Delta MOOVair Bedienungsanleitung

Wireless Power

Transfer

Battery

Charging

Industrial

1 kW Wireless Charging System

MOOV air

User Manual and Professional

Installation Guide

1 About this document............................................................................................................................... 4

1.1 Purpose of this document ........................................................................................................................ 4

1.2 Target audience ....................................................................................................................................... 4

1.3 Products covered ..................................................................................................................................... 4

1.4 Warning notices and warning symbols..................................................................................................... 4

1.4.1 Warning levels.......................................................................................................................................... 4

2 General safety instructions .................................................................................................................... 5

2.1 EU declaration of conformity.................................................................................................................... 6

3 System description ................................................................................................................................. 7

4 Functional description ............................................................................................................................ 8

4.1 Wireless WPB - WSB communication ..................................................................................................... 8

4.2 Hardware features ................................................................................................................................... 8

4.2.1 WPB......................................................................................................................................................... 8

4.2.1.1 Reset button............................................................................................................................................. 8

4.2.1.2 Status LED operation............................................................................................................................... 9

4.2.2 WSB......................................................................................................................................................... 9

4.3 Output power and de-rating ................................................................................................................... 10

4.3.1 Output operating area ............................................................................................................................ 10

4.3.2 Power vs. input voltage.......................................................................................................................... 10

4.3.3 Power vs. ambient temperature ..............................................................................................................11

4.3.4 WPP & WSP Physical Positioning ..........................................................................................................12

4.4 Eﬃciency and losses.............................................................................................................................. 12

................................................................................................................. 12

4.4.2 Temperature of the WPP

4.4.1 Factors that influence losses

........................................................................................................................ 13

4.5 Operating limits ...................................................................................................................................... 13

4.6 Physical dimensions .............................................................................................................................. 14

4.6.1 WPU....................................................................................................................................................... 14

4.6.2 WSU....................................................................................................................................................... 14

5 Installation.............................................................................................................................................. 15

5.1 WPB....................................................................................................................................................... 15

5.1.1 Description ............................................................................................................................................. 15

5.1.2 Mounting pattern .................................................................................................................................... 15

5.2 WSB....................................................................................................................................................... 16

5.2.1 Mounting pattern .................................................................................................................................... 16

5.3 WPP and WSP....................................................................................................................................... 16

5.3.1 Mounting pattern .................................................................................................................................... 17

5.4 Metal near the pads ............................................................................................................................... 17

5.4.1 Mounting to aluminium........................................................................................................................... 18

5.4.2 Mounting to ferrous metal ...................................................................................................................... 18

5.5 Installation of multiple pads.................................................................................................................... 19

5.6 User Considerations .............................................................................................................................. 20

5.6.1 ..................................................................................... 20

5.7 Description of connections..................................................................................................................... 22

5.7.1 WPU: AC Input....................................................................................................................................... 22

5.7.2 WPU: Earth stud .................................................................................................................................... 22

5.7.3 WSU: DC Output.................................................................................................................................... 22

5.7.4 WSU: CAN bus connector ..................................................................................................................... 23

5.7.5 WSU: External control connector ......................................................................................................... 23

Critical RF Exposure Installation Requirements

5.7.5.1 Sleep...................................................................................................................................................... 23

5.7.5.2 Enable.................................................................................................................................................... 23

5.7.6 WSU: Battery temperature probe........................................................................................................... 24

6 Charge modes........................................................................................................................................ 25

6.1 CAN bus mode

6.1.1 CAN bus hardware specification

6.1.2 System configuration

....................................................................................................................................... 25

............................................................................................................ 25

............................................................................................................................. 25

6.1.3 Basic protocol commands...................................................................................................................... 26

6.1.4 CAN bus watchdog

6.2 Profile mode

6.2.1 System configuration

................................................................................................................................ 26

........................................................................................................................................... 26

............................................................................................................................. 27

6.3 Sleep mode............................................................................................................................................ 27

7 Graphical user interface (GUI) for PC.................................................................................................. 28

7.1 Requirements......................................................................................................................................... 28

7.2 Installing PCAN-USB drivers ................................................................................................................. 28

7.3 Connecting the WSU to the PC ............................................................................................................. 28

7.4 Installing the GUI ................................................................................................................................... 28

7.5 Areas of the monitor tab......................................................................................................................... 29

7.6 Basic operation ...................................................................................................................................... 29

7.7 Charger Configuration

7.7.1 CAN bus configuration

7.8 Using the GUI with the WSU in Profile mode

........................................................................................................................... 30

7.7.2 Profile configuration

7.7.3 General Configuration

...............................................................................................................................

...........................................................................................................................

