Wiki source code of 2. Installation and connection

Version 49.1 by Admin on 2025/02/12 11:53

version	line-number	content
31.1	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	= Installation and connection =
30.1	3
28.1	4	== Installation procedure ==
27.1	5
40.1	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.
27.1	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
46.1	16	\|Headers X1-X9 type\|Hirose ZE05
47.1	17	\|Headers X11-X14 type\|Molex series Micro-Fit
27.1	18
30.1	19	== Headers ==
27.1	20
40.1	21	The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
27.1	22
	23	(% contenteditable="false" tabindex="-1" %)
	24	(((
	25	[[image:1732119505664-787.png\|\|data-xwiki-image-style-alignment="center" height="417" width="684"]]
	26	)))
	27
	28	(% class="box warningmessage" %)
	29	(((
	30	Attention!
	31	All headers are shown from the device side!
	32	)))
	33
30.1	34	=== X1 – header to power the device ===
27.1	35
	36	(% class="wikigeneratedid" id="H" %)
	37	(% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png\|\|data-xwiki-image-style-alignment="center" height="85" width="200"]]
	38
	39	\|Pin\|Name\|Description
	40	\|1–2, 5–6\|GND\|Ground
	41	\|3\|KEYRUN\|Power-on signal
	42	\|4\|CHARGE_ON\|Power-on signal (battery charge requirement)
	43	\|7–8\|VIN\|Power line (9-32V)
	44
	45	Power supply connection diagram:
	46
	47	(% 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"]]
	48
30.1	49	=== X2 – header for contactors ===
27.1	50
	51	(% 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" %)
	52
	53	\|Pin\|Name\|Description
	54	\|1–4, 8–9\|GND\|Ground
	55	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	56	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	57	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	58	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	59	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	60	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	61
	62	Contactor connection diagram:
	63
	64	(% 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"]]
	65
30.1	66	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	67
	68	(% 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"]]
	69
	70	\|Pin\|Name\|Description
	71	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	72	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	73	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	74	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	75	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	76	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	77	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	78	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	79	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	80	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	81	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	82	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	83	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	84
	85	Connection diagram of a discrete input to a dry contact output:
	86
	87	(% 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:
	88
	89	(% 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:
	90
	91	(% 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:
	92
30.1	93	=== X4 – header for HVIL ===
27.1	94
30.1	95	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	96
	97	\|Pin\|Name\|Description
	98	\|1\|-\|Not used
	99	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	100	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	101	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	102
40.1	103	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.
27.1	104
	105	Connection diagram to the current loop:
	106
31.1	107	=== X5 – header for current and temperature sensors ===
27.1	108
30.1	109	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	110
	111	(% style="width:539px" %)
	112	\|Pin\|Name\|(% style="width:402px" %)Description
	113	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	114	\|2–6\|GND\|(% style="width:402px" %)Ground
	115	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	116	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	117	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	118	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	119	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	120	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	121	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	122	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	123	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	124	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	125
	126	Current sensor connection diagram (using the example of LEM HASS 100-S):
	127
	128	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	129
	130	Current sensor connection diagram (using the example of LEM DHAB S/118):
	131
	132	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	133
	134	NTC-thermistor connection diagram:
	135
	136	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	137
30.1	138	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	139
	140	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	141
	142	\|Pin\|Name\|Description
	143	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	144	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	145	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	146	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	147	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	148
	149	Connection diagram to the CAN1 bus:
	150
	151	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	152
	153	Connection diagram to the RS-485-1 bus:
	154
	155	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	156
30.1	157	=== X7 – header for CAN2 (internal bus) ===
27.1	158
	159	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	160
	161	\|Pin\|Name\|Description
38.1	162	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	163	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	164	\|3\|GND\|Ground
	165	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	166
	167	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	168
	169	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	170
30.1	171	=== X8 – header for CAN3 ===
27.1	172
	173	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	174
	175	\|Pin\|Name\|Description
38.1	176	\|1\|CAN3_H\|CAN3 line H
	177	\|2\|CAN3_L\|CAN3 line L
27.1	178	\|3\|GND\|Ground
	179	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	180
	181	(% class="box infomessage" %)
	182	(((
38.1	183	Note:
	184	CAN3 operates differently depending on used firmware:
27.1	185
38.1	186	* BMS Main 3: CAN3 bus is reserved;
39.1	187	* 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:
38.1	188
	189	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	190	)))
27.1	191
30.1	192	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	193
	194	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	195
	196	\|Pin\|Name\|Description
	197	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	198	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	199	\|3\|GND\|Ground
	200	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	201
40.1	202	(% class="box infomessage" %)
	203	(((
	204	Note:
	205	RS-485-2 operates differently depending on used firmware:
27.1	206
40.1	207	* BMS Main 3X: RS-485-2 bus is reserved;
	208	* BMS Main 3: RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
27.1	209
40.1	210	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	211	)))
	212
30.1	213	=== X10 – miniUSB connector ===
27.1	214
41.1	215	The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
27.1	216
30.1	217	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	218
	219	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	220
	221	\|Pin\|Name\|Description
	222	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	223	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	224
	225	(% class="box warningmessage" %)
