Wiki source code of 2. Installation and connection

Version 56.2 by Admin on 2025/03/18 11:53

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
56.2	4	(% class="box warningmessage" %)
	5	(((
	6	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.
	7	)))
	8
	9	(% class="box errormessage" %)
	10	(((
	11	The system is not designed to operate with batteries whose total voltage exceeds 3000 V.
	12	)))
	13
28.1	14	== Installation procedure ==
27.1	15
40.1	16	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	17
	18	Overall and mounting dimensions are shown in figure below.
	19
	20	(% 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" %)
	21
	22	\|Parameter\|Value
	23	\|Overall dimensions (length × width × height), mm\|200 × 123 × 12
	24	\|Mounting dimensions (length × width), mm\|194 × 114
	25	\|Mounting holes\|M3
	26
30.1	27	== Headers ==
27.1	28
40.1	29	The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
27.1	30
	31	(% contenteditable="false" tabindex="-1" %)
	32	(((
	33	[[image:1732119505664-787.png\|\|data-xwiki-image-style-alignment="center" height="417" width="684"]]
	34	)))
	35
	36	(% class="box warningmessage" %)
	37	(((
	38	Attention!
	39	All headers are shown from the device side!
	40	)))
	41
30.1	42	=== X1 – header to power the device ===
27.1	43
55.3	44	Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
	45
27.1	46	(% class="wikigeneratedid" id="H" %)
	47	(% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png\|\|data-xwiki-image-style-alignment="center" height="85" width="200"]]
	48
	49	\|Pin\|Name\|Description
	50	\|1–2, 5–6\|GND\|Ground
	51	\|3\|KEYRUN\|Power-on signal
	52	\|4\|CHARGE_ON\|Power-on signal (battery charge requirement)
	53	\|7–8\|VIN\|Power line (9-32V)
	54
	55	Power supply connection diagram:
	56
	57	(% 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"]]
	58
30.1	59	=== X2 – header for contactors ===
27.1	60
55.3	61	Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
	62
27.1	63	(% 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" %)
	64
	65	\|Pin\|Name\|Description
	66	\|1–4, 8–9\|GND\|Ground
	67	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	68	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	69	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	70	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	71	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	72	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	73
	74	Contactor connection diagram:
	75
	76	(% 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"]]
	77
30.1	78	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	79
55.3	80	Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
	81
27.1	82	(% 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"]]
	83
	84	\|Pin\|Name\|Description
	85	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	86	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	87	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	88	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	89	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	90	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	91	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	92	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	93	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	94	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	95	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	96	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	97	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	98
	99	Connection diagram of a discrete input to a dry contact output:
	100
	101	(% 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:
	102
	103	(% 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:
	104
	105	(% 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:
	106
51.1	107	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	108
30.1	109	=== X4 – header for HVIL ===
27.1	110
55.3	111	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	112
30.1	113	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	114
	115	\|Pin\|Name\|Description
	116	\|1\|-\|Not used
	117	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	118	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	119	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	120
40.1	121	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	122
	123	Connection diagram to the current loop:
	124
54.1	125	[[image:1739361367866-742.png\|\|data-xwiki-image-style-alignment="center" height="210" width="281"]]
	126
31.1	127	=== X5 – header for current and temperature sensors ===
27.1	128
55.3	129	Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
	130
30.1	131	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	132
	133	(% style="width:539px" %)
	134	\|Pin\|Name\|(% style="width:402px" %)Description
	135	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	136	\|2–6\|GND\|(% style="width:402px" %)Ground
	137	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	138	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	139	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	140	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	141	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	142	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	143	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	144	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	145	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	146	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	147
	148	Current sensor connection diagram (using the example of LEM HASS 100-S):
	149
	150	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	151
	152	Current sensor connection diagram (using the example of LEM DHAB S/118):
	153
	154	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	155
	156	NTC-thermistor connection diagram:
	157
	158	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	159
30.1	160	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	161
55.3	162	Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
	163
27.1	164	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	165
	166	\|Pin\|Name\|Description
	167	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	168	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	169	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	170	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	171	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	172
	173	Connection diagram to the CAN1 bus:
	174
	175	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	176
	177	Connection diagram to the RS-485-1 bus:
	178
	179	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	180
30.1	181	=== X7 – header for CAN2 (internal bus) ===
27.1	182
55.3	183	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	184
27.1	185	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	186
	187	\|Pin\|Name\|Description
38.1	188	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	189	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	190	\|3\|GND\|Ground
	191	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	192
	193	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	194
