Wiki source code of 2. Installation and connection

Version 51.1 by Admin on 2025/02/12 11:54

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
51.1	93	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	94
30.1	95	=== X4 – header for HVIL ===
27.1	96
30.1	97	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	98
	99	\|Pin\|Name\|Description
	100	\|1\|-\|Not used
	101	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	102	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	103	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	104
40.1	105	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	106
	107	Connection diagram to the current loop:
	108
31.1	109	=== X5 – header for current and temperature sensors ===
27.1	110
30.1	111	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	112
	113	(% style="width:539px" %)
	114	\|Pin\|Name\|(% style="width:402px" %)Description
	115	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	116	\|2–6\|GND\|(% style="width:402px" %)Ground
	117	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	118	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	119	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	120	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	121	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	122	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	123	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	124	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	125	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	126	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	127
	128	Current sensor connection diagram (using the example of LEM HASS 100-S):
	129
	130	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	131
	132	Current sensor connection diagram (using the example of LEM DHAB S/118):
	133
	134	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	135
	136	NTC-thermistor connection diagram:
	137
	138	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	139
30.1	140	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	141
	142	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	143
	144	\|Pin\|Name\|Description
	145	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	146	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	147	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	148	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	149	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	150
	151	Connection diagram to the CAN1 bus:
	152
	153	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	154
	155	Connection diagram to the RS-485-1 bus:
	156
	157	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	158
30.1	159	=== X7 – header for CAN2 (internal bus) ===
27.1	160
	161	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	162
	163	\|Pin\|Name\|Description
38.1	164	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	165	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	166	\|3\|GND\|Ground
	167	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	168
	169	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	170
	171	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	172
30.1	173	=== X8 – header for CAN3 ===
27.1	174
	175	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	176
	177	\|Pin\|Name\|Description
38.1	178	\|1\|CAN3_H\|CAN3 line H
	179	\|2\|CAN3_L\|CAN3 line L
27.1	180	\|3\|GND\|Ground
	181	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	182
	183	(% class="box infomessage" %)
	184	(((
38.1	185	Note:
	186	CAN3 operates differently depending on used firmware:
27.1	187
38.1	188	* BMS Main 3: CAN3 bus is reserved;
39.1	189	* 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	190
	191	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	192	)))
27.1	193
30.1	194	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	195
	196	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	197
	198	\|Pin\|Name\|Description
	199	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	200	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	201	\|3\|GND\|Ground
	202	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	203
40.1	204	(% class="box infomessage" %)
	205	(((
	206	Note:
	207	RS-485-2 operates differently depending on used firmware:
27.1	208
40.1	209	* BMS Main 3X: RS-485-2 bus is reserved;
	210	* 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	211
40.1	212	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	213	)))
	214
30.1	215	=== X10 – miniUSB connector ===
27.1	216
41.1	217	The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
27.1	218
30.1	219	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	220
	221	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	222
	223	\|Pin\|Name\|Description
	224	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	225	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	226
	227	(% class="box warningmessage" %)
	228	(((
	229	The connected voltage must not exceed 1000V.
	230	)))
	231
30.1	232	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	233
	234	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	235
	236	\|Pin\|Name\|Description
	237	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	238	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	239
	240	(% class="box warningmessage" %)
	241	(((
	242	The connected voltage must not exceed 1000V.
	243	)))
	244
30.1	245	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	246
	247	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	248
	249	\|Pin\|Name\|Description
	250	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	251	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	252
	253	(% class="box warningmessage" %)
	254	(((
	255	The connected voltage must not exceed 1000V.
	256	)))
	257
30.1	258	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	259
	260	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	261
	262	\|Pin\|Name\|Description
	263	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	264	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	265
	266	(% class="box warningmessage" %)
	267	(((
	268	The connected voltage must not exceed 1000V.
	269	)))
	270
30.1	271	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	272
	273	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	274
	275	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:
	276
	277	\|Pin\|Name\|Description
	278	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	279	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	280
30.1	281	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	282
	283
	284	[[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:
	285
	286	\|Pin\|Name\|Description
	287	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	288	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	289
30.1	290	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	291
	292
	293	[[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:
	294
	295	\|Pin\|Name\|Description
	296	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	297	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	298
30.1	299	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	300
41.1	301	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	302
30.1	303	== Indicators ==
27.1	304
30.1	305	=== DS1 – LED indicating device power ===
27.1	306
	307	\|State\|Description
	308	\|Lights up green\|Device power (+5V) is present
	309	\|Doesn’t light up\|No device power
	310
30.1	311	=== DS2 – LED indicating device work ===
27.1	312
	313	\|State\|Description
	314	\|Blinking green\|Executing the battery management program
	315	\|No blinking\|Program execution error
	316
30.1	317	=== DS3 – LED indicating interaction with BMS Logic ===
27.1	318
	319	\|State\|Description
	320	\|Blinking yellow\|The device interacts with BMS Logic devices
	321	\|No blinking\|-
	322
30.1	323	=== DS4 – LED indicating loss of connection with BMS Logic ===
27.1	324
	325	\|State\|Description
	326	\|Blinking/lights up red\|Communication with one or more BMS Logic devices is lost
	327	\|No blinking\|Communication with BMS Logic is stable
	328
30.1	329	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	330
	331	\|State\|Description
	332	\|Lights up green\|The switch supplies voltage to the contactor winding
	333	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	334
30.1	335	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	336
	337	\|State\|Description
	338	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	339	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	340
30.1	341	== Connection procedure ==
27.1	342
47.1	343	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.
	344
	345	(% class="box errormessage" %)
	346	(((
48.1	347	The system is not designed to operate with batteries with total voltage more than 3000V.
47.1	348	)))
	349
27.1	350	(% class="box warningmessage" %)
	351	(((
42.1	352	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	353	)))
	354
	355	All operations to connect the device must be carried out with the supply voltage removed.
	356
	357	* Connect the power contactors to header X2.
	358	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	359	* Connect BMS Logic devices to header X9.
	360	* Connect digital inputs and outputs (if necessary) to header X3.
	361	* Connect the high voltage bus (if necessary) to headers X11-X14.
	362	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	363	* Connect external devices (if necessary) to header X6.
	364	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
40.1	365	* 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	366	* 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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