OPERATION MANUAL INDUCTIVE CHARGING SYSTEM ICS115 - INDUCTIVE CHARGING SYSTEM ICS115 - FOR INSTALLATION – OPERATION – MAINTENANCE Translation of original operation manual (English) Read carefully before use! Keep safe for later reference! BRUSA Elektronik AG Neudorf 14 www.brusa.
IMPRINT Title OPERATION MANUAL INDUCTIVE CHARGING SYSTEM ICS115 Publisher BRUSA Elektronik AG Neudorf 14 CH–9466 Sennwald T +41 8175 819–00 F +41 8175 819–99 www.brusa.biz info@brusa.biz Managing Director: Josef Brusa Valid for ICS115 (2017) Edition 1 Edition Number 07/2018 Date of Issue 15.02.2018 Online version Can be found at www.brusa.biz Copyright © 2017 – 2018 BRUSA Elektronik AG st The copyright of this document lies with BRUSA Elektronik AG.
7 15.02.2018 Josef Olliges Review comments Approval TABLE OF CONTENTS 1 List of Abbreviations .......................................................................................................................7 2 Foreword ..........................................................................................................................................8 3 4 2.1 Content and Scope of this Manual ..............................................................................................
5.3.2 Safety Instructions for Electrical Hazards ..........................................................................19 5.3.3 Safety Instructions for Handling and Operation .................................................................20 5.4 Safety Equipment / Power Limitations ......................................................................................22 5.4.1 Overvoltage Protection ...................................................................................................
11 Legal Notices .............................................................................................................................39 11.1 Warranty ...............................................................................................................................39 11.2 Company Names ..................................................................................................................39 12 Annex A1 ....................................................................
12.6.1 12.7 Procedure for the Deinstallation of the GPM (Information for Customer Service): ..........54 Vehicle Integration of the CPM .............................................................................................55 12.7.1 Installation Information ...................................................................................................55 12.7.2 Mounting the CPM .........................................................................................................55 12.7.
1 List of Abbreviations In the course of this manual several trade-specific abbreviations are used. An overview as well as their meanings can be found in the following table: ABB. DESCRIPTION ABB.
2 Foreword Valued Customer! With the BRUSA Inductive Charging System Model ICS115 you have purchased an inductive charging system with st the latest technology. Model ICS115 is an inductive charging system of the 1 Generation for vehicles with highvoltage battery, which is subsequently abbreviated to ICS.
3 Identification of the Product ICS 3.1 Product Identification This manual is valid exclusively for the devices listed in the following table: ICS1 WITH THE FOLLOWING DEVICE DESIGNATIONS ICSP11W-U0-01X-Xxx (GPM) ICSS115-U0-01X-Xxx (CPM, 2-HV-Connectors) 3.
CPM: 3.3 Service- and Contact Data TYPE OF INQUIRY COUNTRIES CONTACT DATA D, A, CH Help and Support BMW Customer Support D–80788 Munich Deinstallation and Disposal Germany Delivery Tel: +49 89 1250-16000 kundenbetreuung@bmw.
3.
4 Product Description of the ICS 4.1 Scope of Application The ICS consists of two separate devices. The Ground Pad Module (GPM) thereby forms that part connected to the power supply network, which transmits the energy to the Car Pad Module (CPM) integrated in the vehicle. The communication between GPM and CPM is automated and takes place via WLAN. NOTE Note: The Car Pad Modules of the possible variants from chapter 3.1 function with all Ground Pad Modules (GPM) of the ICS. 4.1.
The electromagnetic radiation of the ICS remains within the legally permitted limits. During the charging process, the following groups of people are exposed to increased health risks in the vicinity of the ICS: People with active medical implants (e.g. cardiac pacemakers, defibrillators) People with passive medical implants (e.g. stents) People with electrically conductive foreign objects in their bodies (e.g. metallic splinters from accidents / war injuries) 4.1.
