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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

CH–9466 Sennwald

+41 81 758 19 00

www.brusa.biz

Summary of Contents for ICS115

Page 1: ...DUCTIVE 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 Neudo...

Page 2: ...f our products we reserve the right to make constructional changes Any changes will be notified in the individual manuals through exchange of the relevant pages or revision of the electronic data carr...

Page 3: ...tion of the ICS 12 4 1 Scope of Application 12 4 1 1 User Description 12 4 1 2 Health Hazards 12 4 1 3 Proper Intended Use 13 4 1 4 Proper Intended Application 13 4 1 5 Improper Use 13 4 1 6 Delimitat...

Page 4: ...matic Shutdown of the Charging Operation 25 5 5 Warnings 26 5 5 1 Warnings 26 6 Commissioning and Use of the ICS 27 6 1 Installation of the GPM and Commissioning 27 7 Control and Operation 30 7 1 Use...

Page 5: ...rmation about Protective Equipment 45 12 4 1 Protective Equipment during Transport and Storage 45 12 4 2 Protective Equipment during Installation 46 12 4 3 Protective Equipment during Operation 46 12...

Page 6: ...ly and Installation of the CPM 60 12 7 5 Transport and Storage of the CPM 60 12 7 6 Installation of the CPM 61 12 7 7 Deinstallation of the CPM 62 13 Annex A2 64 13 1 Standards and Legal Requirements...

Page 7: ...oltage CPM Car Pad Module OEM Original Equipment Manufacturer DC Direct Current P W Power P in Watt W EMC ElectroMagnetic Compatibility R Electrical Resistance in the unit Ohm f Hz Frequency f in Hert...

Page 8: ...rder to continuously ensure the function of the system The customer package contains the following registers Inductive charging system ICS consisting of Ground Pad Module GPM and Car Pad Module CPM Us...

Page 9: ...owing table ICS1 WITH THE FOLLOWING DEVICE DESIGNATIONS ICSP11W U0 01X Xxx GPM ICSS115 U0 01X Xxx CPM 2 HV Connectors 3 2 Explanation of the code for the product identification The breakdown of the de...

Page 10: ...OF INQUIRY COUNTRIES CONTACT DATA Delivery Help and Support Deinstallation and Disposal D A CH BMW Customer Support D 80788 Munich Germany Tel 49 89 1250 16000 kundenbetreuung bmw de Operation Manual...

Page 11: ...ing items are included in the scope of supply of the ICS system DESCRIPTION QUANTITY ILLUSTRATION 1 Ground Pad Module GPM 1 2 Car Pad Module CPM 1 3 Original Operation Manual 1 11 Operation Manual Ind...

Page 12: ...act with the ICS are knowledgeable of and familiar with the safety instructions in this user manual The user must indicate possible hazards due to the ICS to other persons He must thereby ensure that...

Page 13: ...s 4 1 5 Improper Use All applications that are not included in the intended use described by the manufacturer in 4 1 4 are to be regarded as improper use The device must not be used in particular for...

Page 14: ...the power supply network which transmits the energy to the Car Pad Module CPM integrated in the vehicle by means of magnetic induction The communication between GPM and CPM is automated and takes plac...

Page 15: ...ICS has a fan which causes a noise level during operation No hazardous chemical substances are emitted The transmission of energy of the ICS as well as the positioning functionality are based on the...

Page 16: ...ng tables PROHIBITORY SIGNS SYMBOL DESCRIPTION SYMBOL DESCRIPTION General prohibition Attention high voltage Touching prohibited Switching prohibited No access for people with cardiac pacemakers or im...

Page 17: ...ger Levels DANGER This sign warns of serious irreversible risks of injury with possible fatal consequences Avoid this danger by observing this notice WARNING This sign warns of a serious but reversibl...

Page 18: ...INFORMATION This type of notice is used to communicate important information for the reader Operation Manual Inductive Charging System ICS115 18...

Page 19: ...and with caution 5 3 2 Safety Instructions for Electrical Hazards DANGER High Voltage Danger to life Do not touch HV lines or HV connections under any circumstances without ensuring zero voltage befor...

Page 20: ...f the device is damaged it is possible that live components are exposed People can come into contact with these components It is therefore absolutely imperative to operate the GPM via a separate resid...