	226	(((
	227	The connected voltage must not exceed 1000V.
	228	)))
	229
30.1	230	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	231
	232	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	233
	234	\|Pin\|Name\|Description
	235	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	236	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	237
	238	(% class="box warningmessage" %)
	239	(((
	240	The connected voltage must not exceed 1000V.
	241	)))
	242
30.1	243	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	244
	245	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	246
	247	\|Pin\|Name\|Description
	248	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	249	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	250
	251	(% class="box warningmessage" %)
	252	(((
	253	The connected voltage must not exceed 1000V.
	254	)))
	255
30.1	256	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	257
	258	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	259
	260	\|Pin\|Name\|Description
	261	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	262	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	263
	264	(% class="box warningmessage" %)
	265	(((
	266	The connected voltage must not exceed 1000V.
	267	)))
	268
30.1	269	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	270
	271	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	272
	273	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:
	274
	275	\|Pin\|Name\|Description
	276	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	277	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	278
30.1	279	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	280
	281
	282	[[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:
	283
	284	\|Pin\|Name\|Description
	285	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	286	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	287
30.1	288	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	289
	290
	291	[[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:
	292
	293	\|Pin\|Name\|Description
	294	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	295	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	296
30.1	297	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	298
41.1	299	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.
27.1	300
30.1	301	== Indicators ==
27.1	302
30.1	303	=== DS1 – LED indicating device power ===
27.1	304
	305	\|State\|Description
	306	\|Lights up green\|Device power (+5V) is present
	307	\|Doesn’t light up\|No device power
	308
30.1	309	=== DS2 – LED indicating device work ===
27.1	310
	311	\|State\|Description
	312	\|Blinking green\|Executing the battery management program
	313	\|No blinking\|Program execution error
	314
30.1	315	=== DS3 – LED indicating interaction with BMS Logic ===
27.1	316
	317	\|State\|Description
	318	\|Blinking yellow\|The device interacts with BMS Logic devices
	319	\|No blinking\|-
	320
30.1	321	=== DS4 – LED indicating loss of connection with BMS Logic ===
27.1	322
	323	\|State\|Description
	324	\|Blinking/lights up red\|Communication with one or more BMS Logic devices is lost
	325	\|No blinking\|Communication with BMS Logic is stable
	326
30.1	327	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	328
	329	\|State\|Description
	330	\|Lights up green\|The switch supplies voltage to the contactor winding
	331	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	332
30.1	333	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	334
	335	\|State\|Description
	336	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	337	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	338
30.1	339	== Connection procedure ==
27.1	340
47.1	341	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.
	342
	343	(% class="box errormessage" %)
	344	(((
48.1	345	The system is not designed to operate with batteries with total voltage more than 3000V.
47.1	346	)))
	347
27.1	348	(% class="box warningmessage" %)
	349	(((
42.1	350	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.
27.1	351	)))
	352
	353	All operations to connect the device must be carried out with the supply voltage removed.
	354
	355	* Connect the power contactors to header X2.
	356	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	357	* Connect BMS Logic devices to header X9.
	358	* Connect digital inputs and outputs (if necessary) to header X3.
	359	* Connect the high voltage bus (if necessary) to headers X11-X14.
	360	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	361	* Connect external devices (if necessary) to header X6.
	362	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
40.1	363	* 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.
27.1	364	* 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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