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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 == 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
8 Before use, **configure the system**. Proper operation of the BMS is possible only if it is correctly configured.
9
10 (% class="box errormessage" %)
11 (((
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.
13 )))
14
15 (% class="box errormessage" %)
16 (((
17 The system is not designed to operate with batteries whose total voltage exceeds 3000 V.
18 )))
19
20 == Installation procedure ==
21
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.
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
33 == Headers ==
34
35 The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
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
48 === X1 – header to power the device ===
49
50 Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
51
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
65 === X2 – header for contactors ===
66
67 Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
68
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
84 === (% title="Click and drag to resize" %)​(%%)X3 – header for discrete inputs and outputs ===
85
86 Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
87
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
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”
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
113 [[image:1739361269041-663.png||data-xwiki-image-style-alignment="center" height="93" width="275"]]
114
115 === X4 – header for HVIL ===
116
117 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
118
119 [[image:1732122015188-642.png||data-xwiki-image-style-alignment="center" height="64" width="150"]]
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
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.
128
129 Connection diagram to the current loop:
130
131 [[image:1739361367866-742.png||data-xwiki-image-style-alignment="center" height="210" width="281"]]
132
133 === X5 – header for current and temperature sensors ===
134
135 Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
136
137 [[image:1733311958053-469.png||data-xwiki-image-style-alignment="center" height="83" width="349"]]
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
166 === X6 – header for CAN1 and RS-485-1 (external buses) ===
167
168 Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
169
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
187 === X7 – header for CAN2 (internal bus) ===
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**|**CAN2_H**|CAN2 line H for communication with other BMS devices
195 |**2**|**CAN2_L**|CAN2 line L for communication with other BMS devices
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
203 === X8 – header for CAN3 ===
204
205 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
206
207 [[image:1733316517741-698.png||data-xwiki-image-style-alignment="center" height="59" width="144"]]
208
209 |**Pin**|**Name**|**Description**
210 |**1**|**CAN3_H**|CAN3 line H
211 |**2**|**CAN3_L**|CAN3 line L
212 |**3**|**GND**|Ground
213 |**4**|**CAN3_5V**|CAN3 power line (5 V, max 400 mA)
214
215 (% class="box infomessage" %)
216 (((
217 **Note:**
218 CAN3 operates differently depending on used firmware:
219
220 * **BMS Main 3:** CAN3 bus is reserved;
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:
222
223 [[image:1733316622613-181.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
224 )))
225
226 === X9 – header for BMS Logic (RS-485-2) ===
227
228 Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
229
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
238 (% class="box infomessage" %)
239 (((
240 **Note:**
241 RS-485-2 operates differently depending on used firmware:
242
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:
245
246 [[image:1733316674363-604.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
247 )))
248
249 === X10 – miniUSB connector ===
250
251 The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
252
253 === X11 – header for high-voltage bus before contactors (plus) ===
254
255 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
256
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
268 === X12 – header for high-voltage bus before contactors (minus) ===
269
270 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
271
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
283 === X13 – header for high-voltage bus after contactors (plus) ===
284
285 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
286
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
298 === X14 – header for high-voltage bus after contactors (minus) ===
299
300 Receptacle Housing: Molex 436450200. Terminals: Molex 43030
301
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
313 === J1 – jumper for switching RS-485-1 bus terminal resistor ===
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
323 === J2 – jumper for switching CAN1 bus terminal resistor ===
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
332 === J3 – jumper for switching CAN2 bus terminal resistor ===
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
341 === J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
342
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.
344
345 == Indicators ==
346
347 === DS1 – LED indicating device power ===
348
349 |**State**|**Description**
350 |**Lights up green**|Device power (+5V) is present
351 |**Doesn’t light up**|No device power
352
353 === DS2 – LED indicating device work ===
354
355 |**State**|**Description**
356 |**Blinking green**|Executing the battery management program
357 |**No blinking**|Program execution error
358
359 === DS3 – LED indicating interaction with child devices ===
360
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" %)-
365
366 === DS4 – LED indicating loss of connection with child devices ===
367
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
372
373 === DS5-DS10 – LEDs indicating contactor switches 1-6 ===
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
379 === DS11 – LED indicating the presence of power supply for contactors ===
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
385 == Connection procedure ==
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.
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.
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.