Skip to Content

Wiki source code of 2. Installation and connection

Version 43.1 by Admin on 2025/01/29 13:28
Show last authors
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 == Installation procedure ==
5
6 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
8 Overall and mounting dimensions are shown in figure below.
9
10 (% 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" %)​
11
12 |**Parameter**|**Value**
13 |Overall dimensions (length × width × height), mm|200 × 123 × 12
14 |Mounting dimensions (length × width), mm|194 × 114
15 |Mounting holes|M3
16 |Connector type|Hirose ZE05
17
18 == Headers ==
19
20 The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
21
22 (% contenteditable="false" tabindex="-1" %)
23 (((
24 [[image:1732119505664-787.png||data-xwiki-image-style-alignment="center" height="417" width="684"]]
25 )))
26
27 (% class="box warningmessage" %)
28 (((
29 **Attention!**
30 All headers are shown from the device side!
31 )))
32
33 === X1 – header to power the device ===
34
35 (% class="wikigeneratedid" id="H" %)
36 (% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png||data-xwiki-image-style-alignment="center" height="85" width="200"]]
37
38 |**Pin**|**Name**|**Description**
39 |**1–2, 5–6**|**GND**|Ground
40 |**3**|**KEYRUN**|Power-on signal
41 |**4**|**CHARGE_ON**|Power-on signal (battery charge requirement)
42 |**7–8**|**VIN**|Power line (9-32V)
43
44 Power supply connection diagram:
45
46 (% 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"]]
47
48 === X2 – header for contactors ===
49
50 (% 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" %)​
51
52 |**Pin**|**Name**|**Description**
53 |**1–4, 8–9**|**GND**|Ground
54 |**5**|**CONT1_OUT**|Contactor control 1 (plus)
55 |**6**|**CONT2_OUT**|Contactor control 2 (plus)
56 |**7**|**CONT3_OUT**|Contactor control 3 (plus)
57 |**10**|**CONT4_OUT**|Contactor control 4 (plus)
58 |**11**|**CONT5_OUT**|Contactor control 5 (plus)
59 |**12**|**CONT6_OUT**|Contactor control 6 (plus)
60
61 Contactor connection diagram:
62
63 (% 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"]]
64
65 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
66
67 (% 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"]]
68
69 |**Pin**|**Name**|**Description**
70 |**1–8, 12, 16–17, 21**|**DIO_GND**|Ground of input and output signals
71 |**9**|**DIN1_SIGNAL**|Discrete input 1 “dry contact”
72 |**10**|**DIN2_SIGNAL**|Discrete input 2 “dry contact”
73 |**11**|**DIN3_SIGNAL**|Discrete input 3 “dry contact”
74 |**13**|**DIN4_SIGNAL**|Discrete input 4 “dry contact”
75 |**14**|**DIN5_SIGNAL**|Discrete input 5 “dry contact”
76 |**15**|**DIN6_SIGNAL**|Discrete input 6 “dry contact”
77 |**18**|**DIN7_VIN**|Discrete input 7 (signal detection with voltage 9-32V)
78 |**19**|**DIN8_VIN**|Discrete input 8 (signal detection with voltage 9-32V)
79 |**20**|**DOUT1_OD**|Discrete output 1 “open drain” (60 V, 1A)
80 |**22**|**DOUT2_OD**|Discrete output 2 “open drain” (60 V, 1A)
81 |**23**|**DOUT3_OD**|Discrete output 3 “open drain” (60 V, 1A)
82 |**24**|**DOUT4_OD**|Discrete output 4 “open drain” (60 V, 1A)
83
84 Connection diagram of a discrete input to a dry contact output:
85
86 (% 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:
87
88 (% 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:
89
90 (% 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:
91
92 === X4 – header for HVIL ===
93
94 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
95
96 |**Pin**|**Name**|**Description**
97 |**1**|**-**|Not used
98 |**2**|**HVIL_OUT**|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
99 |**3**|**HVIL_IN**|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
100 |**4**|**HVIL_PWR**|Current loop power supply (max 5V, 25mA)
101
102 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.
