Brusa ICS115 User manual

OPERATION MANUAL
INDUCTIVE CHARGING S
YSTEM 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
[phone]
www.brusa.biz

IMPRINT
Title
O
PERATION 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
[e-mail]
Managing Director: Josef Brusa
Valid for
ICS115 (2017)
Edition
1st
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
The copyright of this document lies with BRUSA Elektronik AG. The content of this document must
not be passed on to third parties
– even in extracts – without the written authorization of BRUSA
Elektronik AG. All technical
specifications, drawings and photos used are protected by copyright.
The violation of the copyrights represents a criminal offence!
Updates
Due to the technical further development of 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 carrier.
Writing style
For reasons of better readability, the simultaneous use of feminine and masculine linguistic forms is
disp
ensed with. All personal designations are always applicable for both genders.
Creator / Author
Pirmin Bader, Sina Kaufmann, Josef Olliges
REVISION INDEX
REVISION DATE NAME CHANGE
1.0 07.02.2017 Pirmin Bader Technical documentation based on the B3 prototype stage
2.0
24.02.2017
Sina Kaufmann
Redesign of the documentation
3.0
11.04.2017
Josef Olliges
Integration of review comments
4 03.05.2017 Josef Olliges Integration of review comments BMW, notes from risk
analysis
5 18.07.2017 Josef Olliges Review comments Daimler, BMW integrated
6
30.10.2017
Josef Olliges
Review comments Zollner integrated, Update GPM-B4
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Inductive Charging System
ICS115
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7 15.02.2018 Josef Olliges Review comments Approval
TABLE OF CONTENTS
1List of Abbreviations.......................................................................................................................7
2Foreword..........................................................................................................................................8
2.1 Content and Scope of this Manual..............................................................................................8
2.2 Requirements for handling the User Manual...............................................................................8
3Identification of the Product ICS....................................................................................................9
3.1 Product Identification..................................................................................................................9
3.2 Explanation of the code for the product identification..................................................................9
3.3 Service- and Contact Data .......................................................................................................10
3.4 Scope of Supply.......................................................................................................................11
4Product Description 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 Delimitation .......................................................................................................................14
4.2 Functionality.............................................................................................................................14
4.2.1 Energy Efficiency ..............................................................................................................15
4.3 Requirements of the ICS..........................................................................................................15
4.4 Emissions.................................................................................................................................15
4.5 Electromagnetic Compatibility ..................................................................................................15
5Safety and Warning Signs ............................................................................................................16
5.1 Symbols and their Meaning......................................................................................................16
5.2 Safety Instructions and Danger Levels.....................................................................................17
5.3 Generally Applicable Safety Instructions ..................................................................................19
5.3.1 Safety Instructions for Thermal Hazards............................................................................19
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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......................................................................................................22
5.4.2 Mains Protection Input Current..........................................................................................22
5.4.3 Overcurrent Protection......................................................................................................22
5.4.4 Thermal Overload Protection (Derating)............................................................................23
5.4.5 HV Interlock.......................................................................................................................23
5.4.6 Living Object Detection (LOD)...........................................................................................23
5.4.7 Foreign Object Detection (FOD)........................................................................................24
5.4.8 Control of the Efficiency ....................................................................................................24
5.4.9 Enabling the Positioning....................................................................................................25
5.4.10 Automatic Shutdown of the Charging Operation............................................................25
5.5 Warnings..................................................................................................................................26
5.5.1 Warnings...........................................................................................................................26
6Commissioning and Use of the ICS.............................................................................................27
6.1 Installation of the GPM and Commissioning.............................................................................27
7Control and Operation ..................................................................................................................30
7.1 Use of the CPM and the GPM..................................................................................................30
7.2 Use of the Charging Function of the ICS..................................................................................30
7.3 Displays and Signals................................................................................................................31
7.3.1 LED Display ......................................................................................................................31
7.4 GPM Cooling System Fan........................................................................................................34
7.5 Emergency Situations ..............................................................................................................34
7.6 Troubleshooting by the User ....................................................................................................35
8Maintenance ..................................................................................................................................36
8.1 Cleanliness...............................................................................................................................37
8.1.1 Cleanliness of the CPM.....................................................................................................37
8.1.2 Cleanliness of the GPM.....................................................................................................37
8.2 Behavior after a vehicle accident..............................................................................................38
9Deinstallation.................................................................................................................................38
10 Disposal......................................................................................................................................38
10.1 Notes for Customer Service..................................................................................................38
