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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
17 == Headers ==
18
19 The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
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
32 === X1 – header to power the device ===
33
34 Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
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 Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
52
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
68 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
69
70 Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
71
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
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”
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
97 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
98
99 === X4 – header for HVIL ===
100
101 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
102
103 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
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
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.
112
113 Connection diagram to the current loop:
114
115 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
116
117 === X5 – header for current and temperature sensors ===
118
119 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
120
121 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
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
150 === X6 – header for CAN1 and RS-485-1 (external buses) ===
151
152 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
153
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
171 === X7 – header for CAN2 (internal bus) ===
172
173 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
174
175 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
176
177 |**Pin**|**Name**|**Description**
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
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
187 === X8 – header for CAN3 ===
188
189 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
190
191 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
192
193 |**Pin**|**Name**|**Description**
194 |**1**|**CAN3_H**|CAN3 line H
195 |**2**|**CAN3_L**|CAN3 line L
196 |**3**|**GND**|Ground
197 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
198
199 (% class="box infomessage" %)
200 (((
201 **Note:**
202 CAN3 operates differently depending on used firmware:
203
204 * **BMS Main 3:** CAN3 bus is reserved;
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:
206
207 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
208 )))
209
210 === X9 – header for BMS Logic (RS-485-2) ===
211
212 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
213
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
222 (% class="box infomessage" %)
223 (((
224 **Note:**
225 RS-485-2 operates differently depending on used firmware:
226
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:
229
230 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
231 )))
232
233 === X10 – miniUSB connector ===
234
235 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
236
237 === X11 – header for high-voltage bus before contactors (plus) ===
238
239 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
240
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
252 === X12 – header for high-voltage bus before contactors (minus) ===
253
254 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
255
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
267 === X13 – header for high-voltage bus after contactors (plus) ===
268
269 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
270
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
282 === X14 – header for high-voltage bus after contactors (minus) ===
283
284 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
285
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
297 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
307 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
316 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
325 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
326
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.
328
329 == Indicators ==
330
331 === DS1 – LED indicating device power ===
332
333 |**State**|**Description**
334 |**Lights up green**|Device power (+5V) is present
335 |**Doesn’t light up**|No device power
336
337 === DS2 – LED indicating device work ===
338
339 |**State**|**Description**
340 |**Blinking green**|Executing the battery management program
341 |**No blinking**|Program execution error
342
343 === DS3 – LED indicating interaction with child devices ===
344
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" %)-
349
350 === DS4 – LED indicating loss of connection with child devices ===
351
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
356
357 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
363 === DS11 – LED indicating the presence of power supply for contactors ===
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
369 == Connection procedure ==
370
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 (((
375 **The system is not designed to operate with batteries with total voltage more than 3000V.**
376 )))
377
378 (% class="box warningmessage" %)
379 (((
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.
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.
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.
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.