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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 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
94
95 === X4 – header for HVIL ===
96
97 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
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
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.
106
107 Connection diagram to the current loop:
108
109 === X5 – header for current and temperature sensors ===
110
111 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
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
140 === X6 – header for CAN1 and RS-485-1 (external buses) ===
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
159 === X7 – header for CAN2 (internal bus) ===
160
161 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
162
163 |**Pin**|**Name**|**Description**
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
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
173 === X8 – header for CAN3 ===
174
175 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
176
177 |**Pin**|**Name**|**Description**
178 |**1**|**CAN3_H**|CAN3 line H
179 |**2**|**CAN3_L**|CAN3 line L
180 |**3**|**GND**|Ground
181 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
182
183 (% class="box infomessage" %)
184 (((
185 **Note:**
186 CAN3 operates differently depending on used firmware:
187
188 * **BMS Main 3:** CAN3 bus is reserved;
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:
190
191 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
192 )))
193
194 === X9 – header for BMS Logic (RS-485-2) ===
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
204 (% class="box infomessage" %)
205 (((
206 **Note:**
207 RS-485-2 operates differently depending on used firmware:
208
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:
211
212 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
213 )))
214
215 === X10 – miniUSB connector ===
216
217 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
218
219 === X11 – header for high-voltage bus before contactors (plus) ===
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
232 === X12 – header for high-voltage bus before contactors (minus) ===
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
245 === X13 – header for high-voltage bus after contactors (plus) ===
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
258 === X14 – header for high-voltage bus after contactors (minus) ===
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
271 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
281 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
290 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
299 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
300
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.
302
303 == Indicators ==
304
305 === DS1 – LED indicating device power ===
306
307 |**State**|**Description**
308 |**Lights up green**|Device power (+5V) is present
309 |**Doesn’t light up**|No device power
310
311 === DS2 – LED indicating device work ===
312
313 |**State**|**Description**
314 |**Blinking green**|Executing the battery management program
315 |**No blinking**|Program execution error
316
317 === DS3 – LED indicating interaction with BMS Logic ===
318
319 |**State**|**Description**
320 |**Blinking yellow**|The device interacts with BMS Logic devices
321 |**No blinking**|-
322
323 === DS4 – LED indicating loss of connection with BMS Logic ===
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
329 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
335 === DS11 – LED indicating the presence of power supply for contactors ===
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
341 == Connection procedure ==
342
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 (((
347 **The system is not designed to operate with batteries with total voltage more than 3000V.**
348 )))
349
350 (% class="box warningmessage" %)
351 (((
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.
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.
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.
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.