4.1.6 Delimitation This operation manual describes the safe handling with the Inductive Charging System in all phases of life. BRUSA Elektronik AG accepts no liability for the incomplete passing on of information from this document, in particular to those persons from the target group defined in chapter 4.1.1 and any damage resulting therefrom. 4.2 Functionality The ICS consists of two separate devices.
4.2.1 Energy Efficiency The energy efficiency is generally dependent on the parking position of the vehicle over the GPM during the charging process. Maximum efficiency is achieved when you park in the optimal position range. The efficiency of the charging process depends, among other things, on the parameters of the drive battery (e.g. performance and charging cycle) of the vehicle in which the ICS is installed. 4.
5 Safety and Warning Signs In this chapter you will find safety instructions that must be taken into consideration in all life phases of the system. Read and observe these instructions without fail, in order to safeguard the safety and the life of people as well as avoid damage to the device! 5.1 Symbols and their Meaning Various symbols are used throughout this manual.
MANDATORY SIGNS SYMBOL DESCRIPTION SYMBOL DESCRIPTION Disconnect device Disconnect device from the mains Wear safety glasses Wear protective gloves INFORMATION SIGNS SYMBOL DESCRIPTION SYMBOL Important information for the avoidance of possible material damage 5.
INFORMATION This type of notice is used to communicate important information for the reader.
5.3 Generally Applicable Safety Instructions 5.3.1 Safety Instructions for Thermal Hazards DANGER Explosive Environment! Danger to life! Do not store any highly flammable substances or combustible liquids in the immediate vicinity of the devices! The generation of sparks at the device connections can ignite these materials and lead to an explosion! CAUTION Hot Surfaces! Risk of burning! The devices generate high temperatures during operation! Therefore always touch them carefully and with caution! 5.3.
INFORMATION Basically observe the following 5 safety rules when working on the HV network: Completely de-energize the system. Switch off the ignition Pull out service- / maintenance plug or switch off main battery switch Remove fuse Secure system against restarting. Keep ignition key secured against unauthorized access. Keep service- / maintenance plug secured against unauthorized access or secure main battery switch against restarting with lockable cover cap.
DANGER Strong magnetic field (non-ionizing radiation)! Effect on living beings! During the charging process there is a strong magnetic field between CPM and GPM, which exceeds the limits for long-term exposure of living beings. In order to exclude acute effects, such as muscle- and nerve stimulation, as well as consequential damage, no body parts may get into and around the space between the GPM and CPM during the charging process. In addition, jewelry (rings, wristwatches, etc.
5.4 Safety Equipment / Power Limitations The charging system has several safety functions in order to avoid personal injury and material damage during commissioning, operation and maintenance of the system.
An overcurrent protection is integrated in the CPM, which continuously protects the charging device from overload damage. Overcurrents are detected by the fast sensor system and, depending on the strength, are either reduced or lead to the shutdown of the charging process. 5.4.4 Thermal Overload Protection (Derating) This safety equipment is self-protection of the system.
Danger for persons due to magnetic field (non-ionizing radiation)! This function does not replace the attention of the user, to keep away from the charging station during the charging process! It can happen, that body parts or living beings are not detected by the LOD function and as a result the protection from electromagnetic hazards is restricted! The LOD function ensures, that body parts of people or animals are detected in the space between GPM and CPM.
5.4.9 Enabling the Positioning With this safety function it is ensured, that no electrical voltage is present on the HV-outputs of the CPM (see chapter 12.7.3), if the connections are not connected. Vice versa, voltage can only be present on the HVconnections of the CPM, if they are connected with a voltage source of 170 V (e.g. through connection to the vehicle drive battery). This prevents people getting an electric shock by touching the connections. 5.4.
5.5 Warnings 5.5.1 Warnings Warning signs are attached to the devices, which warn the operator of possible dangers. On the GPM there are warning notices and a rating plate on the underside. In addition, enclosed in the GPM service flap there is a rating plate as well as information about which types of cables are suitable for the connection of the power supply and which temperature resistance is required for these cables.
