Wiki source code of 2. Installation and connection

Version 58.1 by Admin on 2025/03/18 12:14

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
57.1	4	== Safety rules ==
	5
	6	To perform the protection functions, the BMS must be able to disconnect the battery from the load and charger. To do this, at least one contactor able to break the load and charge circuits must be connected to the BMS.
	7
57.2	8	Before use, configure the system. Proper operation of the BMS is possible only if it is correctly configured.
57.1	9
	10	It is not recommended to use the system in batteries formed by several series of cells connected in parallel. To increase capacity, it is recommended to connect several cells in parallel groups, and then connect the groups in series.
	11
56.2	12	(% class="box warningmessage" %)
	13	(((
57.1	14	The BMS can be connected to batteries with life-threatening and health-hazardous voltage levels. When working with high-voltage batteries, observe electrical safety regulations, use safety glasses, protective clothing, insulated tools and appliances. To prevent the damage of device avoid electrostatic discharges while working with the battery.
56.2	15	)))
	16
	17	(% class="box errormessage" %)
	18	(((
	19	The system is not designed to operate with batteries whose total voltage exceeds 3000 V.
	20	)))
	21
28.1	22	== Installation procedure ==
27.1	23
40.1	24	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	25
	26	Overall and mounting dimensions are shown in figure below.
	27
	28	(% 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" %)
	29
	30	\|Parameter\|Value
	31	\|Overall dimensions (length × width × height), mm\|200 × 123 × 12
	32	\|Mounting dimensions (length × width), mm\|194 × 114
	33	\|Mounting holes\|M3
	34
30.1	35	== Headers ==
27.1	36
40.1	37	The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
27.1	38
	39	(% contenteditable="false" tabindex="-1" %)
	40	(((
	41	[[image:1732119505664-787.png\|\|data-xwiki-image-style-alignment="center" height="417" width="684"]]
	42	)))
	43
	44	(% class="box warningmessage" %)
	45	(((
	46	Attention!
	47	All headers are shown from the device side!
	48	)))
	49
30.1	50	=== X1 – header to power the device ===
27.1	51
55.3	52	Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
	53
27.1	54	(% class="wikigeneratedid" id="H" %)
	55	(% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png\|\|data-xwiki-image-style-alignment="center" height="85" width="200"]]
	56
	57	\|Pin\|Name\|Description
	58	\|1–2, 5–6\|GND\|Ground
	59	\|3\|KEYRUN\|Power-on signal
	60	\|4\|CHARGE_ON\|Power-on signal (battery charge requirement)
	61	\|7–8\|VIN\|Power line (9-32V)
	62
	63	Power supply connection diagram:
	64
	65	(% 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"]]
	66
30.1	67	=== X2 – header for contactors ===
27.1	68
55.3	69	Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
	70
27.1	71	(% 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" %)
	72
	73	\|Pin\|Name\|Description
	74	\|1–4, 8–9\|GND\|Ground
	75	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	76	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	77	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	78	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	79	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	80	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	81
	82	Contactor connection diagram:
	83
	84	(% 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"]]
	85
30.1	86	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	87
55.3	88	Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
	89
27.1	90	(% 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"]]
	91
	92	\|Pin\|Name\|Description
	93	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	94	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	95	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	96	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	97	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	98	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	99	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	100	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	101	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	102	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	103	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	104	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	105	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	106
	107	Connection diagram of a discrete input to a dry contact output:
	108
	109	(% 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:
	110
	111	(% 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:
	112
	113	(% 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:
	114
51.1	115	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	116
30.1	117	=== X4 – header for HVIL ===
27.1	118
55.3	119	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	120
30.1	121	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	122
	123	\|Pin\|Name\|Description
	124	\|1\|-\|Not used
	125	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	126	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	127	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	128
40.1	129	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	130
	131	Connection diagram to the current loop:
	132
54.1	133	[[image:1739361367866-742.png\|\|data-xwiki-image-style-alignment="center" height="210" width="281"]]
	134
31.1	135	=== X5 – header for current and temperature sensors ===
27.1	136
55.3	137	Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
	138
30.1	139	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	140
	141	(% style="width:539px" %)
	142	\|Pin\|Name\|(% style="width:402px" %)Description
	143	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	144	\|2–6\|GND\|(% style="width:402px" %)Ground
	145	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	146	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	147	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	148	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	149	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	150	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	151	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	152	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	153	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	154	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	155
	156	Current sensor connection diagram (using the example of LEM HASS 100-S):
	157
	158	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	159
	160	Current sensor connection diagram (using the example of LEM DHAB S/118):
	161
	162	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	163
	164	NTC-thermistor connection diagram:
	165
	166	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	167
30.1	168	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	169
55.3	170	Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
	171
27.1	172	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	173
	174	\|Pin\|Name\|Description
	175	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	176	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	177	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	178	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	179	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	180
	181	Connection diagram to the CAN1 bus:
	182
