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BMW i Wallbox
Charging cable installation manual
Freude am Fahren
BMW i
BMW i Wallbox
Charging cable installation manual
5
EN
BMW i Wallbox
Charging cable installation manual
EN
5
Contents
INFORMATION 9
Safety instructions 9
About this manual 10
Assignment of the manual to the spare parts 10
Package 10
Warranty conditions and legal information 11
PREPARATIONS 12
Installation requirements 12
List of tools 12
Switch off the voltage supply 12
Remove the connector holder 13
Remove the housing cover 14
Remove the termination panel cover 15
Remove the front part 16
INSTALLATION 17
Overview 17
Disconnect the old charging cable 18
Prepare the new charging cable 20
Connect the new charging cable 21
Final check 21
Install the front part 21
COMMISSIONING & SAFETY TESTS 23
General commissioning procedure 23
Commissioning mode/Self-test 23
Safety tests 24
CONCLUDING WORK 25
Install the terminal cover 25
Install the termination panel cover 25
Test the function 26
Affix warranty seals 27
Install the housing cover 27
6
Install the connector holder 28
ADDITIONAL INFORMATION 30
DISPOSAL 31
INDEX 32
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7
Legal information
Bayerische Motorenwerke Aktiengesellschaft
Munich, Germany
www.bmw.com
Translation of the original installation instructions
Copyright ©2016 BMW AG Munich
This documentation contains information protected by copyright. All rights reserved, especially
the right of reproduction and distribution. No part of this documentation may be reproduced
(photocopying, scanning or any other procedures) or processed, copied or distributed in any form
using electronic systems without the written consent of Bayerische Motorenwerke Aktiengesellschaft.
Contraventions are liable to compensation.
8
About this manual
Keep this manual save for the entire life cycle of the product.
Read this manual carefully and study the device to familiarise yourself with it before you install it.
Use the operating manual for operation and troubleshooting the Wallbox. Use the installation manual to
install the Wallbox and for its storage and transport.
Pictograms
You will find information and warnings about possible dangers at various points in the manual. The
symbols used in the manual mean as follows:
WARNING
Means that death or serious physical injury may occur if the appropriate precautions are not
taken.
CAUTION
Means that property damage or minor physical injury may occur if the appropriate precautions
are not taken.
IMPORTANT
Means that property damage may occur if the appropriate precautions are not taken.
ESD
This warning points out the possible consequences of touching electrostatically sensitive
components.
Note
Indicates procedures which do not involve any danger of injury.
Note
Your BMW dealer will be delighted to help find a qualified installation contractor.
EN
9
INFORMATION
Safety instructions
Read the safety instructions carefully and study the device to familiarise yourself with it before you
attempt to install, operate or service it.
WARNING
Electrical danger.
The Wallbox must be installed, commissioned, maintained and retrofitted by suitably
trained, qualified and authorised electricians
(1)
who bear full responsibility for compliance
with current standards and installation regulations.
Please note that an additional overvoltage protection may be required by vehicles or
national regulations.
Please refer to national connection and installation standards.
Before commissioning the device check that all screw and terminal connections are tight.
The termination panel must never be left opened unattended. Fit the termination panel
cover when you leave the Wallbox.
Correctly tightened screws on the front part and the termination panel cover are an
essential part of the Wallbox's sealing concept. Refer to the torque values specified in the
procedures for further details.
Do not make any unauthorised changes or modifications to the Wallbox.
Do not remove any identifiers such as safety symbols, warning instructions, rating plates,
labels or cable markings.
(1)
Persons who, as a result of their training, skills and experience and their knowledge of the relevant
standards, can assess the work assigned to them and identify possible dangers.
IMPORTANT
Use a damp cloth or a cleaning product suitable for plastics (for example isopropanol) for
cleaning purposes.
Never clean the Wallbox using a jet of water (hosepipe, pressure washer, etc.).
Ensure that the Wallbox is not damaged by incorrect handling (housing cover, internal parts,
etc.).
A failure to follow the safety information may result in a danger of death, injury and damage to the
device. The device manufacturer cannot accept any liability for claims resulting from this.
10
About this manual
This manual and the functions described in it are valid for devices of the following type:
BMW i Wallbox
BMW i Wallbox Plus
BMW i Wallbox Connect
This manual is designed exclusively for trained personnel. These are people who, as a result of their
training, skills and experience and their knowledge of the relevant standards, can assess the work
assigned to them and identify possible dangers.
The illustrations and explanations contained in this manual refer to a typical version of the device. Your
device version may differ from this.
Assignment of the manual to the spare parts
This installation manual applies to the following BMW i Wallbox spare parts:
BMW part number Connector type Phases Length
61 90 2 450 194 Type 2 3 P 5 m (16.5 ft)
61 90 2 450 196 Type 1 1 P 7.6 m (25 ft)
61 90 2 450 197 Type 1 (PSE) 1 P 7.6 m (25 ft)
61 90 2 450 198 Type 4 (GB/T) 3 P 5 m (16.5 ft)
Package
Description Quantity
Charging cable spare part 1x
Brass nut for cable gland 1x
Warranty seal (blue) 2x
Cable tie (10 cm) 1x
Charging cable installation manual 1x
EN
11
Warranty conditions and legal information
BMW Service can inform you about the corresponding warranty conditions. However, the warranty
does not cover the following.
Defects or damage caused by installation work not carried out to the specifications in the BMW i
Wallbox installation manual.
Defects or damage caused by the product not being used to the specifications in the BMW i
Wallbox operating manual.
Costs and damage caused by repairs not carried out by a trained electrician.