Figure 2: Warning notice (black/white) on GPM top side 6 Commissioning and Use of the ICS The commissioning of the ICS assumes, that there is a suitable electrical connection available. The CPM is mounted on the vehicle. The GPM is installed by the service of the vehicle manufacturer at the installation location. The steps necessary for this are described in the annex. After the installation of the GPM it is commissioned by the service and thereby its functionality is explained. 6.
have no influence on the long transport routes in some cases and the loading activities of our products.
WORK STEP ILLUSTRATION / OTHER INFO Connect the cable with the power connection. On the GPM the LED should not light up, in other words OFF, see 7.3.1.1. Make sure, that there are no foreign objects in the charging area. Switch the power supply for the GPM on and check the residual current device.
7 Control and Operation NOTICE The ICS has only one LED display, which signals important states of the GPM. Observe all safety instructions and warnings in the user manual without fail! 7.1 Use of the CPM and the GPM The charging process between GPM and CPM functions automatically and does not need to be controlled. Used on its own, the CPM executes no function; without the presence of the CPM the GPM merely only detects foreign objects and otherwise does not execute any function when used on its own.
WORK STEP ILLUSTRATION / OTHER INFO 1 Make sure, that the GPM is free of objects. Observe the instructions for keeping the GPM clean in chapter 8.1.2. 2 Position the CPM above the GPM or position Observe the instructions. Avoid damage to your vehicle due to positioning malfunctions. your vehicle with the help of the positioning function. On the GPM the LED should flash with the pattern according to 7.3.1.4.
on 0,25s 0,25s 0,25s off 0,25s 0,25s 4s Figure 4: Flashing pattern in status Initialization Foreign-/Living Object Detection In practice this initialization is carried out by making sure that there is no object lying on the GPM surface. Then place an approx. 5cm large piece of metal (e.g. 5cm large steel disk, beverage can, etc.) on the GPM and remove it again after 6-9sec.
7.3.1.5 Status: Charging / Energy Transmission If the vehicle (with CPM) is in the optimal parking position, then the charging process is started automatically. The energy transmission from GPM to the vehicle is signaled by means of LED with this flashing pattern. on 2,5s 2,5s 2,5s off 2,5s 2,5s 2,5s Figure 7: Flashing pattern in status Charging / Energy Transmission 7.3.1.6 Status: General Error With an error the LED flashes with this pattern. Attempt to rectify the error as described in 7.
If a foreign object is detected incorrectly, although the GPM surface is free, then a reset of the GPM is necessary, i.e. the GPM must be disconnected from the power supply until the LED goes out. After switching the GPM on again, a renewed initialization of the FOD is possibly necessary, see 7.3.1.2 Status: Initialization Foreign-/Living Object Detection. 7.3.1.8 Status: Cooling Fan Blocked The GPM is reliant on a sufficient circulation of air, in particular during the charging process.
7.6 Troubleshooting by the User For the following errors, limited troubleshooting can be undertaken by the user. The troubleshooting is to be undertaken as described in this chapter. The user is forbidden to undertake further troubleshooting that goes beyond the troubleshooting specified in this chapter. In the following, situations are described as can occur during the operation.
SITUATION TROUBLESHOOTING The vehicle (the drive battery) is 1. Check, whether the charging time for the complete charge of the battery was not completely charged. sufficient. (Is the charging process resumed when you resume the charging function?) 2. Check, whether the GPM and its immediate environment is free of foreign objects. If necessary clear it, taking into consideration the information specified in chapter 8.1.2.
NOTICE Apart from the cleaning in chapter 8.1.2 all maintenance measures may only be performed by specialists! Contact customer service to have measures carried out for the maintenance of the ICS! This way you avoid material damage to the ICS or the loss of the warranty. The ICS system consists of the components CPM and GPM. In the framework of the guarantee it is possible to have these two components inspected by specialists, if failure symptoms are evident. Contact customer service for this.
