2. Installation and configuration
Installation and connection
Installation and connection
Installation procedure
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.
Overall and mounting dimensions are shown in figure below.
| Parameter | Value |
| Overall dimensions (length × width × height), mm | 200 × 123 × 12 |
| Mounting dimensions (length × width), mm | 194 × 114 |
| Mounting holes | M3 |
Headers
The location and designation of connectors on the BMS Main 3 / BMS Main 3X device are shown below.
X1 – header to power the device
Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1–2, 5–6 | GND | Ground |
| 3 | KEYRUN | Power-on signal |
| 4 | CHARGE_ON | Power-on signal (battery charge requirement) |
| 7–8 | VIN | Power line (9-32V) |
Power supply connection diagram:
X2 – header for contactors
Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1–4, 8–9 | GND | Ground |
| 5 | CONT1_OUT | Contactor control 1 (plus) |
| 6 | CONT2_OUT | Contactor control 2 (plus) |
| 7 | CONT3_OUT | Contactor control 3 (plus) |
| 10 | CONT4_OUT | Contactor control 4 (plus) |
| 11 | CONT5_OUT | Contactor control 5 (plus) |
| 12 | CONT6_OUT | Contactor control 6 (plus) |
Contactor connection diagram:
X3 – header for discrete inputs and outputs
Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1–8, 12, 16–17, 21 | DIO_GND | Ground of input and output signals |
| 9 | DIN1_SIGNAL | Discrete input 1 “dry contact” |
| 10 | DIN2_SIGNAL | Discrete input 2 “dry contact” |
| 11 | DIN3_SIGNAL | Discrete input 3 “dry contact” |
| 13 | DIN4_SIGNAL | Discrete input 4 “dry contact” |
| 14 | DIN5_SIGNAL | Discrete input 5 “dry contact” |
| 15 | DIN6_SIGNAL | Discrete input 6 “dry contact” |
| 18 | DIN7_VIN | Discrete input 7 (signal detection with voltage 9-32V) |
| 19 | DIN8_VIN | Discrete input 8 (signal detection with voltage 9-32V) |
| 20 | DOUT1_OD | Discrete output 1 “open drain” (60 V, 1A) |
| 22 | DOUT2_OD | Discrete output 2 “open drain” (60 V, 1A) |
| 23 | DOUT3_OD | Discrete output 3 “open drain” (60 V, 1A) |
| 24 | DOUT4_OD | Discrete output 4 “open drain” (60 V, 1A) |
Connection diagram of a discrete input to a dry contact output:
Connection diagram of a discrete input to an open collector output:
Connection diagram for a discrete input for detecting a 9-32V signal:
Connection diagram for discrete output:
X4 – header for HVIL
Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1 | - | Not used |
| 2 | HVIL_OUT | Output of the current measurement circuit in the current loop (lower potential, measuring shunt output) |
| 3 | HVIL_IN | Input of the current measurement circuit in the current loop (higher potential, measuring shunt input) |
| 4 | HVIL_PWR | Current loop power supply (max 5V, 25mA) |
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.
Connection diagram to the current loop:
X5 – header for current and temperature sensors
Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1 | CS1_5V | Current sensor 1 power line (5 V, max 50 mA) |
| 2–6 | GND | Ground |
| 7 | CS1_IN1 | Current sensor 1 signal line (for a dual-range current sensor, High range output) |
| 8 | CS1_REF_IN2 | Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output) |
| 9 | CS2_5V | Current sensor 2 power line (5 V, max 50 mA) |
| 10 | CS2_IN1 | Current sensor 2 signal line (for a dual-range current sensor, High range output) |
| 11 | CS2_REF_IN2 | Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output) |
| 12 | CS3_5V | Current sensor 3 power line (5 V, max 50 mA) |
| 13 | CS3_IN1 | Current sensor 3 signal line (for a dual-range current sensor, High range output) |
| 14 | CS3_REF_IN2 | Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output) |
| 15 | TEMP1 | Temperature sensor 1 signal line (NTC-thermistor 100 kOhm) |
| 16 | TEMP2 | Temperature sensor 2 signal line (NTC-thermistor 100 kOhm) |
Current sensor connection diagram (using the example of LEM HASS 100-S):
Current sensor connection diagram (using the example of LEM DHAB S/118):
NTC-thermistor connection diagram:
X6 – header for CAN1 and RS-485-1 (external buses)
Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1 | CAN1_H | CAN1 line H for communication with external equipment |
| 2 | CAN1_L | CAN1 line L for communication with external equipment |
| 3 | CAN1_RS485_1_GND | Ground of CAN1 and RS-485-1 |
| 4 | RS485_1_A | RS-485-1 line A for communication with external equipment |
| 5 | RS485_1_B | RS-485-1 line B for communication with external equipment |
Connection diagram to the CAN1 bus:
Connection diagram to the RS-485-1 bus:
X7 – header for CAN2 (internal bus)
Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1 | CAN2_H | CAN2 line H for communication with other BMS devices |
| 2 | CAN2_L | CAN2 line L for communication with other BMS devices |
| 3 | GND | Ground |
| 4 | CAN2_5V | CAN2 power line (5 V, max 400 mA) |
Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
X8 – header for CAN3
Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1 | CAN3_H | CAN3 line H |
| 2 | CAN3_L | CAN3 line L |
| 3 | GND | Ground |
| 4 | CAN3_5V | CAN3 power line (5 V, max 400 mA) |
Note:
CAN3 operates differently depending on used firmware:
- BMS Main 3: CAN3 bus is reserved;
- 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:
X9 – header for BMS Logic (RS-485-2)
Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
| Pin | Name | Description |
| 1 | LOGIC_B | RS-485 line B for communication with BMS Logic |
| 2 | LOGIC_A | RS-485 line A for communication with BMS Logic |
| 3 | GND | Ground |
| 4 | LOGIC_5V | BMS Logic power line (+5V, max 400mA) |
Note:
RS-485-2 operates differently depending on used firmware:
- BMS Main 3X: RS-485-2 bus is reserved;
- BMS Main 3: RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
X10 – miniUSB connector
The miniUSB connector is used to configure the parameters of the BMS Main 3 / BMS Main 3X device.
