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Wiki source code of 2. Installation and connection

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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 |Headers X1-X9 type|Hirose ZE05
17 |Headers X11-X14 type|Molex series Micro-Fit
18
19 == Headers ==
20
21 The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
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
34 === X1 – header to power the device ===
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
49 === X2 – header for contactors ===
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
66 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
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
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”
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
93 === X4 – header for HVIL ===
94
95 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
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
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.
104
105 Connection diagram to the current loop:
106
107 === X5 – header for current and temperature sensors ===
108
109 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
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
138 === X6 – header for CAN1 and RS-485-1 (external buses) ===
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
157 === X7 – header for CAN2 (internal bus) ===
158
159 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
160
161 |**Pin**|**Name**|**Description**
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
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
171 === X8 – header for CAN3 ===
172
173 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
174
175 |**Pin**|**Name**|**Description**
176 |**1**|**CAN3_H**|CAN3 line H
177 |**2**|**CAN3_L**|CAN3 line L
178 |**3**|**GND**|Ground
179 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
180
181 (% class="box infomessage" %)
182 (((
183 **Note:**
184 CAN3 operates differently depending on used firmware:
185
186 * **BMS Main 3:** CAN3 bus is reserved;
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:
188
189 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
190 )))
191
192 === X9 – header for BMS Logic (RS-485-2) ===
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
202 (% class="box infomessage" %)
203 (((
204 **Note:**
205 RS-485-2 operates differently depending on used firmware:
206
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:
209
210 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
211 )))
212
213 === X10 – miniUSB connector ===
214
215 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
216
217 === X11 – header for high-voltage bus before contactors (plus) ===
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
230 === X12 – header for high-voltage bus before contactors (minus) ===
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
243 === X13 – header for high-voltage bus after contactors (plus) ===
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
256 === X14 – header for high-voltage bus after contactors (minus) ===
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
269 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
279 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
288 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
297 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
298
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.
300
301 == Indicators ==
302
303 === DS1 – LED indicating device power ===
304
305 |**State**|**Description**
306 |**Lights up green**|Device power (+5V) is present
307 |**Doesn’t light up**|No device power
308
309 === DS2 – LED indicating device work ===
310
311 |**State**|**Description**
312 |**Blinking green**|Executing the battery management program
313 |**No blinking**|Program execution error
314
315 === DS3 – LED indicating interaction with BMS Logic ===
316
317 |**State**|**Description**
318 |**Blinking yellow**|The device interacts with BMS Logic devices
319 |**No blinking**|-
320
321 === DS4 – LED indicating loss of connection with BMS Logic ===
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
327 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
333 === DS11 – LED indicating the presence of power supply for contactors ===
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
339 == Connection procedure ==
340
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 (((
345 **The system is not designed to operate with batteries with total voltage more than 3000V.**
346 )))
347
348 (% class="box warningmessage" %)
349 (((
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.
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.
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.
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.