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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 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
110
111 === X5 – header for current and temperature sensors ===
112
113 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
114
115 (% style="width:539px" %)
116 |**Pin**|**Name**|(% style="width:402px" %)**Description**
117 |**1**|**CS1_5V**|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
118 |**2–6**|**GND**|(% style="width:402px" %)Ground
119 |**7**|**CS1_IN1**|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
120 |**8**|**CS1_REF_IN2**|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
121 |**9**|**CS2_5V**|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
122 |**10**|**CS2_IN1**|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
123 |**11**|**CS2_REF_IN2**|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
124 |**12**|**CS3_5V**|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
125 |**13**|**CS3_IN1**|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
126 |**14**|**CS3_REF_IN2**|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
127 |**15**|**TEMP1**|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
128 |**16**|**TEMP2**|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
129
130 Current sensor connection diagram (using the example of LEM HASS 100-S):
131
132 [[image:1733316158040-285.png||data-xwiki-image-style-alignment="center" height="170" width="412"]]
133
134 Current sensor connection diagram (using the example of LEM DHAB S/118):
135
136 [[image:1733316170709-142.png||data-xwiki-image-style-alignment="center" height="171" width="413"]]
137
138 NTC-thermistor connection diagram:
139
140 [[image:1733316189878-329.png||data-xwiki-image-style-alignment="center" height="130" width="260"]]
141
142 === X6 – header for CAN1 and RS-485-1 (external buses) ===
143
144 [[image:1733316218666-814.png||data-xwiki-image-style-alignment="center" height="55" width="162"]]
145
146 |**Pin**|**Name**|**Description**
147 |**1**|**CAN1_H**|CAN1 line H for communication with external equipment
148 |**2**|**CAN1_L**|CAN1 line L for communication with external equipment
149 |**3**|**CAN1_RS485_1_GND**|Ground of CAN1 and RS-485-1
150 |**4**|**RS485_1_A**|RS-485-1 line A for communication with external equipment
151 |**5**|**RS485_1_B**|RS-485-1 line B for communication with external equipment
152
153 Connection diagram to the CAN1 bus:
154
155 [[image:1733316241362-843.png||data-xwiki-image-style-alignment="center" height="153" width="410"]]
156
157 Connection diagram to the RS-485-1 bus:
158
159 [[image:1733316483336-290.png||data-xwiki-image-style-alignment="center" height="152" width="417"]]
160
161 === X7 – header for CAN2 (internal bus) ===
162
163 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
164
165 |**Pin**|**Name**|**Description**
166 |**1**|**CAN2_H**|CAN2 line H for communication with other BMS devices
167 |**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
168 |**3**|**GND**|Ground
169 |**4**|**CAN2_5V**|CAN2 power line (5 V, max 400 mA)
170
171 Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
172
173 [[image:1733316563149-458.png||data-xwiki-image-style-alignment="center" height="158" width="392"]]
174
175 === X8 – header for CAN3 ===
176
177 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
178
179 |**Pin**|**Name**|**Description**
180 |**1**|**CAN3_H**|CAN3 line H
181 |**2**|**CAN3_L**|CAN3 line L
182 |**3**|**GND**|Ground
183 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
184
185 (% class="box infomessage" %)
186 (((
187 **Note:**
188 CAN3 operates differently depending on used firmware:
189
190 * **BMS Main 3:** CAN3 bus is reserved;
191 * **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:
192
193 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
194 )))
195
196 === X9 – header for BMS Logic (RS-485-2) ===
197
198 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
199
200 |**Pin**|**Name**|**Description**
201 |**1**|**LOGIC_B**|RS-485 line B for communication with BMS Logic
202 |**2**|**LOGIC_A**|RS-485 line A for communication with BMS Logic
203 |**3**|**GND**|Ground
204 |**4**|**LOGIC_5V**|BMS Logic power line (+5V, max 400mA)
205
206 (% class="box infomessage" %)
207 (((
208 **Note:**
209 RS-485-2 operates differently depending on used firmware:
210
211 * **BMS Main 3X:** RS-485-2 bus is reserved;
212 * **BMS Main 3:** RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
213
214 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
215 )))
216
217 === X10 – miniUSB connector ===
218
219 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
220
221 === X11 – header for high-voltage bus before contactors (plus) ===
222
223 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
224
225 |**Pin**|**Name**|**Description**
226 |**1**|**IN1+**|Plus of the high-voltage bus (before contactors)
227 |**2**|**IN1+**|Plus of the high-voltage bus (before contactors)
228
229 (% class="box warningmessage" %)