X11 – header for high-voltage bus before contactors (plus)
Receptacle Housing: Molex 436450200. Terminals: Molex 43030
| Pin | Name | Description |
| 1 | IN1+ | Plus of the high-voltage bus (before contactors) |
| 2 | IN1+ | Plus of the high-voltage bus (before contactors) |
X12 – header for high-voltage bus before contactors (minus)
Receptacle Housing: Molex 436450200. Terminals: Molex 43030
| Pin | Name | Description |
| 1 | IN1- | Minus of the high-voltage bus (before contactors) |
| 2 | IN1- | Minus of the high-voltage bus (before contactors) |
X13 – header for high-voltage bus after contactors (plus)
Receptacle Housing: Molex 436450200. Terminals: Molex 43030
| Pin | Name | Description |
| 1 | IN2+ | Plus of the high-voltage bus (after contactors) |
| 2 | IN2+ | Plus of the high-voltage bus (after contactors) |
X14 – header for high-voltage bus after contactors (minus)
Receptacle Housing: Molex 436450200. Terminals: Molex 43030
| Pin | Name | Description |
| 1 | IN2- | Minus of the high-voltage bus (after contactors) |
| 2 | IN2- | Minus of the high-voltage bus (after contactors) |
J1 – jumper for switching RS-485-1 bus terminal resistor
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:
| Pin | Name | Description |
| 1-2 | 120 Ohm | The 120 Ohm terminal resistor of the RS-485-1 bus is connected |
| 2-3 | - | The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected |
J2 – jumper for switching CAN1 bus terminal resistor
To connect a terminal resistor between the CAN1_H and CAN1_L lines, install a jumper. The jumper is installed according to the table:
| Pin | Name | Description |
| 1-2 | 120 Ohm | The 120 Ohm terminal resistor of the CAN1 bus is connected |
| 2-3 | - | The 120 Ohm terminal resistor of the CAN1 bus is disconnected |
J3 – jumper for switching CAN2 bus terminal resistor
To connect a terminal resistor between the CAN2_H and CAN2_L lines, install a jumper. The jumper is installed according to the table:
| Pin | Name | Description |
| 1-2 | 120 Ohm | The 120 Ohm terminal resistor of the CAN2 bus is connected |
| 2-3 | - | The 120 Ohm terminal resistor of the CAN2 bus is disconnected |
J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8
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.
Indicators
DS1 – LED indicating device power
| State | Description |
| Lights up green | Device power (+5V) is present |
| Doesn’t light up | No device power |
DS2 – LED indicating device work
| State | Description |
| Blinking green | Executing the battery management program |
| No blinking | Program execution error |
DS3 – LED indicating interaction with child devices
| State | Description (Main 3) | Description (Main 3X) |
| Blinking yellow | The device interacts with BMS Logic devices | The device interacts with BMS Main 3 devices |
| No blinking | - | - |
DS4 – LED indicating loss of connection with child devices
| State | Description (Main 3) | Description (Main 3X) |
| Blinking/lights up red | Communication with one or more BMS Logic devices is lost | Communication with one or more BMS Main 3 devices is lost |
| No blinking | Communication with BMS Logic devices is stable | Communication with BMS Main 3 devices is stable |
DS5-DS10 – LEDs indicating contactor switches 1-6
| State | Description |
| Lights up green | The switch supplies voltage to the contactor winding |
| Doesn’t light up | The switch doesn’t supply voltage to the contactor winding |
DS11 – LED indicating the presence of power supply for contactors
| State | Description |
| Lights up green | Power supply for contactor switches (9-32V) is present |
| Doesn’t light up | Power supply for contactor switches (9-32V) is not present |
Connection procedure
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.
All operations to connect the device must be carried out with the supply voltage removed.
- Connect the power contactors to header X2.
- Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
- Connect BMS Logic devices to header X9.
- Connect digital inputs and outputs (if necessary) to header X3.
- Connect the high voltage bus (if necessary) to headers X11-X14.
- Connect the high-voltage network integrity circuit (if necessary) to header X4.
- Connect external devices (if necessary) to header X6.
- Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
- 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.
- 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.