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11 Legal Notices .............................................................................................................................39
11.1 Warranty...............................................................................................................................39
11.2 Company Names..................................................................................................................39
12 Annex A1....................................................................................................................................40
12.1 Technical Specifications of the ICS.......................................................................................40
12.1.1 Emissions......................................................................................................................40
12.1.2 Dimensions and Center of Gravity .................................................................................40
12.1.3 Dimensions CPM [mm]....................................................................................................1
12.1.4 Center of Gravity CPM [mm]..........................................................................................42
12.2 Technical Data......................................................................................................................43
12.2.1 Conditions for Storage and Transport of the ICS ...........................................................44
12.2.2 Conditions for Operation of the ICS...............................................................................44
12.2.3 Mechanical Data of the CPM .........................................................................................45
12.2.4 Mechanical Data of the GPM.........................................................................................45
12.3 Requirements on Specialist Personnel .................................................................................45
12.3.1 Specialist Requirements................................................................................................45
12.3.2 Health-related Requirements.........................................................................................45
12.4 Information 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
12.4.4 Protective Equipment during Disposal / Deinstallation ...................................................46
12.5 Preparation of the ICS for Use..............................................................................................46
12.5.1 Installation Information...................................................................................................46
12.5.2 Placement of the GPM...................................................................................................46
12.5.3 Alignment of GPM to CPM.............................................................................................46
12.5.4 Optional Installation of the GPM with Mounting Rails.....................................................48
12.5.5 Line Connections CPM..................................................................................................50
12.5.6 Line Connections GPM..................................................................................................50
12.5.7 Planning the Assembly and Installation of the ICS.........................................................52
Planning the assembly and installation of the CPM, see Annex 12.7.4............................................52
12.5.8 Transport and Storage...................................................................................................52
12.6 Deinstallation of the GPM .....................................................................................................54
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12.6.1 Procedure for the Deinstallation of the GPM (Information for Customer Service):..........54
12.7 Vehicle Integration of the CPM .............................................................................................55
12.7.1 Installation Information...................................................................................................55
12.7.2 Mounting the CPM.........................................................................................................55
12.7.3 Line Connections CPM..................................................................................................56
12.7.4 Planning the Assembly 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......................................................................................64
13.2 DECLARATIONS OF CONFORMITY...................................................................................65
13.2.1 SIMPLIFIED EU-DECLARATION OF CONFORMITY ICS115.......................................65
13.2.2 SIMPLIFIED EU-DECLARATION OF CONFORMITY ICS1-WLAN-ATWILC-MU-D.......65
14 Index...........................................................................................................................................66
15 Glossary.....................................................................................................................................68
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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. DESCRIPTION
AC
Alternating Current
ICSP
ICS Primary (GPM)
B [T]
Magnetic flux density B in Tesla T
ICSS
ICS Secondary (CPM)
C [F]
Electrical capacity C in Farad F
LOD
Living Object Detection
CAN
Controller Area Network
LV
Low Voltage
CPM
Car Pad Module
OEM
Original Equipment Manufacturer
DC
Direct Current
P [W]
Power P in Watt W
EMC
ElectroMagnetic Compatibility
R [Ω]
Electrical Resistance in the unit Ohm Ω
f [Hz]
Frequency f in Hertz Hz
RCD
Residual Current Device
FOD Foreign Object Detection s [m] Distance s in Meter m
FW
Firmware
SSID
Service Set IDentifier
GPM
Ground Pad Module
SW
Software
HV
High Voltage
t [s]
Time t in second s
I [A]
Electrical Current Intensity I in Ampere A
T [°C]
Temperature T in degrees Celsius °C
ICS
Inductive Charging System (CPM+GPM)
U [V]
Electrical voltage U in Volt V
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2 Foreword
Valued Customer!
With the BRUSA Inductive Charging System Model ICS115 you have purchased an inductive charging system with
the latest technology. Model ICS115 is an inductive charging system of the 1st Generation for vehicles with high-
voltage battery, which is subsequently abbreviated to ICS. Since it concerns high-performance electronics devices,
we expect particular caution when dealing with it as well as when handling it!
Read through this manual carefully – in particular the chapter entitled Safety and Warning Signs – before you
install the device or perform other work on it!
2.1 Content and Scope of this Manual
This documentation conveys to the reader an overview of all the work steps required for the installation as well as
operation of the system and the safety measures necessary for this.
The specified operation- and safety instructions must be observed precisely, in order 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)
User manual
2.2 Requirements for handling the User Manual
The user manual must be read and understood by all persons who work with or use the ICS.
All safety instructions at the beginning of a chapter are valid in equal measure for all subsequent and associated
subchapters following the chapter.
As user and also as customer service of the ICS, familiarize yourself with the user manual, so that you have fast
access to required information. Keep the user manual safe for later reference. Select an appropriate storage
location, so that the user manual is ready to hand and easy to find.
INFORMATION
In order to successfully commission the system, you require this user manual.
The completeness
and topicality is ensured with provision of the customer package. Updates of individual documents
are performed automatically and are visible in a history.
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Inductive Charging System
ICS115
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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)
3.2 Explanation of the code for the product identification
The breakdown of the device designation for the complete system, the GPM and the CPM, is as follows:
GPM:
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CPM:
3.3 Service- and Contact Data
TYPE OF INQUIRY COUNTRIES CONTACT DATA
Delivery
Help and Support
Deinstallation and Disposal
D, A, CH
BMW Customer Support
D–80788 Munich
Germany
Tel: [phone]
[e-mail]
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Inductive Charging System
ICS115
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