Wiki source code of 2. Installation and connection

Version 55.3 by Admin on 2025/02/20 13:10

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
	16
30.1	17	== Headers ==
27.1	18
40.1	19	The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
27.1	20
	21	(% contenteditable="false" tabindex="-1" %)
	22	(((
	23	[[image:1732119505664-787.png\|\|data-xwiki-image-style-alignment="center" height="417" width="684"]]
	24	)))
	25
	26	(% class="box warningmessage" %)
	27	(((
	28	Attention!
	29	All headers are shown from the device side!
	30	)))
	31
30.1	32	=== X1 – header to power the device ===
27.1	33
55.3	34	Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
	35
27.1	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
55.3	51	Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
	52
27.1	53	(% 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" %)
	54
	55	\|Pin\|Name\|Description
	56	\|1–4, 8–9\|GND\|Ground
	57	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	58	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	59	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	60	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	61	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	62	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	63
	64	Contactor connection diagram:
	65
	66	(% 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"]]
	67
30.1	68	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	69
55.3	70	Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
	71
27.1	72	(% 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"]]
	73
	74	\|Pin\|Name\|Description
	75	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	76	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	77	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	78	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	79	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	80	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	81	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	82	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	83	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	84	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	85	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	86	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	87	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	88
	89	Connection diagram of a discrete input to a dry contact output:
	90
	91	(% 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:
	92
	93	(% 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:
	94
	95	(% 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:
	96
51.1	97	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	98
30.1	99	=== X4 – header for HVIL ===
27.1	100
55.3	101	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	102
30.1	103	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	104
	105	\|Pin\|Name\|Description
	106	\|1\|-\|Not used
	107	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	108	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	109	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	110
40.1	111	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	112
	113	Connection diagram to the current loop:
	114
54.1	115	[[image:1739361367866-742.png\|\|data-xwiki-image-style-alignment="center" height="210" width="281"]]
	116
31.1	117	=== X5 – header for current and temperature sensors ===
27.1	118
55.3	119	Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
	120
30.1	121	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	122
	123	(% style="width:539px" %)
	124	\|Pin\|Name\|(% style="width:402px" %)Description
	125	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	126	\|2–6\|GND\|(% style="width:402px" %)Ground
	127	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	128	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	129	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	130	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	131	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	132	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	133	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	134	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	135	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	136	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	137
	138	Current sensor connection diagram (using the example of LEM HASS 100-S):
	139
	140	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	141
	142	Current sensor connection diagram (using the example of LEM DHAB S/118):
	143
	144	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	145
	146	NTC-thermistor connection diagram:
	147
	148	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	149
30.1	150	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	151
55.3	152	Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
	153
27.1	154	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	155
	156	\|Pin\|Name\|Description
	157	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	158	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	159	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	160	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	161	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	162
	163	Connection diagram to the CAN1 bus:
	164
	165	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	166
	167	Connection diagram to the RS-485-1 bus:
	168
	169	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	170
30.1	171	=== X7 – header for CAN2 (internal bus) ===
27.1	172
55.3	173	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	174
27.1	175	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	176
	177	\|Pin\|Name\|Description
38.1	178	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	179	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	180	\|3\|GND\|Ground
	181	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	182
	183	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	184
	185	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	186
30.1	187	=== X8 – header for CAN3 ===
27.1	188
55.3	189	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	190
27.1	191	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	192
	193	\|Pin\|Name\|Description
38.1	194	\|1\|CAN3_H\|CAN3 line H
	195	\|2\|CAN3_L\|CAN3 line L
27.1	196	\|3\|GND\|Ground
	197	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	198
	199	(% class="box infomessage" %)
	200	(((
38.1	201	Note:
	202	CAN3 operates differently depending on used firmware:
27.1	203
38.1	204	* BMS Main 3: CAN3 bus is reserved;
39.1	205	* 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	206
	207	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	208	)))
27.1	209
30.1	210	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	211
55.3	212	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	213
27.1	214	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	215
	216	\|Pin\|Name\|Description
	217	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	218	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	219	\|3\|GND\|Ground
	220	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	221
40.1	222	(% class="box infomessage" %)
	223	(((
	224	Note:
	225	RS-485-2 operates differently depending on used firmware:
27.1	226
40.1	227	* BMS Main 3X: RS-485-2 bus is reserved;
	228	* 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	229
40.1	230	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	231	)))
	232
30.1	233	=== X10 – miniUSB connector ===
27.1	234
41.1	235	The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
27.1	236
30.1	237	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	238
55.3	239	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	240
27.1	241	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	242
	243	\|Pin\|Name\|Description
	244	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	245	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	246
	247	(% class="box warningmessage" %)