......................................................................................... 31

7.9 Data logging

7.10 Updating firmware

........................................................................................................................................... 32

.................................................................................................................................. 32

8 Warranty information.............................................................................................................................33

9 Appendix ................................................................................................................................................34

8.1 Guarantee conditions............................................................................................................................. 33

8.2 Returns procedure ................................................................................................................................. 33

9.1 Evaluating the charger system without a battery ......................................................................................... 34

9.2 Flow chart .............................................................................................................................................. 34

9.3 Troubleshooting .................................................................................................................................... 35

9.4 Charger system fault and status messages

9.4.1

...........................................................................................

.....................................................................................................................................................

36Faults

9.4.2 ..................................................................................................................................................... 37Status

9.5 ....................................................................................................................................... 39Default profiles

1 About this document

1.1 Purpose of this document

This document is to provide information that will allow the wireless charger system to be used safely

and reliably when it is installed in another product such as an AGV. Whilst the document contains some

information on how to use the charger system as a stand-alone product, this is only for evaluation

Read this document before working with the wireless charger system.

Always follow the safety instructions and guidance messages in this document. This will ensure that the

charger can be safely installed, commissioned and operated.

Delta Energy Systems is not responsible for damage or harm resulting from failure to follow the safety

and operating instructions set out in this document.

1.2 Target audience

charger system into a larger system such as an AGV. The engineer must be trained and approved for

working with electrical and electronic equipment. The engineer must also be experienced in how to

apply safe working practices for connecting and charging batteries.

Although this documentation is not aimed at the end users of the wireless charging system, it does

the system after installation.

1.3 Products covered

WPU (Wireless Primary Unit), transmitter, TX: WPU 1000 W 1 AC US

WPU 1000 W 1 AC EU

WSU (Wireless Secondary Unit), receiver, RX: WSU 1000 W 24 V

WSU 1000 W 48 V

1.4 Warning notices and warning symbols

This document uses the following warning notices and symbols to describe potential dangers and the

measures necessary for reducing these dangers.

1.4.1 Warning levels

DANGER

Indicates a dangerous situation that will always

lead to death or severe injuries if not avoided.

WARNING

Indicates a dangerous situation that can lead to

death or severe injuries if not avoided.

CAUTION

Indicates a dangerous situation that can lead to

light or medium injuries if not avoided.

ATTENTION

Indicates possible material damage that can be

caused to other objects by the charger system.

If necessary, the warning labels are also marked

with warning symbols indicating the source of the

danger.

High electrical voltages or currents

Hot surfaces

General danger

Sharp edges

The firmware and/or hardware may be changed at any time without prior notice. For this reason it is

possible that parts of these instructions, technical data and images in this documentation to differ

slightly from the product in your possession. All points described in these instructions only serve the

purpose of clarification and may not correspond to every situation. Legal claims cannot be made on

the basis of this document.

2 General safety instructions

DANGER

Electric shock

Potentially fatal voltages are present in the charger system during operation.

►No item in the charging system contains user serviceable parts and enclosures

should not be opened for any reason.

WARNING

►People must be > 20 cm away from the WPP.

►People with medical devices such as metallic prostheses, cardiac pacemakers and

cochlear implants, must be > 1mfrom the WPP.

►Warning signs giving the above advice must be clearly displayed at the WPU

installation.

►Operators must be trained toinform them of the EMF risk, and tokeep enough

distance from the WPP at all times, including when not charging.

►The wireless charging system is not suitable for use in location where children are

likely tobe present.

►Charging must take place in an area where the general public are forbidden to

• Do not open any enclosure and do no try to repair it by yourself. The product does not contain user

serviceable parts. Opening any enclosure will invalidate the product warranty.

• No cable or connector on any part of the system can be altered or removed. Doing so will invalidate

the product warranty.

• Firmware must not be downgraded. Doing so will invalidate the product warranty.

• Do not use the device if it is visibly damaged.

• All cables must be routed to avoid a trip hazard and accidental damage of the cables.

• Operate the adapter only on earthed sockets with 100 to 240 VAC, 50 / 60 Hz. If the power supply

is not safe at the installation site, ask the competent power supplier.

• To interrupt the power supply of your device, disconnect the power supply from the power socket.

When disconnecting, always hold the plug. Never pull the cable.

• Operate the device at -20 to 50 °C and maximum 95% relative humidity. The range of the ambient

temperature affects the charging speed, as the charging control of most chargers reduces the

output current at higher temperatures

enter.

EXCLUSION OF LIABILITY

2.1 EU declaration of conformity

Hereby, Delta Energy Systems (Germany) GmbH declares that the radio equipment types WPU 1000 W

1AC EU / WSU 1000 W 24 V / WSU 1000 W 48 V are in compliance with Directive 2014/53/EU.

