Instructors Manual for EV-601-TS_053322 EV-601-TS_053322-96_V2024-3 © ConsuLab Educatech Inc, 2024. Tous droits réservés. Interactive Demonstrative Electric Vehicle EV-601-TS_053322-96 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of Contents Introduction to High Voltage EVs 4 Instructors’ Notes 6 Required Equipment and PPE 7 Working on High Voltage Vehicles 8 Maintenance and Safety 12 Educational Outcomes 20 Student Assignments Answers Student Learning Module 1 Component Identification 37 Trainer Layout and Familiarization 38 iDev Component locator 38 Tesla Model 3 Components 39 SA-1 Component #1 — Answers 41 SA-2 Component #2 — Answers 42 SA-3 Component #3 — Answers 43 SA-4 Component #4 — Answers 44 SA-5 Component #5 — Answers 45 SA-6 Component #6 — Answers 46 SA-7 Component #7 — Answers 47 SA-8 Component #8 — Answers 48 SA-9 Component #9 — Answers 49 SA-10 Component #10 — Answers 50 SA-11 Component #11 — Answers 51 SA-12 Component #12 — Answers 52 SA-13 Component #13 — Answers 53 SA-14 Component #14 — Answers 54 SA-15 Component #15 — Answers 55 SA-16 Component #16 — Answers 56 SA-17 Component #17 — Answers 57 SA-18 Component #18 — Answers 58 SA-19 Component #19 — Answers 59 SA-20 Component #20 — Answers 60 SA-21 Component #21 — Answers 61 SA-22 Component #22 — Answers 62 SA-23 Component #23 — Answers 63 SA-24 Component #24 — Answers 64 SA-25 Component #25 — Answers 65 Power Flow of an Electric System 66 EV-601-TS_053322-96 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2024. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. SA-26 Quiz on Power Flow 70 SA-26 Quiz on Power Flow — Answer Sheet 71 SA-26 Quiz on Power Flow — Answers 72 Student Learning Module 2 High Voltage Battery Construction 73 High Voltage Battery Construction 74 SA-27 High Voltage Battery Specifications — Answers 76 SA-28 High Voltage Battery Modules — Answers 77 SA-29 High Voltage Battery Configuration — Answers 78 Student Learning Module 3 EV Charging Systems and Operation Drive Modes 79 EV Charging Systems 80 SA-30 Opening the Charge Port — Answers 82 SA-31 Charging with Battery Temperature Hot — Answers 85 SA-32 Onboard Charger and How it Works — Answers 86 Drive mode of the EV-601 87 SA-33 Touchscreen Drive Mode A — Answers 88 SA-34 Touchscreen Drive Mode B — Answers 90 SA-35 Watching the Power Drive to the Rear Drive Unit — Answers 91 Student Learning Module 4 First Responder Training 92 First responder Training for EV’s with the EV-601-TS 93 First Responder Loop 105 SA-36 First responder loop Function — Answers 108 Quiz on First Responder for EV-601 109 Quiz on First Responder for EV-601 Answer Sheet 113 Quiz on First Responder for EV-601 — Answers 114 Student Learning Module 5 Autopilot (ADAS) 115 Student Learning Module 6 Isolation Testing – Loss of Isolation (LOI) 117 Isolation Testing – Loss of Isolation (LOI) 118 SA-37 A/C Compressor Testing – Component Side for Loss of Isolation (LOI) — Answers 122 SA-38 PTC Heater Testing – Component Side for Loss of Isolation (LOI) — Answers 123 SA-39 High Voltage Safety Fundamentals — Answers 124 SA-40 Identifying High Voltage Components and Circuits —Answers 128 High Voltage Safety Certification Testing Beta 130 High Voltage Safety Certification — Answers 131 consulab.com info@consulab.com 4 EV-601-TS_053322-96 Introduction Introduction to High Voltage EVs This course is designed to give personnel the confidence to work around high voltage vehicles, to identify the vehicles and the high voltage components, to consider the safety precautions, identify and select the correct tools and person- al protective equipment when working on, or near, a high voltage vehicle, and have an awareness of what to do in the event of an emergency. In the last several years, electric vehicles have they been taken more seriously as an alternative to gasoline-powered vehicles. We may think of electric vehicles as ‘new technology,’ but they have been around for a long time. The first electric car made its debut around 1890. By the early 1900s electric vehicles were available on the market to those who could afford them, alongside steam and gasoline-powered vehicles. Innovators such as Ferdinand Porsche had tried to improve on their performance by invent- ing the first gas/electric hybrid vehicle in 1898 and Henry Ford looked for lower cost options for manufacturing electric vehicles. But the death blow for the electric vehicle ultimately came as a result of Ford’s low-cost mass production. Introduced in 1908, Ford created a low-cost gasoline-powered Model T for