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Last modified by Admin on 2025/03/18 12:51
From version 37.1
edited by Admin
on 2024/12/12 16:14
Change comment: There is no comment for this version
To version 57.2
edited by Admin
on 2025/03/18 12:13
Change comment: There is no comment for this version

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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 2  = Installation and connection =
3 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 +
4 4  == Installation procedure ==
5 5  
6 -The mounting location of the BMS Main 3 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.
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.
7 7  
8 8  Overall and mounting dimensions are shown in figure below.
9 9  
... ... @@ -16,7 +16,7 @@
16 16  
17 17  == Headers ==
18 18  
19 -The location and designation of connectors on the BMS Main 3 device are shown below.
37 +The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
20 20  
21 21  (% contenteditable="false" tabindex="-1" %)
22 22  (((
... ... @@ -31,6 +31,8 @@
31 31  
32 32  === X1 – header to power the device ===
33 33  
52 +Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
53 +
34 34  (% class="wikigeneratedid" id="H" %)
35 35  (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png||data-xwiki-image-style-alignment="center" height="85" width="200"]]
36 36  
... ... @@ -46,6 +46,8 @@
46 46  
47 47  === X2 – header for contactors ===
48 48  
69 +Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
70 +
49 49  (% 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" %)​
50 50  
51 51  |**Pin**|**Name**|**Description**
... ... @@ -63,6 +63,8 @@
63 63  
64 64  === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
65 65  
88 +Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
89 +
66 66  (% 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"]]
67 67  
68 68  |**Pin**|**Name**|**Description**
... ... @@ -88,8 +88,12 @@
88 88  
89 89  (% 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:
90 90  
115 +[[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
116 +
91 91  === X4 – header for HVIL ===
92 92  
119 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
120 +
93 93  [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
94 94  
95 95  |**Pin**|**Name**|**Description**
... ... @@ -98,12 +98,16 @@
98 98  |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
99 99  |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
100 100  
101 - 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.
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.
102 102  
103 103  Connection diagram to the current loop:
104 104  
133 +[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
134 +
105 105  === X5 – header for current and temperature sensors ===
106 106  
137 +Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
138 +
107 107  [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
108 108  
109 109  (% style="width:539px" %)
... ... @@ -135,6 +135,8 @@
135 135  
136 136  === X6 – header for CAN1 and RS-485-1 (external buses) ===
137 137  
170 +Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
171 +
138 138  [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
139 139  
140 140  |**Pin**|**Name**|**Description**
... ... @@ -154,11 +154,13 @@
154 154  
155 155  === X7 – header for CAN2 (internal bus) ===
156 156  
191 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
192 +
157 157  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
158 158  
159 159  |**Pin**|**Name**|**Description**
160 -|**1**|**CAN2_H**|CAN2 line H for communication with BMS devices
161 -|**2**|**CAN2_L**|CAN2 line L for communication with BMS devices
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
162 162  |**3**|**GND**|Ground
163 163  |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
164 164  
... ... @@ -168,25 +168,31 @@
168 168  
169 169  === X8 – header for CAN3 ===
170 170  
207 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
208 +
171 171  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
172 172  
173 173  |**Pin**|**Name**|**Description**
174 -|**1**|**CAN3_H**|CAN3 line H for communication with battery modules (for BMS Main 3X)
175 -|**2**|**CAN3_L**|CAN3 line L for communication with battery modules (for BMS Main 3X)
212 +|**1**|**CAN3_H**|CAN3 line H
213 +|**2**|**CAN3_L**|CAN3 line L
176 176  |**3**|**GND**|Ground
177 177  |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
178 178  
179 179  (% class="box infomessage" %)
180 180  (((
181 -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.