The full text of the EUdeclaration of conformity is available at the following internet address:

https://filecenter.deltaww.com/Products/Download/21/2110/1kW%20Wireless%20Charging%20System

_EU%20DoC_EN_20207.pdf

CAUTION

Material damage

No metallic objects are allowed between the pads during charging, as they may get

heated and damage the plastic cover.

►Select the installation site where no metallic objectscan go into the air-gap and stay

on the plastic cover of the pads.

►The pads must be mounted vertically. If the user insists on mounting the pads

horizontally, then they will take full responsibility toensure there are no metallic

objects between the pads during charging.

►Heated metallic objects could ignite combustible materials if also present.

This equipment has been tested and found to comply with the limits for a Class A

device, pursuant to EN 55011 Group 2, EN 55032 Group 2, as well as a Class A

digital device, pursuant to part 15 of the FCC Rules. These limits are designed to

provide reasonable protection against harmful interference when the equipment is

operated in a commercial environment. This equipment generates, uses, and can

radiate radio frequency energy and, if not installed and used in accordance with the

user manual, may cause harmful interference to radio communications. Operation of

this equipment in a residential area is likely to cause harmful interference in which

case the user will be required to correct the interference at his own expense.

CAUTION

Hot surfaces

All parts of the charging system can become hot during operation.

►Always wear safety gloves before handling, or allow 30 minutes toallow the charger

system tocool when not operating.

CAUTION

Sharp edges

The heatsink attached tothe WPPhas sharp edges.

►Protective gloves should be worn when handling the heatsink.

WARNING

ELECTROMAGNETIC INTERFERENCE POSSIBILITY

3 System description

The wireless charger system consists of two main assemblies:

1. The WPU: Wireless Primary Unit (transmitter, TX)

a. WPB (Wireless Primary Box) connected to AC

The WPU is typically installed on the wall of the infrastructure.

2. The WSU: Wireless Secondary Unit (receiver, RX)

b. WSB (Wireless Secondary Box) thatproduces a DC output that is typically used to charge a

battery. The output the WSB producescan be controlled via CAN bus, or via inbuilt charging

The WSU is typically installed on moving equipment containing a battery, such as an AGV or pallet

jack. However the wireless charging system can be used in other applications where there is a

need to transfer power over an air gap.

WPB

WPP

WSP

WSB

WSUWPU

WPB

WPP

WSP

WSB

WSU

WPU

4 Functional description

Typically the WPB is permanently supplied with AC, and the WSB is permanently connected to the

battery. Charging can commence when:

The operating frequency for wireless power transfer (WPT) is 160…250 kHz at steady state,

depending on the air-gap, misalignment and output voltage.

●The WPPand WSPare correctly aligned: face-to-face,parallel,and within the specified

misalignment and air gap ranges

●and the charger system is instructed to start charging, either via CAN busor by the charger

system's ENABLE input

●The charger system does not detect any fault conditions.

●The WPB and WSB are able tocommunicate with each other.

4.1 Wireless WPB - WSB communication

For internal system communication the WPB and WSB both contain a radio frequency transceiver

module with integral antenna. The transceiver module is IEEE Std. 802.15.4 compliant and has Radio

The transceiver module operates at ISM Band 2.405 to 2.480 GHz, with maximum RF transmit power

as 2.09 dBm. The wireless communication WPB and WSB uses a proprietary protocol and cannot be

accessed by the user.

4.2 Hardware features

4.2.1 WPB

Reset button

Earth stud

To AC socket

To WPP

Thermal expansion ventPlastic window for WPB/WSB

communication

Status LEDs

Reset button

Earth stud

To AC socket

To WPP

Thermal expansion vent

Plastic window for WPB/WSB

communication

Status LEDs

4.2.1.1 Reset button

The WPB has a non-latching push button that can be used to restart the charging process.

The charger has been considered for use at an altitude of up to 3000 m, pollution degree

2 environment and overvoltage category II application.

4.2.1.2 Status LED operation

The WPB has three LEDs that show basic information about the charger system's status.

AC present Charging Fault

No input

Ready On

Charging On Flash

Charge complete1On On

Fault On Flash

4.2.2 WSB

4.3 Output power and de-rating

4.3.1 Output operating area

The charger system can provide an output within the bounds of the graphs below.

24 V operating area

48Voperatingarea48V operating area

Using the 48 V charger system as an example:

●Between 24V and 38V the charger system canprovide a maximum of 3 A

●Between 38V and 48V the charger system canprovide upto 20.8 A

●Between 48 V and 60 V the charger system can provide a maximum of 1,000 W, and will

reduce theoutput current to achieve this

4.3.2 Power vs. input voltage

The charger system can operate from an AC supply of 85 to 265 VAC. However when input voltage is

less than 100 VAC, the output power is automatically reduced to avoid the input current exceeding 13 A.

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