the masses. It sold for around $650 compared to other competing electric models that sold for roughly three times that amount. However, electric vehicles didn’t disappear entirely. They made a resurgence in popularity after the 1973 Arab Oil Em- bargo caused gas prices to soar. Electric vehicles emerged once again in the 1990s but this time with a new champion – global warming. Beginning in the 1990s governments in Canada and the US began introducing vehicle emission reduction targets and vehicle manufactures began exploring alternatives through advanced battery technology and hybrid options in order to meet government targets and a growing consumer demand for environmentally friendly vehicles. The EV-1 was GM’s first experiment with an all-electric car in the 1990s When Toyota launched the first Prius Hybrid in the 1990s, it moved electric vehicles from obscurity to mainstream acceptance. Tesla introduced its first all-electric vehicle to the market in 2008, and the Nissan Leaf and Chevrolet Volt were introduced in 2010. MORE CHANGES TO COME IN THE NEXT 5 YEARS THAN IN THE LAST 50. This course is designed to give personnel the confidence to work around high voltage vehicles, to identify the vehicles and the high voltage components, to consider the safety precautions, identify and select the correct tools and personal protective equipment when working on, or near, a high voltage vehicle, and have an awareness of what to do in the event of an emergency. In the last several years, electric vehicles have they been taken more seriously as an alternative to gasoline- powered vehicles. We may think of electric vehicles as ‘new technology,’ but they have been around for a long time. The first electric car made its debut around 1890. By the early 1900s electric vehicles were available on the market to those who could afford them, alongside steam and gasoline-powered vehicles. Innovators such as Ferdinand Porsche had tried to improve on their performance by inventing the first gas/electric hybrid vehicle in 1898 and Henry Ford looked for lower cost options for manufacturing electric vehicles. But the death blow for the electric vehicle ultimately came as a result of Ford’s low-cost mass production. Introduced in 1908, Ford created a low- cost gasoline-powered Model T for the masses. It sold for around $650 compared to other competing electric models that sold for roughly three times that amount. But electric vehicles didn’t disappear entirely. They made a resurgence in popularity after the 1973 Arab Oil Embargo caused gas prices to soar. Electric vehicles emerged once again in the 1990s but this time with a new champion – global warming. Beginning in the 1990s governments in Canada and the US began introducing vehicle emission reduction targets and vehicle manufactures began exploring alternatives through advanced battery technology and hybrid options in order to meet government targets and a growing consumer demand for environmentally friendly vehicles. The EV-1 was GM's first experiment with an all-electric car in the 1990s This course is designed to give personnel the confidence to work around high voltage vehicles, to identify the vehicles and the high voltage components, to consider the safety precautions, identify and select the correct tools and personal protective equipment when working on, or near, a high voltage vehicle, and have an awareness of what to do in the event of an emergency. In the last several years, electric vehicles have they been taken more seriously as an alternative to gasoline- powered vehicles. We may think of electric vehicles as ‘new technology,’ but they have been around for a long time. The first electric car made its debut around 1890. By the early 1900s electric vehicles were available on the market to those who could afford them, alongside steam and gasoline-powered vehicles. Innovators such as Ferdinand Porsche had tried to improve on their performance by inventing the first gas/electric hybrid vehicle in 1898 and Henry Ford looked for lower cost options for manufacturing electric vehicles. But the death blow for the electric vehicle ultimately came as a result of Ford’s low-cost mass production. Introduced in 1908, Ford created a low- cost gasoline-powered Model T for the masses. It sold for around $650 compared to other competing electric models that sold for roughly three times that amount. But electric vehicles didn’t disappear entirely. They made a resurgence in popularity after the 1973 Arab Oil Embargo caused gas prices to soar. Electric vehicles