Manual clearing of the GPM surroundings Sweeping off the GPM Moist wiping of the GPM with a mild cleaning agent Cleaning the fan intake duct In particular the following measures should not be applied to keep the GPM clean: High-pressure cleaner, e.g. Kärcher (strong) chemical cleaning agent Road sweeper Snow plough 8.2 Behavior after a vehicle accident After an accident with the vehicle in which the CPM is installed, the CPM must be inspected for functionality by a specialist.
11 Legal Notices 11.1 Warranty For damage that occurs during proper intended use and despite observance of the safety instructions in this document, BRUSA provides a warranty for the ICS. The warranty is in accordance with the provisions in our currently valid General Terms and Conditions, which can be viewed at www.brusa.biz/support/agb.html. No warranty is provided for damage that can be traced back to improper use or non-observance of the safety instructions. 11.
12 Annex A1 12.1 Technical Specifications of the ICS 12.1.1 Emissions Table 1: Emissions PARAMETER Max. magnetic flux density between GPM and CPM Magnetic flux density of the GPM at vehicle limitation CHARACTERISTIC VALUE -3 7*10 UNIT T -6 4.6*10 T WLAN-Signal - Frequency 2.4 GHz - Max. transmit power 19 dBm 79 mW Positioning signal - Frequency s 125 kHz - Max. radiated magnetic field strength at 125 kHz 17.5 dBµA/m 12.1.2 Dimensions and Center of Gravity 12.1.2.
12.1.2.2 Center of Gravity GPM [mm] Intake duct 12.1.
12.1.
12.2 Technical Data BASIC DATA ICS VALUE UNIT Total weight approx. 52 kg Rated input voltage (single-phase L1/N) 200 – 240 VAC Rated input voltage (two-phase L1/L2) 100 – 120 VAC Rated input frequency 50 – 60 Hz Maximum input current 16 Arms Max. input power 3600 W Charging voltage 200 – 440 VDC 12 ADC Charging capacity 500 – 3200 W Energy transmission frequency 81.38 – 90 kHz Duration of a charging process Dependent on type of vehicle Max.
Maximum offset GPM to CPM in travel direction (x-direction) -75 75 mm Maximum offset GPM to CPM transverse to travel direction (y-direction) -150 150 mm 0 |x| + |y| < 175 mm mm Above specified applies, if This inductive charging system also functions outside these specified system limits, but with restricted efficiency and restricted transmission power.
12.2.3 Mechanical Data of the CPM PART OF THE SYSTEM CPM PHYSICAL SIZE [UNIT] Weight [kg] CHARACTERISTIC VALUE/(-RANGE) approx. 3 Dimensions [mm] 344 x 250 x 30 12.2.4 Mechanical Data of the GPM PART OF THE SYSTEM GPM PHYSICAL SIZE [UNIT] Weight [kg] CHARACTERISTIC VALUE/(-RANGE) approx. 49 Dimensions [mm] 930 x 800 x 62 12.3 Requirements on Specialist Personnel 12.3.
12.4.2 Protective Equipment during Installation During the installation the following protective equipment must be worn, to prevent possible injuries in the respective work steps: Installation: Safety shoes 12.4.3 Protective Equipment during Operation No protective equipment is required during the operation. 12.4.
Figure 12: Alignment of GPM to the CPM, as should be taken into consideration during the installation 1. For the alignment of the GPM to the CPM, at best proceed as follows: During the installation of the GPM (Ground Pad Module) the vehicle must be present. 2. Establish exactly the required parking position, at which the vehicle should later be charged. a. Park the vehicle in the intended position, so that the charging later in this position is ensured. 3.