	248	(((
	249	The connected voltage must not exceed 1000V.
	250	)))
	251
30.1	252	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	253
55.3	254	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	255
27.1	256	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	257
	258	\|Pin\|Name\|Description
	259	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	260	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	261
	262	(% class="box warningmessage" %)
	263	(((
	264	The connected voltage must not exceed 1000V.
	265	)))
	266
30.1	267	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	268
55.3	269	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	270
27.1	271	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	272
	273	\|Pin\|Name\|Description
	274	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	275	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	276
	277	(% class="box warningmessage" %)
	278	(((
	279	The connected voltage must not exceed 1000V.
	280	)))
	281
30.1	282	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	283
55.3	284	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	285
27.1	286	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	287
	288	\|Pin\|Name\|Description
	289	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	290	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	291
	292	(% class="box warningmessage" %)
	293	(((
	294	The connected voltage must not exceed 1000V.
	295	)))
	296
30.1	297	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	298
	299	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	300
	301	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:
	302
	303	\|Pin\|Name\|Description
	304	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	305	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	306
30.1	307	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	308
	309
	310	[[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:
	311
	312	\|Pin\|Name\|Description
	313	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	314	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	315
30.1	316	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	317
	318
	319	[[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:
	320
	321	\|Pin\|Name\|Description
	322	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	323	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	324
30.1	325	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	326
41.1	327	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	328
30.1	329	== Indicators ==
27.1	330
30.1	331	=== DS1 – LED indicating device power ===
27.1	332
	333	\|State\|Description
	334	\|Lights up green\|Device power (+5V) is present
	335	\|Doesn’t light up\|No device power
	336
30.1	337	=== DS2 – LED indicating device work ===
27.1	338
	339	\|State\|Description
	340	\|Blinking green\|Executing the battery management program
	341	\|No blinking\|Program execution error
	342
54.2	343	=== DS3 – LED indicating interaction with child devices ===
27.1	344
54.2	345	(% style="width:447px" %)
	346	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	347	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	348	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	349
54.2	350	=== DS4 – LED indicating loss of connection with child devices ===
27.1	351
54.4	352	(% style="width:601px" %)
	353	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	354	\|Blinking/lights up red\|(% style="width:220px" %)Communication with one or more BMS Logic devices is lost\|(% style="width:218px" %)Communication with one or more BMS Main 3 devices is lost
	355	\|No blinking\|(% style="width:220px" %)Communication with BMS Logic devices is stable\|(% style="width:218px" %)Communication with BMS Main 3 devices is stable
27.1	356
30.1	357	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	358
	359	\|State\|Description
	360	\|Lights up green\|The switch supplies voltage to the contactor winding
	361	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	362
30.1	363	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	364
	365	\|State\|Description
	366	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	367	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	368
30.1	369	== Connection procedure ==
27.1	370
47.1	371	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.
	372
	373	(% class="box errormessage" %)
	374	(((
48.1	375	The system is not designed to operate with batteries with total voltage more than 3000V.
47.1	376	)))
	377
27.1	378	(% class="box warningmessage" %)
	379	(((
42.1	380	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	381	)))
	382
	383	All operations to connect the device must be carried out with the supply voltage removed.
	384
	385	* Connect the power contactors to header X2.
	386	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	387	* Connect BMS Logic devices to header X9.
	388	* Connect digital inputs and outputs (if necessary) to header X3.
	389	* Connect the high voltage bus (if necessary) to headers X11-X14.
	390	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	391	* Connect external devices (if necessary) to header X6.
	392	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
40.1	393	* 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	394	* 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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