emerged once again in the 1990s but this time with a new champion – global warming. Beginning in the 1990s governments in Canada and the US began introducing vehicle emission reduction targets and vehicle manufactures began exploring alternatives through advanced battery technology and hybrid options in order to meet government targets and a growing consumer demand for environmentally friendly vehicles. The EV-1 was GM's first experiment with an all-electric car in the 1990s EV-601-TS_053322-96 Titre de la section consulab.com info@consulab.com 5 What does the future hold for EVs? As an update to its original mandate, in October 2021 the provincial government stated that 100% of all new light-duty vehicle sales will be zero emission vehicles by 2035. Other jurisdictions like California, Quebec, and most EU countries have also set aggressive timelines. We can safely assume that by 2035, most vehicle manufacturers will have completely transformed their production lines to 100% electric. We can already see this trend emerging. In keeping with current projected growth rates, by 2035, over 50% of vehicles on the road will be fully electric. This is a conservative estimate. It is even more likely that, electric vehi- cles will account for a much greater percentage of vehicles on the road – perhaps close to 100%. consulab.com info@consulab.com 6 EV-601-TS_053322-96 Instructors’ Notes Instructors’ Notes Welcome to the world of immersive automotive education with the EV-601, ConsuLab’s testament to hands-on learning and technical excellence. Born from a blend of industry insights, customer collaboration, and strategic partnerships, the EV-601 represents the evolution of the iDEV prototype into a revolutionary training tool. At ConsuLab, our mission resonates through every facet of the EV-601 — to simplify and enhance the hands-on training and evaluation of technicians. We have channeled our passion for vehicle technology into creating a trainer that unravels the complexities of electric vehicles with unprecedented clarity. Opting for the Tesla Model 3 platform, the EV-601 stands out in supply chain availability and educational design. Its lay- out breaks down the barriers of conventional EV training, spreading key components across the vehicle’s architecture, thus enabling an intuitive, teachable experience. Essential Guidelines for Instructors 1. Understanding the EV-601: We suggest you familiarize yourself with all EV-601 components, including the Tesla keycard, ConsuLab touchscreen, and LED indicators, before beginning. 2. Safety First: Prioritize safety in every session. Reinforce the importance of safety protocols with your students, and practice using the EV-601 knowing that there is no live high voltage system. 3. Interactive Learning with Touchscreen: Utilize the interactive ConsuLab touchscreen to demonstrate myriad vehicle modes and scenarios, enriching the learning experience. 4. Real-World Applications: Use the EV-601 to simulate real-life scenarios, focusing on diagnostics, troubleshooting, and understanding EV systems. 5. Clarification on High Voltage System: It’s important to note that the EV-601 does not contain an active high voltage system. This aspect is crucial for understanding the safety context and limitations of the training environment. ConsuLab EV-601-TS Tesla Model 3 consulab.com info@consulab.com 7 EV-601-TS_053322-96 Required Equipment and PPE Required Equipment and PPE We suggest that you have at your disposal the following: 1. DVOM or DMM: Fluke 1587 or equivalent insulation multimeter. 2. Scanner: Scan accessing EV-601 (ELM 327 with Scan My Tesla). 3. EV Tools: Tools working with the EV-601 (further EV work on high voltage systems follow manufactures procedures), insulated hand tools meeting CAT rating, emergency rescue kit. 4. PPE: Insulated gloves (recently certified), safety glasses or goggles, safety shoes, ear protection. incident energy is calculated based on known system parameters, allowing for the determination of appropriate safety measures and PPE requirements for workers. Regular arc flash risk assessments are crucial to ensuring that protective measures are up-to-date and aligned with the current state of the electrical system. 