Figure 14: Recommendation for cable laying (blue) with desired forward parking 12.5.4 Optional Installation of the GPM with Mounting Rails Optionally the GPM can be fixed against shifting with the help of mounting rails. This prevents the GPM from shifting. Figure 15: Bottom of the GPM with mounting rails (blue). The right-hand rail snaps into recesses of the GPM-housing. The left-hand rail (on the cable bushing) is screwed tight at the side of the service cover.
Figure 16: View of GPM with mounting rails.
1. For the mounting rails 8 mm diameter holes are drilled according to the drilling template (see Figure 17: Drilling template for GPM mounting rail). 2. The rails are then fastened to the floor with the help of the plastic frame plugs 0912 808 602. The screws must be screwed in flush. (see data sheet in the annex) 3. The GPM is then pushed into the rear rail. To do this hold the GPM a little inclined. The rear rail disappears under the ground frame. Check whether the rail engages in the GPM.
Figure 18: Service flap with LED - View Figure 19: Connection of a cable to the cage clamp in the service flap Operation Manual Inductive Charging System ICS115 51
12.5.7 Planning the Assembly and Installation of the ICS Planning the assembly and installation of the CPM, see Annex 12.7.4. 12.5.7.1 Planning the Installation of the GPM WORK STEP ILLUSTRATION / OTHER INFO 1 Determine the installation position of the GPM.
WORK STEP ILLUSTRATION / OTHER INFO 1 Ensure cautious and careful handling of the ICS (possibly in packaging) during the preparation for transport or storage. 2 For transport or storage, place the ICS on a level surface. 3 Ensure cautious and careful handling of Note the total weight of approx. 52 kg for the ICS. Avoid impacts on the ICS. Ensure compliance with the conditions in chapter 12.2.1 for storage or transport of the ICS. Note the weight of the ICS. Avoid impacts on the ICS.
WORK STEP 4 Transport: Transport the GPM, so that you ILLUSTRATION / OTHER INFO Note the weight and center of gravity of the GPM. can move comfortably. As a result you avoid posture injuries. Use auxiliary equipment to protect the transport, such as handcart and lashing straps. 5 Setting down: Place the GPM (possibly in packaging) on a level surface. Ensure compliance with the conditions in chapter 12.5.8 for storage or transport of the GPM.
WORK STEP 6 Clear the charging system of tools and auxiliary equipment that was used during the assembly and installation. ILLUSTRATION / OTHER INFO Do not forget any utensils, that you have required for the assembly and installation of the CPM. Do not leave any waste behind (packaging material) with the user of the ICS. 7 Dispose of the GPM taking into consideration the instructions for the disposal of electrical devices in chapter 10.1. 12.7 Vehicle Integration of the CPM 12.7.
1 1 1 12.7.
1. 3. Ground screws GND for screws M6 HV-connector (Code A) 2. 4. LV-connector vehicle 12-pin (Code B) HV-connector (Code B) 12.7.3.1 Ground GND INFORMATION The ground screw must be connected with the ground of the vehicle or the test stand. We generally recommend to route the ground lines of all drive components together at one ground point.
12.7.3.2 Pin-Assignment LV-Connector Vehicle 12-pin (Code B, device-side) 1. Kl30 +12 V (supply system Plus) 2. EV_CAN_H EV CAN high 3. Kl30C Kl30 Crash 4. HVIL_out HV-Interlock loop output 5. --- Not contacted 6. --- Not contacted 7. Kl31 Ground (supply system Minus) 8. EV_CAN_L EV CAN low 9. HVIL_in HV-Interlock loop input 11 Debug_CAN_H Debug CAN high 58 10. --- Not contacted 12.