Page 21: ...ecified in chapter 3 3 NOTICE Damage to the devices Regularly check the GPM for defects and report defects or damage to your customer service A visibly damaged GPM must be replaced in order to exclude...

Page 22: ...erload damage Overvoltages in the mains are detected by the fast sensor system and lead to the shutdown of the device An overvoltage protection is also integrated at the output side By means of the fa...

Page 23: ...he CPM and the GPM notify their respective Derating Status in the CAN as well as the capacity reduction as percentage When the CPM goes into derating the GPM reduces the transmission power If the meas...

Page 24: ...the charging process Electrically conducting objects are relevant as they can experience heating through electromagnetic induction in the electromagnetic field This function stops the charging proces...

Page 25: ...ing charging Overvoltage on the CPM HVDC connector 450 V or greater than the specified maximum value Undervoltage on the CPM HVDC connector 170 V Separation of the Interlock circuit Missing CAN comman...

Page 26: ...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 If one of these warning signs is mi...

Page 27: ...icular with the LED flashing patterns NOTICE The installation of the GPM may only be carried out by a qualified electrician In particular country specific regulations for electrical lines and installa...

Page 28: ...al current device RCD Type A Customary local mains cable of sufficient length with at least 1 5 mm 2 line cross section Floor mounted ducting resistant against being run over for the protection of the...

Page 29: ...follows 1 In the vehicle display a list of all GPMs in the reception range of the CPM is displayed 2 The required GPM is selected 3 The password for the selected GPM is entered Once this step is succ...

Page 30: ...e to the vehicle A faulty positioning display or incorrect position of the GPM e g due to the GPM shifting on the ground can lead to damage to your vehicle during the parking process Therefore always...

Page 31: ...r states 7 3 1 1 Status Off The GPM is without power or defective After unpacking the GPM the LEDs are off Likewise after installation before the circuit breaker has been switched on If the LEDs remai...

Page 32: ...tatus Not Connected The GPM is in this status when the power supply for the GPM has been switched on the initialization of the foreign living object detection has already been performed but there is n...

Page 33: ...n Attempt to rectify the error as described in 7 6 Troubleshooting by the User off on 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25s Figure 8 Flashing pattern in status...

Page 34: ...n Please treat the fan with care and observe the instructions for cleaning see section 8 1 Cleanliness In particular clean the fan intake duct regularly Do not use any high pressure cleaner such as e...

Page 35: ...her the power supply for the GPM has been interrupted by electrical safety devices If so re establish the power supply for the GPM by switching on the electrical safety device 4 Check whether the WLAN...

Page 36: ...the drive battery was discharged again 2 If the error still occurs contact customer service The ICS System can no longer be used it is switched off 1 Check whether the GPM can be supplied with power F...

Page 37: ...ave to be replaced the descriptions for the preparation of the ICS for use or for deinstallation in chapter 6 resp 9 are to be observed for the removal of the old components and the installation of th...

Page 38: ...ge or dangers for nature and the environment The deinstallation of the GPM is described in chapter 12 7 7 10 Disposal The disposal of the ICS is carried out by customer service after the deinstallatio...

Page 39: ...s 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 2 Comp...

Page 40: ...nd CPM 7 10 3 T Magnetic flux density of the GPM at vehicle limitation 4 6 10 6 T WLAN Signal Frequency 2 4 GHz Max transmit power 19 dBm 79 mW Positioning signal Frequency s Max radiated magnetic fie...

Page 41: ...ter of Gravity GPM mm 12 1 3 Dimensions CPM mm Intake duct fan Figure 11 Center of gravity of GPM with fan intake duct Service flap with mains cable connection 41 Operation Manual Inductive Charging S...

Page 42: ...12 1 4 Center of Gravity CPM mm Operation Manual Inductive Charging System ICS115 42...

Page 43: ...transmission frequency 81 38 90 kHz Duration of a charging process Dependent on type of vehicle Transmission frequency WLAN ISM Band 2 412 2 462 GHz Max transmit power WLAN 100 mW Transmission frequen...

Page 44: ...sport 70 12 2 2 Conditions for Operation of the ICS ICS UNIT LV wiring system CPM 9 16 VDC Max LV wiring system voltage CPM device destruction 27 VDC LV current consumption CPM 0 2 2 ADC LV current co...