	183	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	184
	185	Connection diagram to the RS-485-1 bus:
	186
	187	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	188
30.1	189	=== X7 – header for CAN2 (internal bus) ===
27.1	190
55.3	191	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	192
27.1	193	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	194
	195	\|Pin\|Name\|Description
38.1	196	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	197	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	198	\|3\|GND\|Ground
	199	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	200
	201	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	202
	203	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	204
30.1	205	=== X8 – header for CAN3 ===
27.1	206
55.3	207	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	208
27.1	209	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	210
	211	\|Pin\|Name\|Description
38.1	212	\|1\|CAN3_H\|CAN3 line H
	213	\|2\|CAN3_L\|CAN3 line L
27.1	214	\|3\|GND\|Ground
	215	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	216
	217	(% class="box infomessage" %)
	218	(((
38.1	219	Note:
	220	CAN3 operates differently depending on used firmware:
27.1	221
38.1	222	* BMS Main 3: CAN3 bus is reserved;
39.1	223	* 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	224
	225	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	226	)))
27.1	227
30.1	228	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	229
55.3	230	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	231
27.1	232	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	233
	234	\|Pin\|Name\|Description
	235	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	236	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	237	\|3\|GND\|Ground
	238	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	239
40.1	240	(% class="box infomessage" %)
	241	(((
	242	Note:
	243	RS-485-2 operates differently depending on used firmware:
27.1	244
40.1	245	* BMS Main 3X: RS-485-2 bus is reserved;
	246	* 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	247
40.1	248	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	249	)))
	250
30.1	251	=== X10 – miniUSB connector ===
27.1	252
41.1	253	The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
27.1	254
30.1	255	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	256
55.3	257	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	258
27.1	259	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	260
	261	\|Pin\|Name\|Description
	262	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	263	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	264
	265	(% class="box warningmessage" %)
	266	(((
	267	The connected voltage must not exceed 1000V.
	268	)))
	269
30.1	270	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	271
55.3	272	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	273
27.1	274	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	275
	276	\|Pin\|Name\|Description
	277	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	278	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	279
	280	(% class="box warningmessage" %)
	281	(((
	282	The connected voltage must not exceed 1000V.
	283	)))
	284
30.1	285	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	286
55.3	287	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	288
27.1	289	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	290
	291	\|Pin\|Name\|Description
	292	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	293	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	294
	295	(% class="box warningmessage" %)
	296	(((
	297	The connected voltage must not exceed 1000V.
	298	)))
	299
30.1	300	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	301
55.3	302	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	303
27.1	304	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	305
	306	\|Pin\|Name\|Description
	307	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	308	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	309
	310	(% class="box warningmessage" %)
	311	(((
	312	The connected voltage must not exceed 1000V.
	313	)))
	314
30.1	315	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	316
	317	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	318
	319	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:
	320
	321	\|Pin\|Name\|Description
	322	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	323	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	324
30.1	325	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	326
	327
	328	[[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:
	329
	330	\|Pin\|Name\|Description
	331	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	332	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	333
30.1	334	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	335
	336
	337	[[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:
	338
	339	\|Pin\|Name\|Description
	340	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	341	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	342
30.1	343	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	344
41.1	345	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	346
30.1	347	== Indicators ==
27.1	348
30.1	349	=== DS1 – LED indicating device power ===
27.1	350
	351	\|State\|Description
	352	\|Lights up green\|Device power (+5V) is present
	353	\|Doesn’t light up\|No device power
	354
30.1	355	=== DS2 – LED indicating device work ===
27.1	356
	357	\|State\|Description
	358	\|Blinking green\|Executing the battery management program
	359	\|No blinking\|Program execution error
	360
54.2	361	=== DS3 – LED indicating interaction with child devices ===
27.1	362
54.2	363	(% style="width:447px" %)
	364	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	365	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	366	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	367
54.2	368	=== DS4 – LED indicating loss of connection with child devices ===
27.1	369
54.4	370	(% style="width:601px" %)
	371	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	372	\|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
	373	\|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	374
30.1	375	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	376
	377	\|State\|Description
	378	\|Lights up green\|The switch supplies voltage to the contactor winding
	379	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	380
30.1	381	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	382
	383	\|State\|Description
	384	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	385	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	386
30.1	387	== Connection procedure ==
27.1	388
	389	All operations to connect the device must be carried out with the supply voltage removed.
	390
	391	* Connect the power contactors to header X2.
	392	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	393	* Connect BMS Logic devices to header X9.
	394	* Connect digital inputs and outputs (if necessary) to header X3.
	395	* Connect the high voltage bus (if necessary) to headers X11-X14.
	396	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	397	* Connect external devices (if necessary) to header X6.
	398	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
40.1	399	* 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	400	* 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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