Wiki source code of 2. Installation and connection

Last modified by Admin on 2025/03/18 12:51

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
61.1	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.
57.1	7
59.1	8	Before use, configure the system. Proper operation of the BMS is possible only if it is correctly configured.
57.1	9
62.1	10	(% class="box errormessage" %)
56.2	11	(((
57.1	12	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	13	)))
	14
	15	(% class="box errormessage" %)
	16	(((
62.1	17	The system is not designed to operate with batteries whose total voltage exceeds 3000 V.
56.2	18	)))
	19
28.1	20	== Installation procedure ==
27.1	21
40.1	22	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	23
	24	Overall and mounting dimensions are shown in figure below.
	25
	26	(% 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" %)
	27
	28	\|Parameter\|Value
	29	\|Overall dimensions (length × width × height), mm\|200 × 123 × 12
	30	\|Mounting dimensions (length × width), mm\|194 × 114
	31	\|Mounting holes\|M3
	32
30.1	33	== Headers ==
27.1	34
40.1	35	The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
27.1	36
	37	(% contenteditable="false" tabindex="-1" %)
	38	(((
	39	[[image:1732119505664-787.png\|\|data-xwiki-image-style-alignment="center" height="417" width="684"]]
	40	)))
	41
	42	(% class="box warningmessage" %)
	43	(((
	44	Attention!
	45	All headers are shown from the device side!
	46	)))
	47
30.1	48	=== X1 – header to power the device ===
27.1	49
55.3	50	Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
	51
27.1	52	(% class="wikigeneratedid" id="H" %)
	53	(% data-widget="image" contenteditable="false" tabindex="-1" %)[[image:1732121673277-246.png\|\|data-xwiki-image-style-alignment="center" height="85" width="200"]]
	54
	55	\|Pin\|Name\|Description
	56	\|1–2, 5–6\|GND\|Ground
	57	\|3\|KEYRUN\|Power-on signal
	58	\|4\|CHARGE_ON\|Power-on signal (battery charge requirement)
	59	\|7–8\|VIN\|Power line (9-32V)
	60
	61	Power supply connection diagram:
	62
	63	(% 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"]]
	64
30.1	65	=== X2 – header for contactors ===
27.1	66
55.3	67	Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
	68
27.1	69	(% 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" %)
	70
	71	\|Pin\|Name\|Description
	72	\|1–4, 8–9\|GND\|Ground
	73	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	74	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	75	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	76	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	77	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	78	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	79
	80	Contactor connection diagram:
	81
	82	(% 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"]]
	83
30.1	84	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	85
55.3	86	Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
	87
27.1	88	(% 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"]]
	89
	90	\|Pin\|Name\|Description
	91	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	92	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	93	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	94	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	95	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	96	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	97	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	98	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	99	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	100	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	101	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	102	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	103	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	104
	105	Connection diagram of a discrete input to a dry contact output:
	106
	107	(% 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:
	108
	109	(% 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:
	110
	111	(% 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:
	112
51.1	113	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	114
30.1	115	=== X4 – header for HVIL ===
27.1	116
55.3	117	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	118
30.1	119	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	120
	121	\|Pin\|Name\|Description
	122	\|1\|-\|Not used
	123	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	124	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	125	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	126
40.1	127	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	128
	129	Connection diagram to the current loop:
	130
54.1	131	[[image:1739361367866-742.png\|\|data-xwiki-image-style-alignment="center" height="210" width="281"]]
	132
31.1	133	=== X5 – header for current and temperature sensors ===
27.1	134
55.3	135	Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
	136
30.1	137	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	138
	139	(% style="width:539px" %)
	140	\|Pin\|Name\|(% style="width:402px" %)Description
	141	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	142	\|2–6\|GND\|(% style="width:402px" %)Ground
	143	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	144	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	145	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	146	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	147	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	148	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	149	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	150	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	151	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	152	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	153
	154	Current sensor connection diagram (using the example of LEM HASS 100-S):
	155
	156	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	157
	158	Current sensor connection diagram (using the example of LEM DHAB S/118):
	159
	160	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	161
	162	NTC-thermistor connection diagram:
	163
	164	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	165
30.1	166	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	167
55.3	168	Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
	169
27.1	170	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	171
	172	\|Pin\|Name\|Description
	173	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	174	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	175	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	176	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	177	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	178
	179	Connection diagram to the CAN1 bus:
	180
	181	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	182
	183	Connection diagram to the RS-485-1 bus:
	184
	185	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	186
30.1	187	=== X7 – header for CAN2 (internal bus) ===
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\|CAN2_H\|CAN2 line H for communication with other BMS devices