230 (((
231 The connected voltage must not exceed 1000V.
232 )))
233
234 === X12 – header for high-voltage bus before contactors (minus) ===
235
236 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
237
238 |**Pin**|**Name**|**Description**
239 |**1**|**IN1-**|Minus of the high-voltage bus (before contactors)
240 |**2**|**IN1-**|Minus of the high-voltage bus (before contactors)
241
242 (% class="box warningmessage" %)
243 (((
244 The connected voltage must not exceed 1000V.
245 )))
246
247 === X13 – header for high-voltage bus after contactors (plus) ===
248
249 [[image:1733316780753-798.png||data-xwiki-image-style-alignment="center" height="60" width="91"]]
250
251 |**Pin**|**Name**|**Description**
252 |**1**|**IN2+**|Plus of the high-voltage bus (after contactors)
253 |**2**|**IN2+**|Plus of the high-voltage bus (after contactors)
254
255 (% class="box warningmessage" %)
256 (((
257 The connected voltage must not exceed 1000V.
258 )))
259
260 === X14 – header for high-voltage bus after contactors (minus) ===
261
262 [[image:1733316843397-336.png||data-xwiki-image-style-alignment="center" height="53" width="79"]]
263
264 |**Pin**|**Name**|**Description**
265 |**1**|**IN2-**|Minus of the high-voltage bus (after contactors)
266 |**2**|**IN2-**|Minus of the high-voltage bus (after contactors)
267
268 (% class="box warningmessage" %)
269 (((
270 The connected voltage must not exceed 1000V.
271 )))
272
273 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
274
275 [[image:1733316982359-759.png||data-xwiki-image-style-alignment="center" height="77" width="148"]]
276
277 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:
278
279 |**Pin**|**Name**|**Description**
280 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
281 |**2-3**|**-**|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
282
283 === J2 – jumper for switching CAN1 bus terminal resistor ===
284
285
286 [[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:
287
288 |**Pin**|**Name**|**Description**
289 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN1 bus is connected
290 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
291
292 === J3 – jumper for switching CAN2 bus terminal resistor ===
293
294
295 [[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:
296
297 |**Pin**|**Name**|**Description**
298 |**1-2**|**120 Ohm**|The 120 Ohm terminal resistor of the CAN2 bus is connected
299 |**2-3**|**-**|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
300
301 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
302
303 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.
304
305 == Indicators ==
306
307 === DS1 – LED indicating device power ===
308
309 |**State**|**Description**
310 |**Lights up green**|Device power (+5V) is present
311 |**Doesn’t light up**|No device power
312
313 === DS2 – LED indicating device work ===
314
315 |**State**|**Description**
316 |**Blinking green**|Executing the battery management program
317 |**No blinking**|Program execution error
318
319 === DS3 – LED indicating interaction with child devices ===
320
321 (% style="width:447px" %)
322 |**State**|(% style="width:166px" %)**Description (Main 3)**|(% style="width:168px" %)**Description (Main 3X)**
323 |**Blinking yellow**|(% style="width:166px" %)The device interacts with BMS Logic devices|(% style="width:168px" %)The device interacts with BMS Main 3 devices
324 |**No blinking**|(% style="width:166px" %)-|(% style="width:168px" %)-
325
326 === DS4 – LED indicating loss of connection with child devices ===
327
328 |**State**|**Description (Main 3)**|
329 |**Blinking/lights up red**|Communication with one or more BMS Logic devices is lost|
330 |**No blinking**|Communication with BMS Logic is stable|
331
332 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
333
334 |**State**|**Description**
335 |**Lights up green**|The switch supplies voltage to the contactor winding
336 |**Doesn’t light up**|The switch doesn’t supply voltage to the contactor winding
337
338 === DS11 – LED indicating the presence of power supply for contactors ===
339
340 |**State**|**Description**
341 |**Lights up green**|Power supply for contactor switches (9-32V) is present
342 |**Doesn’t light up**|Power supply for contactor switches (9-32V) is not present
343
344 == Connection procedure ==
345
346 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.
347
348 (% class="box errormessage" %)
349 (((
350 **The system is not designed to operate with batteries with total voltage more than 3000V.**
351 )))
352
353 (% class="box warningmessage" %)
354 (((
355 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.
356 )))
357
358 All operations to connect the device must be carried out with the supply voltage removed.
359
360 * Connect the power contactors to header X2.
361 * Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
362 * Connect BMS Logic devices to header X9.
363 * Connect digital inputs and outputs (if necessary) to header X3.
364 * Connect the high voltage bus (if necessary) to headers X11-X14.
365 * Connect the high-voltage network integrity circuit (if necessary) to header X4.
366 * Connect external devices (if necessary) to header X6.
367 * Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
368 * 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.
369 * 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.