]](% title="Click and drag to resize" %)(% style="color:inherit; font-family:inherit; font-size:max(18px, min(20px,14.4444px + 0.462963vw))"%)2.2.5 X5 – header for current and temperature sensors131 +[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]] 105 105 106 - (% aria-label="imagewidget"data-widget="image"contenteditable="false"role="region"tabindex="-1"%)[[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83"width="349"]](% title="Click and drag toesize"%)133 +=== X5 – header for current and temperature sensors === 107 107 135 +Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF 136 + 137 +[[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]] 138 + 108 108 (% style="width:539px" %) 109 109 |**Pin**|**Name**|(% style="width:402px" %)**Description** 110 110 |**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA) ... ... @@ -132,8 +132,10 @@ 132 132 133 133 [[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]] 134 134 135 -=== 2.2.6X6 – header for CAN1 and RS-485-1 (external buses) ===166 +=== X6 – header for CAN1 and RS-485-1 (external buses) === 136 136 168 +Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF 169 + 137 137 [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]] 138 138 139 139 |**Pin**|**Name**|**Description** ... ... @@ -151,13 +151,15 @@ 151 151 152 152 [[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]] 153 153 154 -=== 2.2.7X7 – header for CAN2 (internal bus) ===187 +=== X7 – header for CAN2 (internal bus) === 155 155 189 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF 190 + 156 156 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]] 157 157 158 158 |**Pin**|**Name**|**Description** 159 -|**1**|**CAN2_H**|CAN2 line H for communication with BMS devices 160 -|**2**|**CAN2_L**|CAN2 line L for communication with BMS devices 194 +|**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices 195 +|**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices 161 161 |**3**|**GND**|Ground 162 162 |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA) 163 163 ... ... @@ -165,27 +165,33 @@ 165 165 166 166 [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]] 167 167 168 -=== 2.2.8X8 – header for CAN3 ===203 +=== X8 – header for CAN3 === 169 169 205 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF 206 + 170 170 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]] 171 171 172 172 |**Pin**|**Name**|**Description** 173 -|**1**|**CAN3_H**|CAN3 line H for communication with battery modules (for BMS Main 3X)174 -|**2**|**CAN3_L**|CAN3 line L for communication with battery modules (for BMS Main 3X)210 +|**1**|**CAN3_H**|CAN3 line H 211 +|**2**|**CAN3_L**|CAN3 line L 175 175 |**3**|**GND**|Ground 176 176 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA) 177 177 178 178 (% class="box infomessage" %) 179 179 ((( 180 - If the BMS Main 3 device acts as a controller for a battery system consisting of several battery modules connected in parallel, then the parallel battery BMS must be connected to the CAN3 bus.181 - )))217 +**Note:** 218 +CAN3 operates differently depending on used firmware: 182 182 183 -Diagram for connecting battery modules to the CAN3 bus: 220 +* **BMS Main 3:** CAN3 bus is reserved; 221 +* **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: 184 184 185 -[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" height="153" width="417"]] 223 +[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]] 224 +))) 186 186 187 -=== 2.2.9X9 – header for BMS Logic (RS-485-2) ===226 +=== X9 – header for BMS Logic (RS-485-2) === 188 188 228 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF 229 + 189 189 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]] 190 190 191 191 |**Pin**|**Name**|**Description** ... ... @@ -194,16 +194,25 @@ 194 194 |**3**|**GND**|Ground 195 195 |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA) 196 196 197 -Connection diagram for BMS Logic devices: 238 +(% class="box infomessage" %) 239 +((( 240 +**Note:** 241 +RS-485-2 operates differently depending on used firmware: 198 198 199 -[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" height="163" width="400"]] 243 +* **BMS Main 3X:** RS-485-2 bus is reserved; 244 +* **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices: 200 200 201 -=== 2.2.10 X10 – miniUSB connector === 246 +[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]] 247 +))) 202 202 203 - TheminiUSB connectoris used to configure the parameters of the BMS Main 3.0 device.249 +=== X10 – miniUSB connector === 204 204 205 - === 2.2.11 X11 –headerforhigh-voltagebusbeforecontactors(plus)===251 +The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device. 206 206 253 +=== X11 – header for high-voltage bus before contactors (plus) === 254 + 255 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 256 + 207 207 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]] 208 208 209 209 |**Pin**|**Name**|**Description** ... ... @@ -215,8 +215,10 @@ 215 215 The connected voltage must not exceed 1000V. 216 216 ))) 217 217 218 -=== 2.2.12X12 – header for high-voltage bus before contactors (minus) ===268 +=== X12 – header for high-voltage bus before contactors (minus) === 219 219 270 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 271 + 220 220 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]] 221 221 222 222 |**Pin**|**Name**|**Description** ... ... @@ -228,8 +228,10 @@ 228 228 The connected voltage must not exceed 1000V. 229 229 ))) 230 230 231 -=== 2.2.13X13 – header for high-voltage bus after contactors (plus) ===283 +=== X13 – header for high-voltage bus after contactors (plus) === 232 232 285 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 286 + 233 233 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]] 234 234 235 235 |**Pin**|**Name**|**Description** ... ... @@ -241,8 +241,10 @@ 241 241 The connected voltage must not exceed 1000V. 242 242 ))) 243 243 244 -=== 2.2.14X14 – header for high-voltage bus after contactors (minus) ===298 +=== X14 – header for high-voltage bus after contactors (minus) === 245 245 300 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030 301 + 246 246 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]] 247 247 248 248 |**Pin**|**Name**|**Description** ... ... @@ -254,7 +254,7 @@ 254 254 The connected voltage must not exceed 1000V. 255 255 ))) 256 256 257 -=== 2.2.15J1 – jumper for switching RS-485-1 bus terminal resistor ===313 +=== J1 – jumper for switching RS-485-1 bus terminal resistor === 258 258 259 259 [[image:1733316982359-759.png||data-xwiki-image-style-alignment="center" height="77" width="148"]] 260 260 ... ... @@ -264,7 +264,7 @@ 264 264 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the RS-485-1 bus is connected 265 265 |**2-3**|**-**|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected 266 266 267 -=== 2.2.16J2 – jumper for switching CAN1 bus terminal resistor ===323 +=== J2 – jumper for switching CAN1 bus terminal resistor === 268 268 269 269 270 270 [[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: ... ... @@ -273,7 +273,7 @@ 273 273 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN1 bus is connected 274 274 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN1 bus is disconnected 275 275 276 -=== 2.2.17J3 – jumper for switching CAN2 bus terminal resistor ===332 +=== J3 – jumper for switching CAN2 bus terminal resistor === 277 277 278 278 279 279 [[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: ... ... @@ -282,55 +282,52 @@ 282 282 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN2 bus is connected 283 283 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN2 bus is disconnected 284 284 285 -=== 2.2.18J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===341 +=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 === 286 286 287 -The BMS Main 3 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. 343 +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. 288 288 289 -== 2.3Indicators ==345 +== Indicators == 290 290 291 -=== 2.3.1DS1 – LED indicating device power ===347 +=== DS1 – LED indicating device power === 292 292 293 293 |**State**|**Description** 294 294 |**Lights up green**|Device power (+5V) is present 295 295 |**Doesn’t light up**|No device power 296 296 297 -=== 2.3.2DS2 – LED indicating device work ===353 +=== DS2 – LED indicating device work === 298 298 299 299 |**State**|**Description** 300 300 |**Blinking green**|Executing the battery management program 301 301 |**No blinking**|Program execution error 302 302 303 -=== 2.3.3DS3 – LED indicating interaction withBMSLogic ===359 +=== DS3 – LED indicating interaction with child devices === 304 304 305 -|**State**|**Description** 306 -|**Blinking yellow**|The device interacts with BMS Logic devices 307 -|**No blinking**|- 361 +(% style="width:447px" %) 362 +|**State**|(% style="width:166px" %)**Description (Main 3)**|(% style="width:168px" %)**Description (Main 3X)** 363 +|**Blinking yellow**|(% style="width:166px" %)The device interacts with BMS Logic devices|(% style="width:168px" %)The device interacts with BMS Main 3 devices 364 +|**No blinking**|(% style="width:166px" %)-|(% style="width:168px" %)- 308 308 309 -=== 2.3.4DS4 – LED indicating loss of connection withBMS Logic ===366 +=== DS4 – LED indicating loss of connection with child devices === 310 310 311 -|**State**|**Description** 312 -|**Blinking/lights up red**|Communication with one or more BMS Logic devices is lost 313 -|**No blinking**|Communication with BMS Logic is stable 368 +(% style="width:601px" %) 369 +|**State**|(% style="width:220px" %)**Description (Main 3)**|(% style="width:218px" %)**Description (Main 3X)** 370 +|**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 371 +|**No blinking**|(% style="width:220px" %)Communication with BMS Logic devices is stable|(% style="width:218px" %)Communication with BMS Main 3 devices is stable 314 314 315 -=== 2.3.5DS5-DS10 – LEDs indicating contactor switches 1-6 ===373 +=== DS5-DS10 – LEDs indicating contactor switches 1-6 === 316 316 317 317 |**State**|**Description** 318 318 |**Lights up green**|The switch supplies voltage to the contactor winding 319 319 |**Doesn’t light up**|The switch doesn’t supply voltage to the contactor winding 320 320 321 -=== 2.3.6DS11 – LED indicating the presence of power supply for contactors ===379 +=== DS11 – LED indicating the presence of power supply for contactors === 322 322 323 323 |**State**|**Description** 324 324 |**Lights up green**|Power supply for contactor switches (9-32V) is present 325 325 |**Doesn’t light up**|Power supply for contactor switches (9-32V) is not present 326 326 327 -== 2.4Connection procedure ==385 +== Connection procedure == 328 328 329 -(% class="box warningmessage" %) 330 -((( 331 -Before connection, configure the device (see ). Correct operation of the BMS system is only possible with correct configuration. 332 -))) 333 - 334 334 All operations to connect the device must be carried out with the supply voltage removed. 335 335 336 336 * Connect the power contactors to header X2. ... ... @@ -341,5 +341,5 @@ 341 341 * Connect the high-voltage network integrity circuit (if necessary) to header X4. 342 342 * Connect external devices (if necessary) to header X6. 343 343 * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7. 344 -* If the BMS Main 3 .0is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.397 +* 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. 345 345 * 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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