	195	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	196	\|3\|GND\|Ground
	197	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	198
	199	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	200
	201	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	202
30.1	203	=== X8 – header for CAN3 ===
27.1	204
55.3	205	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	206
27.1	207	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	208
	209	\|Pin\|Name\|Description
38.1	210	\|1\|CAN3_H\|CAN3 line H
	211	\|2\|CAN3_L\|CAN3 line L
27.1	212	\|3\|GND\|Ground
	213	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	214
	215	(% class="box infomessage" %)
	216	(((
38.1	217	Note:
	218	CAN3 operates differently depending on used firmware:
27.1	219
38.1	220	* BMS Main 3: CAN3 bus is reserved;
39.1	221	* 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	222
	223	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	224	)))
27.1	225
30.1	226	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	227
55.3	228	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	229
27.1	230	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	231
	232	\|Pin\|Name\|Description
	233	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	234	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	235	\|3\|GND\|Ground
	236	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	237
40.1	238	(% class="box infomessage" %)
	239	(((
	240	Note:
	241	RS-485-2 operates differently depending on used firmware:
27.1	242
40.1	243	* BMS Main 3X: RS-485-2 bus is reserved;
	244	* 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	245
40.1	246	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	247	)))
	248
30.1	249	=== X10 – miniUSB connector ===
27.1	250
41.1	251	The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
27.1	252
30.1	253	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	254
55.3	255	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	256
27.1	257	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	258
	259	\|Pin\|Name\|Description
	260	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	261	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	262
	263	(% class="box warningmessage" %)
	264	(((
	265	The connected voltage must not exceed 1000V.
	266	)))
	267
30.1	268	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	269
55.3	270	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	271
27.1	272	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	273
	274	\|Pin\|Name\|Description
	275	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	276	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	277
	278	(% class="box warningmessage" %)
	279	(((
	280	The connected voltage must not exceed 1000V.
	281	)))
	282
30.1	283	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	284
55.3	285	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	286
27.1	287	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	288
	289	\|Pin\|Name\|Description
	290	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	291	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	292
	293	(% class="box warningmessage" %)
	294	(((
	295	The connected voltage must not exceed 1000V.
	296	)))
	297
30.1	298	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	299
55.3	300	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	301
27.1	302	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	303
	304	\|Pin\|Name\|Description
	305	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	306	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	307
	308	(% class="box warningmessage" %)
	309	(((
	310	The connected voltage must not exceed 1000V.
	311	)))
	312
30.1	313	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	314
	315	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	316
	317	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:
	318
	319	\|Pin\|Name\|Description
	320	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	321	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	322
30.1	323	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	324
	325
	326	[[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:
	327
	328	\|Pin\|Name\|Description
	329	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	330	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	331
30.1	332	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	333
	334
	335	[[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:
	336
	337	\|Pin\|Name\|Description
	338	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	339	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	340
30.1	341	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	342
41.1	343	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	344
30.1	345	== Indicators ==
27.1	346
30.1	347	=== DS1 – LED indicating device power ===
27.1	348
	349	\|State\|Description
	350	\|Lights up green\|Device power (+5V) is present
	351	\|Doesn’t light up\|No device power
	352
30.1	353	=== DS2 – LED indicating device work ===
27.1	354
	355	\|State\|Description
	356	\|Blinking green\|Executing the battery management program
	357	\|No blinking\|Program execution error
	358
54.2	359	=== DS3 – LED indicating interaction with child devices ===
27.1	360
54.2	361	(% style="width:447px" %)
	362	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	363	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	364	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	365
54.2	366	=== DS4 – LED indicating loss of connection with child devices ===
27.1	367
54.4	368	(% style="width:601px" %)
	369	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	370	\|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
	371	\|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	372
30.1	373	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	374
	375	\|State\|Description
	376	\|Lights up green\|The switch supplies voltage to the contactor winding
	377	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	378
30.1	379	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	380
	381	\|State\|Description
	382	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	383	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	384
30.1	385	== Connection procedure ==
27.1	386
	387	All operations to connect the device must be carried out with the supply voltage removed.
	388
	389	* Connect the power contactors to header X2.
	390	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	391	* Connect BMS Logic devices to header X9.
	392	* Connect digital inputs and outputs (if necessary) to header X3.
	393	* Connect the high voltage bus (if necessary) to headers X11-X14.
	394	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	395	* Connect external devices (if necessary) to header X6.
	396	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
40.1	397	* 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	398	* 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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