12.7.3.3 Pin Assignment HV-Connector (Code A) 3 2 1 4 5 1. HV_DC_+ HV Battery Plus 2. HV_DC_- HV Battery Minus 3. HVIL_in HV-Interlock Loop Input 4. HVIL_out HV-Interlock Loop Output 5. GND Housing (equipotential bonding) 12.7.3.4 Pin Assignment HV-Connector (Code B) 3 2 1 4 5 1. HV_DC_+ HV Battery Plus 2. HV_DC_- HV Battery Minus 3. HVIL_in HV-Interlock Loop Input 4. HVIL_out HV-Interlock Loop Output 5.
12.7.4 Planning the Assembly and Installation of the CPM CAUTION Installation of the CPM requires a vehicle with insulation monitor The CPM may only be installed in vehicles with an insulation monitor. In the CPM the HVDC live parts are basic insulated against SELV (Safety Extra Low Voltage). As error protection the IT-network of the vehicle traction circuit is used. If the insulation monitor detects a failure of the insulation, a connection of the HV-battery should be prevented.
WORK STEP ILLUSTRATION / OTHER INFO 1 Preparation: Determine, whether a cautious and careful handling of the CPM Make sure, that routes for the manual transport are free (no (possibly in packaging) is possible. You tripping hazards) and provide sufficient space! thereby avoid transport damage to the CPM. 2 Lifting: Lift the CPM taking into consideration the weight, the dimensions and the center of gravity. 3 Handling and Transport: Make sure, that you can safely hold the CPM while working.
WORK STEP ILLUSTRATION / OTHER INFO 1 Separate the CPM from the rest of the packaging material. Remove the film from the heat conducting pad. Remove the CPM carefully from the packaging. Make sure not to damage the CPM. Do not wear any jewelry during the installation. 2 Follow the installation instructions of the CPM for the target vehicle of the respective vehicle manufacturer. 3 Install the CPM mechanically at the intended location. For the installation use Observe the installation instructions (e.g.
WORK STEP ILLUSTRATION / OTHER INFO 1 Ensure for a safe working environment during the deinstallation. If the CPM is hot, wait until it has cooled down. Make sure, that no sources of danger can occur during the deinstallation (e.g. crushing due to the vehicle rolling away). Do not wear any jewelry during the deinstallation. Danger of injury with hot CPM. 2 Interrupt the CPM Interlock. 3 Follow the instructions for the removal of the CPM for the intended vehicle of the respective vehicle manufacturer.
13 Annex A2 13.
NO REQUIREMENT 14 IEC 61980-1:2015 CONTENT Electric vehicle wireless power transfer (WPT) systems - Part 1: General requirements 15 ICNIRP 1998 Directives for the limitation of the exposure due to time-varying electric, magnetic and electromagnetic fields (up to 300 GHz) 16 EN 50581:2012 Assessment of electrical and electronic products with respect to the restriction of hazardous substances 13.2 DECLARATIONS OF CONFORMITY 13.2.
14 Index Abbreviations, 7 Foreword, 8 Alignment GPM, 43 Functionality, 13 Center of Gravity Functionality CPM, 39 LOD, 22 GPM, 38 Functionality Cleaning, 35 FOD, 22 Cleanliness Functionality CPM, 35 GPM, 35 Connections CPM, 51 Contact Customer Service, 10 Efficiency Control, 23 Imprint, 2 Installation CPM, 56 Installation and Commissioning GPM, 26 Manufacturer, 10 Installation information, 42, 50 Service, 10 Maintenance, 34 Deinstallation, 36 Mounting Rails GPM, 44 CPM, 57 Position
Storage CPM, 55 ICS, 40 Transport GPM, 49 CPM, 55 Support, 10 GPM, 49 Technical Data Troubleshooting CPM, 41 by User, 33 Energy Supply, 14 Warranty, 36 GPM, 41 Operation Manual Inductive Charging System ICS115 67
15 Glossary Derating Reduction of the charging capacity. Protective function of the system when limits are exceeded, e.g. temperature limits. Electromagnetic Field Physical effect, during which electrically conductive objects situated within the field heat up and therefore can cause dangers for people (e.g. burning, fire).
