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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 62.1
edited by Admin
on 2025/03/18 12:51
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 +(% 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 +
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.
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.
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.
35 +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  (((
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31 31  
32 32  === X1 – header to power the device ===
33 33  
50 +Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
51 +
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  
67 +Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
68 +
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  
86 +Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
87 +
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  
113 +[[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
114 +
91 91  === X4 – header for HVIL ===
92 92  
117 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
118 +
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.
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.
102 102  
103 103  Connection diagram to the current loop:
104 104  
131 +[[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
132 +
105 105  === X5 – header for current and temperature sensors ===
106 106  
135 +Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
136 +
107 107  [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
108 108  
109 109  (% style="width:539px" %)
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135 135  
136 136  === X6 – header for CAN1 and RS-485-1 (external buses) ===
137 137  
168 +Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
169 +
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  
189 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
190 +
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
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
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  
205 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
206 +
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)
210 +|**1**|**CAN3_H**|CAN3 line H
211 +|**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 -)))
217 +**Note:**
218 +CAN3 operates differently depending on used firmware:
183 183  
184 -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:
185 185  
186 -[[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 +)))
187 187  
188 188  === X9 – header for BMS Logic (RS-485-2) ===
189 189  
228 +Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
229 +
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:
238 +(% class="box infomessage" %)
239 +(((
240 +**Note:**
241 +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"]]
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:
201 201  
246 +[[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
247 +)))
248 +
202 202  === X10 – miniUSB connector ===
203 203  
204 -The miniUSB connector is used to configure the parameters of the BMS Main 3 device.
251 +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  
255 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
256 +
208 208  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
209 209  
210 210  |**Pin**|**Name**|**Description**
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218 218  
219 219  === X12 – header for high-voltage bus before contactors (minus) ===
220 220  
270 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
271 +
221 221  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
222 222  
223 223  |**Pin**|**Name**|**Description**
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231 231  
232 232  === X13 – header for high-voltage bus after contactors (plus) ===
233 233  
285 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
286 +
234 234  [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
235 235  
236 236  |**Pin**|**Name**|**Description**
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244 244  
245 245  === X14 – header for high-voltage bus after contactors (minus) ===
246 246  
300 +Receptacle Housing: Molex 436450200. Terminals: Molex 43030
301 +
247 247  [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
248 248  
249 249  |**Pin**|**Name**|**Description**
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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.
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.
289 289  
290 290  == Indicators ==
291 291  
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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 ===
359 +=== 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**|-
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" %)-
309 309  
310 -=== DS4 – LED indicating loss of connection with BMS Logic ===
366 +=== 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
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
315 315  
316 316  === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
317 317  
... ... @@ -327,11 +327,6 @@
327 327  
328 328  == Connection procedure ==
329 329  
330 -(% class="box warningmessage" %)
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.
333 -)))
334 -
335 335  All operations to connect the device must be carried out with the supply voltage removed.
336 336  
337 337  * Connect the power contactors to header X2.
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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.
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.
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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