182 -)))
219 +**Note:**
220 +CAN3 operates differently depending on used firmware:
183 183  
184 -Diagram for connecting battery modules to the CAN3 bus:
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:
185 185  
186 -[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" height="153" width="417"]]
225 +[[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
226 +)))
187 187  
188 188  === X9 – header for BMS Logic (RS-485-2) ===
189 189  
230 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
231 +
190 190  [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
191 191  
192 192  |**Pin**|**Name**|**Description**
... ... @@ -195,16 +195,25 @@
195 195  |**3**|**GND**|Ground
196 196  |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
197 197  
198 -Connection diagram for BMS Logic devices:
240 +(% class="box infomessage" %)
241 +(((
242 +**Note:**
243 +RS-485-2 operates differently depending on used firmware:
199 199  
200 -[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" height="163" width="400"]]
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:
201 201  
248 +[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
249 +)))
250 +
202 202  === X10 – miniUSB connector ===
203 203  
204 -The miniUSB connector is used to configure the parameters of the BMS Main 3 device.
253 +The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
205 205  
206 206  === X11 – header for high-voltage bus before contactors (plus) ===
207 207  
257 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
258 +
208 208  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
209 209  
210 210  |**Pin**|**Name**|**Description**
... ... @@ -218,6 +218,8 @@
218 218  
219 219  === X12 – header for high-voltage bus before contactors (minus) ===
220 220  
272 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
273 +
221 221  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
222 222  
223 223  |**Pin**|**Name**|**Description**
... ... @@ -231,6 +231,8 @@
231 231  
232 232  === X13 – header for high-voltage bus after contactors (plus) ===
233 233  
287 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
288 +
234 234  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
235 235  
236 236  |**Pin**|**Name**|**Description**
... ... @@ -244,6 +244,8 @@
244 244  
245 245  === X14 – header for high-voltage bus after contactors (minus) ===
246 246  
302 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
303 +
247 247  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
248 248  
249 249  |**Pin**|**Name**|**Description**
... ... @@ -285,7 +285,7 @@
285 285  
286 286  === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
287 287  
288 -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.
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.
289 289  
290 290  == Indicators ==
291 291  
... ... @@ -301,17 +301,19 @@
301 301  |**Blinking green**|Executing the battery management program
302 302  |**No blinking**|Program execution error
303 303  
304 -=== DS3 – LED indicating interaction with BMS Logic ===
361 +=== DS3 – LED indicating interaction with child devices ===
305 305  
306 -|**State**|**Description**
307 -|**Blinking yellow**|The device interacts with BMS Logic devices
308 -|**No blinking**|-
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" %)-
309 309  
310 -=== DS4 – LED indicating loss of connection with BMS Logic ===
368 +=== DS4 – LED indicating loss of connection with child devices ===
311 311  
312 -|**State**|**Description**
313 -|**Blinking/lights up red**|Communication with one or more BMS Logic devices is lost
314 -|**No blinking**|Communication with BMS Logic is stable
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
315 315  
316 316  === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
317 317  
... ... @@ -327,9 +327,16 @@
327 327  
328 328  == Connection procedure ==
329 329  
389 +The BMS can connect to batteries with voltage levels dangerous to life and health. When working with high voltage batteries, follow electrical safety rules, use safety glasses, protective clothing, insulated tools and devices.
390 +
391 +(% class="box errormessage" %)
392 +(((
393 +**The system is not designed to operate with batteries with total voltage more than 3000V.**
394 +)))
395 +
330 330  (% class="box warningmessage" %)
331 331  (((
332 -Before connection, configure the device (see [[Settings>>doc:Battery management systems.BMS Main 3.3\. Settings.WebHome]]). Correct operation of the BMS system is only possible with correct configuration.
398 +Before connection, configure the device (see [[Settings>>doc:Battery management systems.BMS Main 3.3\. Configuration.WebHome]]). Correct operation of the BMS system is only possible with correct configuration.
333 333  )))
334 334  
335 335  All operations to connect the device must be carried out with the supply voltage removed.
... ... @@ -342,5 +342,5 @@
342 342  * Connect the high-voltage network integrity circuit (if necessary) to header X4.
343 343  * Connect external devices (if necessary) to header X6.
344 344  * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
345 -* If the BMS Main 3 is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
411 +* 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.
346 346  * 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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