103
104 Connection diagram to the current loop:
105
106 === X5 – header for current and temperature sensors ===
107
108 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
109
110 (% style="width:539px" %)
111 |**Pin**|**Name**|(% style="width:402px" %)**Description**
112 |**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
113 |**2–6**|**GND**|(% style="width:402px" %)Ground
114 |**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
115 |**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
116 |**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
117 |**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
118 |**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
119 |**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
120 |**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
121 |**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
122 |**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
123 |**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
124
125 Current sensor connection diagram (using the example of LEM HASS 100-S):
126
127 [[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
128
129 Current sensor connection diagram (using the example of LEM DHAB S/118):
130
131 [[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
132
133 NTC-thermistor connection diagram:
134
135 [[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
136
137 === X6 – header for CAN1 and RS-485-1 (external buses) ===
138
139 [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
140
141 |**Pin**|**Name**|**Description**
142 |**1**|**CAN1_H**|CAN1 line H for communication with external equipment
143 |**2**|**CAN1_L**|CAN1 line L for communication with external equipment
144 |**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
145 |**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
146 |**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
147
148 Connection diagram to the CAN1 bus:
149
150 [[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
151
152 Connection diagram to the RS-485-1 bus:
153
154 [[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
155
156 === X7 – header for CAN2 (internal bus) ===
157
158 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
159
160 |**Pin**|**Name**|**Description**
161 |**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
162 |**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
163 |**3**|**GND**|Ground
164 |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
165
166 Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
167
168 [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
169
170 === X8 – header for CAN3 ===
171
172 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
173
174 |**Pin**|**Name**|**Description**
175 |**1**|**CAN3_H**|CAN3 line H
176 |**2**|**CAN3_L**|CAN3 line L
177 |**3**|**GND**|Ground
178 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
179
180 (% class="box infomessage" %)
181 (((
182 **Note:**
183 CAN3 operates differently depending on used firmware:
184
185 * **BMS Main 3:** CAN3 bus is reserved;
186 * **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:
187
188 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
189 )))
190
191 === X9 – header for BMS Logic (RS-485-2) ===
192
193 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
194
195 |**Pin**|**Name**|**Description**
196 |**1**|**LOGIC_B**|RS-485 line B for communication with BMS Logic
197 |**2**|**LOGIC_A**|RS-485 line A for communication with BMS Logic
198 |**3**|**GND**|Ground
199 |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
200
201 (% class="box infomessage" %)
202 (((
203 **Note:**
204 RS-485-2 operates differently depending on used firmware:
205
206 * **BMS Main 3X:** RS-485-2 bus is reserved;
207 * **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
208
209 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
210 )))
211
212 === X10 – miniUSB connector ===
213
214 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
215
216 === X11 – header for high-voltage bus before contactors (plus) ===
217
218 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
219
220 |**Pin**|**Name**|**Description**
221 |**1**|**IN1+**|Plus of the high-voltage bus (before contactors)
222 |**2**|**IN1+**|Plus of the high-voltage bus (before contactors)
223
224 (% class="box warningmessage" %)
225 (((
226 The connected voltage must not exceed 1000V.
227 )))
228
229 === X12 – header for high-voltage bus before contactors (minus) ===
230
231 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
232
233 |**Pin**|**Name**|**Description**
234 |**1**|**IN1-**|Minus of the high-voltage bus (before contactors)
235 |**2**|**IN1-**|Minus of the high-voltage bus (before contactors)
236
237 (% class="box warningmessage" %)
238 (((
239 The connected voltage must not exceed 1000V.
240 )))
241
242 === X13 – header for high-voltage bus after contactors (plus) ===
243
244 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
245
246 |**Pin**|**Name**|**Description**
247 |**1**|**IN2+**|Plus of the high-voltage bus (after contactors)
248 |**2**|**IN2+**|Plus of the high-voltage bus (after contactors)
249
250 (% class="box warningmessage" %)
251 (((
252 The connected voltage must not exceed 1000V.
253 )))
254
255 === X14 – header for high-voltage bus after contactors (minus) ===
256
257 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
258
259 |**Pin**|**Name**|**Description**
260 |**1**|**IN2-**|Minus of the high-voltage bus (after contactors)
261 |**2**|**IN2-**|Minus of the high-voltage bus (after contactors)
262
263 (% class="box warningmessage" %)
264 (((
265 The connected voltage must not exceed 1000V.
266 )))
267
268 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
269
270 [[image:1733316982359-759.png||data-xwiki-image-style-alignment="center" height="77" width="148"]]
271
272 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:
273
274 |**Pin**|**Name**|**Description**
275 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
276 |**2-3**|**-**|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
277
278 === J2 – jumper for switching CAN1 bus terminal resistor ===
279
280
281 [[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:
282
283 |**Pin**|**Name**|**Description**
284 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN1 bus is connected
285 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
286
287 === J3 – jumper for switching CAN2 bus terminal resistor ===
288
289
290 [[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:
291
292 |**Pin**|**Name**|**Description**
293 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN2 bus is connected
294 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
295
296 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
297
298 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.
299
300 == Indicators ==
301
302 === DS1 – LED indicating device power ===
303
304 |**State**|**Description**
305 |**Lights up green**|Device power (+5V) is present
306 |**Doesn’t light up**|No device power
307
308 === DS2 – LED indicating device work ===
309
310 |**State**|**Description**
311 |**Blinking green**|Executing the battery management program
312 |**No blinking**|Program execution error
313
314 === DS3 – LED indicating interaction with BMS Logic ===
315
316 |**State**|**Description**
317 |**Blinking yellow**|The device interacts with BMS Logic devices
318 |**No blinking**|-
319
320 === DS4 – LED indicating loss of connection with BMS Logic ===
321
322 |**State**|**Description**
323 |**Blinking/lights up red**|Communication with one or more BMS Logic devices is lost
324 |**No blinking**|Communication with BMS Logic is stable
325
326 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
327
328 |**State**|**Description**
329 |**Lights up green**|The switch supplies voltage to the contactor winding
330 |**Doesn’t light up**|The switch doesn’t supply voltage to the contactor winding
331
332 === DS11 – LED indicating the presence of power supply for contactors ===
333
334 |**State**|**Description**
335 |**Lights up green**|Power supply for contactor switches (9-32V) is present
336 |**Doesn’t light up**|Power supply for contactor switches (9-32V) is not present
337
338 == Connection procedure ==
339
340 (% class="box warningmessage" %)
341 (((
342 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.
343 )))
344
345 All operations to connect the device must be carried out with the supply voltage removed.
346
347 * Connect the power contactors to header X2.
348 * Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
349 * Connect BMS Logic devices to header X9.
350 * Connect digital inputs and outputs (if necessary) to header X3.
351 * Connect the high voltage bus (if necessary) to headers X11-X14.
352 * Connect the high-voltage network integrity circuit (if necessary) to header X4.
353 * Connect external devices (if necessary) to header X6.
354 * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
355 * 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.
356 * 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.