	195	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	196
30.1	197	=== X8 – header for CAN3 ===
27.1	198
55.3	199	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	200
27.1	201	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	202
	203	\|Pin\|Name\|Description
38.1	204	\|1\|CAN3_H\|CAN3 line H
	205	\|2\|CAN3_L\|CAN3 line L
27.1	206	\|3\|GND\|Ground
	207	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	208
	209	(% class="box infomessage" %)
	210	(((
38.1	211	Note:
	212	CAN3 operates differently depending on used firmware:
27.1	213
38.1	214	* BMS Main 3: CAN3 bus is reserved;
39.1	215	* 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	216
	217	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	218	)))
27.1	219
30.1	220	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	221
55.3	222	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	223
27.1	224	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	225
	226	\|Pin\|Name\|Description
	227	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	228	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	229	\|3\|GND\|Ground
	230	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	231
40.1	232	(% class="box infomessage" %)
	233	(((
	234	Note:
	235	RS-485-2 operates differently depending on used firmware:
27.1	236
40.1	237	* BMS Main 3X: RS-485-2 bus is reserved;
	238	* 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	239
40.1	240	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	241	)))
	242
30.1	243	=== X10 – miniUSB connector ===
27.1	244
41.1	245	The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
27.1	246
30.1	247	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	248
55.3	249	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	250
27.1	251	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	252
	253	\|Pin\|Name\|Description
	254	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	255	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	256
	257	(% class="box warningmessage" %)
	258	(((
	259	The connected voltage must not exceed 1000V.
	260	)))
	261
30.1	262	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	263
55.3	264	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	265
27.1	266	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	267
	268	\|Pin\|Name\|Description
	269	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	270	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	271
	272	(% class="box warningmessage" %)
	273	(((
	274	The connected voltage must not exceed 1000V.
	275	)))
	276
30.1	277	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	278
55.3	279	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	280
27.1	281	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	282
	283	\|Pin\|Name\|Description
	284	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	285	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	286
	287	(% class="box warningmessage" %)
	288	(((
	289	The connected voltage must not exceed 1000V.
	290	)))
	291
30.1	292	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	293
55.3	294	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	295
27.1	296	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	297
	298	\|Pin\|Name\|Description
	299	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	300	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	301
	302	(% class="box warningmessage" %)
	303	(((
	304	The connected voltage must not exceed 1000V.
	305	)))
	306
30.1	307	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	308
	309	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	310
	311	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:
	312
	313	\|Pin\|Name\|Description
	314	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	315	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	316
30.1	317	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	318
	319
	320	[[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:
	321
	322	\|Pin\|Name\|Description
	323	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	324	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	325
30.1	326	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	327
	328
	329	[[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:
	330
	331	\|Pin\|Name\|Description
	332	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	333	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	334
30.1	335	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	336
41.1	337	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	338
30.1	339	== Indicators ==
27.1	340
30.1	341	=== DS1 – LED indicating device power ===
27.1	342
	343	\|State\|Description
	344	\|Lights up green\|Device power (+5V) is present
	345	\|Doesn’t light up\|No device power
	346
30.1	347	=== DS2 – LED indicating device work ===
27.1	348
	349	\|State\|Description
	350	\|Blinking green\|Executing the battery management program
	351	\|No blinking\|Program execution error
	352
54.2	353	=== DS3 – LED indicating interaction with child devices ===
27.1	354
54.2	355	(% style="width:447px" %)
	356	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	357	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	358	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	359
54.2	360	=== DS4 – LED indicating loss of connection with child devices ===
27.1	361
54.4	362	(% style="width:601px" %)
	363	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	364	\|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
	365	\|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	366
30.1	367	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	368
	369	\|State\|Description
	370	\|Lights up green\|The switch supplies voltage to the contactor winding
	371	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	372
30.1	373	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	374
	375	\|State\|Description
	376	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	377	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	378
30.1	379	== Connection procedure ==
27.1	380
47.1	381	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.
	382
	383	(% class="box errormessage" %)
	384	(((
48.1	385	The system is not designed to operate with batteries with total voltage more than 3000V.
47.1	386	)))
	387
27.1	388	(% class="box warningmessage" %)
	389	(((
42.1	390	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	391	)))
	392
	393	All operations to connect the device must be carried out with the supply voltage removed.
	394
	395	* Connect the power contactors to header X2.
	396	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	397	* Connect BMS Logic devices to header X9.
	398	* Connect digital inputs and outputs (if necessary) to header X3.
	399	* Connect the high voltage bus (if necessary) to headers X11-X14.
	400	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	401	* Connect external devices (if necessary) to header X6.
	402	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
40.1	403	* 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	404	* 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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