Page 45: ...the installation instructions and recognize any dangers 12 3 2 Health related Requirements WARNING Risk of injury due to electromagnetic field During inductive charging an electromagnetic field is gen...

Page 46: ...r 12 7 2 The manufacturer is not liable for damage that results from the faulty integration of the CPM in the target vehicle of the vehicle manufacturer 12 5 2 Placement of the GPM The GPM is placed f...

Page 47: ...ehicle in the intended position so that the charging later in this position is ensured 3 Mark the planned position on the floor according to the positioning sketch This step decides about the function...

Page 48: ...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 G...

Page 49: ...Figure 16 View of GPM with mounting rails Figure 17 Drilling template for GPM mounting rail Proceed as follows 49 Operation Manual Inductive Charging System ICS115...

Page 50: ...he fixed connection variant is not chosen a suitable country specific connector with a minimum current carrying capacity of 16A must be selected and connected Table 2 Assignment Mains Connection Cable...

Page 51: ...Figure 18 Service flap with LED View Figure 19 Connection of a cable to the cage clamp in the service flap 51 Operation Manual Inductive Charging System ICS115...

Page 52: ...ect installation Make sure that the space requirement for the installation is covered Note the use of the respective auxiliary material that is required for the GPM during the installation see install...

Page 53: ...es and protective gloves as protective equipment for handling the GPM Use a handcart and lashing straps as auxiliary equipment for the transport of the GPM WORK STEP ILLUSTRATION OTHER INFO 1 Preparat...

Page 54: ...nt may only be performed by specialist personnel Contact customer service 12 6 1 Procedure for the Deinstallation of the GPM Information for Customer Service WORK STEP ILLUSTRATION OTHER INFO 1 Ensure...

Page 55: ...in chapter 10 1 12 7 Vehicle Integration of the CPM 12 7 1 Installation Information The electrical mechanical and thermal integration of the CPM is to be ensured by the vehicle manufacturer 12 7 2 Mo...

Page 56: ...12 7 3 Line Connections CPM 1 4 3 2 1 1 1 1 1 1 Operation Manual Inductive Charging System ICS115 56...

Page 57: ...nd of the vehicle or the test stand We generally recommend to route the ground lines of all drive components together at one ground point This minimizes the risk of potential differences which can lea...

Page 58: ...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 10 Not contac...

Page 59: ...ut HV Interlock Loop Output 5 GND Housing equipotential bonding 12 7 3 4 Pin Assignment HV Connector Code B 1 HV_DC_ HV Battery Plus 2 HV_DC_ HV Battery Minus 3 HVIL_in HV Interlock Loop Input 4 HVIL_...

Page 60: ...e vehicle for that work step determined at 2 Take into consideration the ordering and delivery times 4 Ensure the availability of the connections in the vehicle required for the CPM Note the mechanica...

Page 61: ...5 Storage Store the CPM possibly in packaging horizontal on a level surface Place the base area of the CPM possibly in packaging completely on the storage surface Avoid damage to the CPM due to incor...

Page 62: ...rcuit of the intended vehicle or with the air conditioning compressor of the intended vehicle The connections for the respective HV connector are to be connected color matched black and white The HV c...

Page 63: ...g 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...

Page 64: ...eband transmission systems Data transmission equipment operating in the 2 4 GHz ISM band and using wide band modulation techniques 8 EN 300 330 V2 1 1 Electromagnetic Compatibility and Radio Spectrum...

Page 65: ...EU DECLARATION OF CONFORMITY ICS115 BRUSA Elektronik AG herewith declares that the radio equipment type ICS115 conforms to the directive 2014 53 EU The complete text of the EU Declaration of Conformit...

Page 66: ...Emergency situations 32 Energy Efficiency 14 Foreword 8 Functionality 13 Functionality LOD 22 Functionality FOD 22 Functionality Efficiency Control 23 Imprint 2 Installation CPM 56 Installation and C...

Page 67: ...torage CPM 55 GPM 49 Support 10 Technical Data CPM 41 Energy Supply 14 GPM 41 ICS 40 Transport CPM 55 GPM 49 Troubleshooting by User 33 Warranty 36 67 Operation Manual Inductive Charging System ICS115...

Page 68: ...eld Physical effect during which electrically conductive objects situated within the field heat up and therefore can cause dangers for people e g burning fire Electromagnetic Induction Physical effect...

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