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
Operation Manual
Inductive Charging System
ICS115
2

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
3
Operation Manual
Inductive Charging System
ICS115

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
Operation Manual
Inductive Charging System
ICS115
4

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
5
Operation Manual
Inductive Charging System
ICS115

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
Operation Manual
Inductive Charging System
ICS115
6

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
7
Operation Manual
Inductive Charging System
ICS115

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.
Operation Manual
Inductive Charging System
ICS115
8

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:
9
Operation Manual
Inductive Charging System
ICS115

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]
Operation Manual
Inductive Charging System
ICS115
10

3.4 Scope of Supply
The following 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
Inductive Charging System
ICS115

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.
4.1.1 User Description
The user group of the system ICS includes all persons who are able to operate a vehicle. The user of the system is
responsible for the observance of and compliance with the safety instructions contained in this user manual. The
user is also responsible, that persons in his environment, in particular all persons who come into contact 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 individual, particularly endangered
persons, e.g. children and disabled persons, have understood the safety instructions – or on the other hand
ensure, that access to the ICS is not possible for these persons.
All activities that concern the installation, commissioning and deinstallation / disposal of the ICS may only be
performed by specialist personnel. The specialist personnel or qualified electricians must satisfy the specialist
requirements specified in chapter 12.3.
4.1.2 Health Hazards
WARNING
Risk of injury from electromagnetic field!
With inductive charging an electromagnetic field is generated under the vehicle.
Cardiac pacemakers and medical implants can be affected.
Do not reach underneath the vehicle or perform maintenance work during the charging process.
Operation Manual
Inductive Charging System
ICS115
12

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)
4.1.3 Proper Intended Use
It is not permitted to use the products in any way other than the intended way described in section 4.1.4.
4.1.4 Proper Intended Application
The ICS is a system for the cordless transmission of energy and is designed to be integrated in an electric or hybrid
vehicle with high-voltage battery. The product ICS is designed exclusively for use under consideration of the limits
specified in chapter 12.2.1 and 12.2.2.
With a planned use in areas other than those previously defined, the purchaser shall be obliged to coordinate this
accordingly in advance with the manufacturer and obtain a written release for this.
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 charging vehicles that do not use the ICS as charging function
for charging accumulators / batteries of devices, that are also based on an inductive charging function, e.g.
electric toothbrushes, Smartphones
to replace the function of an induction hob, e.g. heating meals by using pots / bowls / grilling appliances
for drying objects (e.g. skiing equipment) or living things (e.g. pets)
for the use for functions other than the function of charging, e.g. as seating surface or for sports activities,
such as skateboarding.
The following areas must not be used as charging station, i.e. for the installation of the GPM:
public parking places and parking lots
Under consideration of the proper intended uses specified in chapter 4.1.4,limits have been defined for the
storage, transport and operation of the ICS product, see chapter 12.2.1 and 12.2.2.The product must not be used
outside these limits within the respective life phases. Modification of products.
It is not permitted to undertake modifications to the product and then continue to use the product.
13
Operation Manual
Inductive Charging System
ICS115

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. 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 by
means of magnetic induction. The communication between GPM and CPM is automated and takes place via
WLAN.
Basically the charging process takes place in these steps:
•The vehicle parks over the GPM with the help of the positioning function with optimal coverage between
GPM and CPM.
•The charging process is started automatically from the vehicle and also ended automatically.
•After the charging process the battery is charged according to the charging time and the charging
efficiency. The vehicle is ready to use.
Operation Manual
Inductive Charging System
ICS115
14

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.
4.3 Requirements of the ICS
The CPM is maintenance-free and does not require any supply materials, such as coolant, lubricants, etc. For the
cooling of the GPM, air circulation is a prerequisite, in particular during the charging process. Regular cleaning of
the fan intake duct and keeping the GPM clean extends the service life of the charging system, see chapter 8.1.2.
4.4 Emissions
The 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 principle of magnetic
induction. In addition WLAN is used for the communication between the two components CPM and GPM.
Associated with this are emissions due to electromagnetic radiation. The characteristic values of these emissions
are to be taken from Table 1: Emissions.
4.5 Electromagnetic Compatibility
The ICS system meets the requirements on the electromagnetic environmental compatibility without constraints,
see No. 11 – 15, 22 in Table 3: Standards. Normally no disturbances that unacceptably impair the functionality of
other electrical operating equipment are caused through the use of the ICS. Nevertheless, a disturbance of Comfort
Access Systems of adjacent vehicles cannot be excluded, since both systems are based on the use of WLAN.
15
Operation Manual
Inductive Charging System
ICS115

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. An overview as well as their meanings can be found in the
following tables:
PROHIBITORY SIGNS
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
General prohibition
Attention high voltage
Touching prohibited
Switching prohibited
No access for people with cardiac
pacemakers or implanted defibrillators.
WARNING SIGNS
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
General warning of a hazard point
Warning of electric shock
Warning of potentially explosive
environment
Warning of dangers from batteries
Warning of hot surface Warning of high electric voltage
Warning of non-ionizing radiation
Warning of the risk of fire
Warning of magnetic field Warning of hot surfaces
Operation Manual
Inductive Charging System
ICS115
16

MANDATORY SIGNS
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
Disconnect device
Disconnect device from the mains
Wear safety glasses
Wear protective gloves
INFORMATION SIGNS
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
Important information for the avoidance of
possible material damage
Important Information
5.2 Safety Instructions and Danger 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 reversible risk of injury!
Avoid this danger by observing this notice!
CAUTION
This sign warns of a minor risk of injury!
Avoid this danger by observing this notice!
NOTICE
This notice warns of possible material damage, if the following instructions and work sequences are
not observed.
17
Operation Manual
Inductive Charging System
ICS115

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

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!
5.3.2 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
beforehand!
The device may only be connected by a qualified electrician!
Do not bridge or bypass safety equipment under any circumstances! Resulting malfunctions can have
life
-threatening consequences!
CAUTION
Overheating the cable!
Risk of fire!
Mains connection cables must not be operated coiled up. In the coiled up state the cable can ignite
due to a build
-up of heat! Therefore basically uncoil the mains connection cable completely!
19
Operation Manual
Inductive Charging System
ICS115

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.
Establish zero voltage with suitable volta
ge tester (observe voltage range!)
Ground and short
-circuit system.
Cover or cordon off adjacent live parts.
5.3.3 Safety Instructions for Handling and Operation
DANGER
Danger of electric shock!
In the operating state the ICS is subjected to high voltages and currents. If 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 residual current device (RCD),
which monitors exclusively the function of the GPM.
WARNING
Heating of foreign objects during the inductive transmission of energy!
Risk of fire!
Electrically conducting objects inside the charging magnetic field can heat up considerably, and under
certain circumstances can lead to damage / ignition of other materials. Therefore during the charging
process
there must be no objects between CPM and GPM.
WARNING
GPM Magnetic Field!
Danger for living beings and objects!
No person must connect a GPM to the power supply without knowing the safety
- and warning signs.
A GPM may only be connected to the power supply, when all persons who are
working near the GPM
are aware of the potential dangers.
Operation Manual
Inductive Charging System
ICS115
20