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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 (% 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
14 == Installation procedure ==
15
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.
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
27 == Headers ==
28
29 The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
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
42 === X1 – header to power the device ===
43
44 Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
45
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
59 === X2 – header for contactors ===
60
61 Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
62
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
78 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
79
80 Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
81
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
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”
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
107 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
108
109 === X4 – header for HVIL ===
110
111 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
112
113 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
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
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.
122
123 Connection diagram to the current loop:
124
125 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
126
127 === X5 – header for current and temperature sensors ===
128
129 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
130
131 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
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
160 === X6 – header for CAN1 and RS-485-1 (external buses) ===
161
162 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
163
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
181 === X7 – header for CAN2 (internal bus) ===
182
183 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
184
185 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
186
187 |**Pin**|**Name**|**Description**
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
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
197 === X8 – header for CAN3 ===
198
199 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
200
201 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
202
203 |**Pin**|**Name**|**Description**
204 |**1**|**CAN3_H**|CAN3 line H
205 |**2**|**CAN3_L**|CAN3 line L
206 |**3**|**GND**|Ground
207 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
208
209 (% class="box infomessage" %)
210 (((
211 **Note:**
212 CAN3 operates differently depending on used firmware:
213
214 * **BMS Main 3:** CAN3 bus is reserved;
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:
216
217 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
218 )))
219
220 === X9 – header for BMS Logic (RS-485-2) ===
221
222 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
223
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
232 (% class="box infomessage" %)
233 (((
234 **Note:**
235 RS-485-2 operates differently depending on used firmware:
236
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:
239
240 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
241 )))
242
243 === X10 – miniUSB connector ===
244
245 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
246
247 === X11 – header for high-voltage bus before contactors (plus) ===
248
249 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
250
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
262 === X12 – header for high-voltage bus before contactors (minus) ===
263
264 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
265
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
277 === X13 – header for high-voltage bus after contactors (plus) ===
278
279 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
280
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
292 === X14 – header for high-voltage bus after contactors (minus) ===
293
294 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
295
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
307 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
317 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
326 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
335 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
336
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.
338
339 == Indicators ==
340
341 === DS1 – LED indicating device power ===
342
343 |**State**|**Description**
344 |**Lights up green**|Device power (+5V) is present
345 |**Doesn’t light up**|No device power
346
347 === DS2 – LED indicating device work ===
348
349 |**State**|**Description**
350 |**Blinking green**|Executing the battery management program
351 |**No blinking**|Program execution error
352
353 === DS3 – LED indicating interaction with child devices ===
354
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" %)-
359
360 === DS4 – LED indicating loss of connection with child devices ===
361
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
366
367 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
373 === DS11 – LED indicating the presence of power supply for contactors ===
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
379 == Connection procedure ==
380
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 (((
385 **The system is not designed to operate with batteries with total voltage more than 3000V.**
386 )))
387
388 (% class="box warningmessage" %)
389 (((
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.
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.
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.
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.