If a system or a component is repaired, installed or commissioned incorrectly or not in compliance
with the BMW regulations (particularly this manual), the warranty will be voided and the specific
certifications will be invalidated.
If the installation work is carried out correctly as described in this manual, by suitably qualified
personnel and using BMW i Wallbox original spare parts, it may be assumed that the warranty and the
specific certifications will remain in force.
Responsibility for the correct installation is in the hands of the trained electrician.
12
PREPARATIONS
Installation requirements
Comply with local installation guidelines.
The product must be repaired in a suitable environment. The Wallbox must be protected from rain,
snow and dirt during the procedure. If it is installed outdoors, the termination panel cover and the
front part must not be opened in rain, wind, snow, etc.
Ensure access to the shut-off device and prepare suitable material to secure it to prevent it being
switched on again.
The following components must not show any signs of damage or defects during the procedure:
–
Housing or housing parts
–
Plug connectors
–
Contact points/Terminal connectors
–
Seals
–
Circuit boards
–
Signs of water ingress inside the Wallbox
WARNING
Electrical danger!
If the installation conditions are not satisfied, the spare part must not be installed. In this case,
have the action required for the repair or replacement carried out by the manufacturer.
List of tools
The following tools will be required for the installation work:
Flat screwdriver with a blade width of 5.5 mm
PH2 and PZ2 cross head screwdrivers
PH2x30 cross head screw driver (recommended for removing the connector holder)
Torx T25 screwdriver
36 mm open-ended spanner
Side cutter
Switch off the voltage supply
WARNING
The Wallbox does not have its own mains switch. The circuit breaker on the building
installation is used as a mains isolation device.
EN
13
CAUTION
5 safety rules:
Switch off on all poles and from all sources.
Secure it to prevent it being switched on again.
Verify isolation from the supply.
Earth and short-circuit.
Cover neighbouring live parts and cordon off danger areas.
1. End any charging session currently taking place and disconnect the vehicle from the Wallbox.
2. Coil the charging cable from the Wallbox.
3. Switch off the voltage supply to the Wallbox.
4. Secure the shut-off device to prevent it being switched on again.
Remove the connector holder
1. Undo the screw at the bottom of the design
frame using the PH2 cross head screwdriver.
2. Raise the front connector holder slightly 1 and
guide it out towards the front 2.
14
Remove the housing cover
1. Press the two interlocks 1 for the housing
cover on the underside of the Wallbox
upwards.
The housing cover should then jump out
slightly at the bottom.
2. Swing the housing cover forwards a little on
the underside 2.
3. Then release the housing cover by raising it 3.
Note
Keep the housing cover carefully to prevent
it being scratched or suffering other
damage.
EN
15
Remove the termination panel cover
1. Undo the four screws used to secure the
termination panel cover 1.
ESD
Danger of damage. Electronic components may be destroyed if touched.
Before handling modules, perform an electrical discharge process by touching a metallic
earthed object.
16
Remove the front part
IMPORTANT
Danger of damage.
The front part and the bottom of the housing are connected by a ribbon cable. Ensure that you
do not damage the ribbon table or its plug connectors by handling the front part with care.
1. Remove the four screws 1 in the front part 2
using a T25 Torx screwdriver.
2. Disconnect the ribbon cable from the circuit
board inside the front part and put the front
part to one side.
EN
17
INSTALLATION
Overview
1 Switch feedback connector
2 Switch feedback cable tie
3 Earth terminal
4 Contactor terminals
5 Cable gland lock nut
6 Pilot cable connector
7 Electronics cover
18
Disconnect the old charging cable
Note
Make a note of or photograph the assignment of all connected cables so that you can
reconnect them correctly after replacing the charging cable.
Disconnect the switch feedback (connector
at top right)
1. Remove the cable tie 2 using a side cutter.
2. Disconnect the connector 1 by pressing the
clips on the right and left together and pulling
out the connector.
Disconnect the pilot contact (connector at
bottom right)
3. Disconnect the connector for the pilot contact
by pressing the bottom clip with your index
finger and carefully pulling out the connector.
EN
19
Disconnect the cable from the earth
terminal: Remove the charging cable's
earth conductor
4. Push a flat screwdriver (blade width 5.5 mm)
into the terminal as shown in the figure.
5. Press the flat screwdriver with moderate force
straight into the terminal until the contact
opens fully.
6. Pull the protective conductor out of the
terminal.
7. Pull the flat screwdriver out of the terminal.
Disconnect the cable from the earth
terminal: Remove the pilot contact's earth
conductor
8. Repeat steps 4-7 to disconnect the pilot
contact's earth conductor.
Disconnected the charging cable from the contactor
9. Disconnect the cores of the charging cable from the contactor (bottom row of terminals) using a
PZ2 cross head screw driver.
Note
Only disconnect those cables required to replace the charging cable. The switch contact A2
can remain connected.
20
Remove the lock nut on the cable gland
10. Remove the lock nut 1 on the cable gland
using an open-ended spanner.
11. Pull the old charging cable downwards out of
the Wallbox.
Prepare the new charging cable
CAUTION
The design current for the charging cable must not be less than the design current for
the Wallbox. To check this, compare the figures on the model plate of the Wallbox with the
figures on the charging cable.
Check the spare part for possible signs of damage and ensure it is in perfect condition.
The cable gland on the new charging cable must not be opened. The charging cable can
be replaced by opening the lock nut inside the housing.
1. Remove the cable ties holding the new charging cable together.
2. Thread the new charging cable into the
Wallbox.
3. Secure the screw connection using the brass
nut in the package (torque: 4 Nm).
/