5. Wheel chocks 6. Assorted hand tools as needed. consulab.com info@consulab.com 8 EV-601-TS_053322-96 Working on High Voltage Vehicles consulab.com info@consulab.com 8 Working on High Voltage Vehicles WARNING: NEVER ATTEMPT TO SERVICE OR DISMANTLE A HYBRID OR ELECTRIC VEHICLE WITHOUT THE PROPER TRAINING AND SAFETY EQUIPMENT. Working on high voltage vehicles is not dangerous, as long as you are trained and follow the correct procedures. EVs have a range of sophisticated systems designed to keep the passengers and technicians safe, even in the event of a serious crash or during complex work. This resource is designed to help you learn about pure electric and hybrid vehicles in general, and the issues associated with towing and recovery service and maintenance of these high-voltage vehicles. It is an exciting change to our industry, so you should find it interesting. However, even more important is that learning about how to work with high voltage vehicles safely could save your life! Conducting Visual Checks Before beginning to work on an EV, it is important to inspect high voltage components. Before commencing work, be sure to inspect the following: Cables High voltage components and high-voltage cables should undergo a visual check for damage and correct routing as well as security. During the visual inspection, look for any external damage, such as broken or torn sheathing, unusual defor- mations or discolouration. Battery Check high-voltage batteries for cracks or deformations in the upper part of battery housing or battery tray, colour changes due to temperature, and tarnishing of housing, escaping electrolyte, damage to high-voltage contacts. Look for the fitted and information stickers and ensure they are legible. Look for any corrosion damage. Other Components In the engine compartment area, check the condition of the power and control electronics for electric drive, high-voltage cables for the battery and air conditioning compressor, high-voltage cables for the electric drive, as well as the high-volt- age charging socket in the radiator grille or in tank cap, as equipped. Underbody Check the high-voltage battery as well as high-voltage cables for battery. consulab.com info@consulab.com 9 EV-601-TS_053322-96 Working on High Voltage Vehicles EV Layouts and How EVs Work Conducting Visual Checks Before beginning to work on an EV, it is important to inspect high voltage components. Before commencing work, be sure to inspect the following: Cables High voltage components and high-voltage cables should undergo a visual check for damage and correct routing as well as security. During the visual inspection, look for any external damage, such as broken or torn sheathing, unusual deformations or discolouration. Battery Check high-voltage batteries for cracks or deformations in the upper part of battery housing or battery tray, colour changes due to temperature, and tarnishing of housing, escaping electrolyte, damage to high-voltage contacts. Look for the fitted and information stickers and ensure they are legible. Look for any corrosion damage. Other components In the engine compartment area, check the condition of the power and control electronics for electric drive, high-voltage cables for the battery and air conditioning compressor, high-voltage cables for the electric drive, as well as the high-voltage charging socket in the radiator grille or in tank cap, as equipped. Underbody Check the high-voltage battery as well as high-voltage cables for battery. EV Layouts and How EVs Work The above is a simplified diagram illustrating a generic layout for a self-charging, or a plug-in hybrid. The drive train is shown in grey and can be powered by either the engine or the electric The aside simplified diagram illustrates a generic layout for a self-charging, or a plug-in hybrid. The drive train is shown in grey and can be powered by either the engine or the electric motor. The electrical energy is stored in the battery as DC (Direct Current) and the electric motor operates using AC (Alternating Current). The energy goes through an inverter and converter between these two compo- nents. The electric motor drives the vehicle when the accelerator pedal is depressed. The energy is drawn from the battery as DC, inverted to AC, and then used to power the motor and drive the vehicle. You will notice two lines between the battery and converter and three between the converter and motor. This is be- cause the energy flows both ways. As you depress the accelerator, the energy is used to drive the vehicle, as you come off the accelerator pedal, the electric motor becomes a generator, and this power is used to charge the battery. The electric motor is connected directly to the transmission, so as the wheels turn, the electric motor will turn. During deceleration, load is put onto the motor to slow the vehicle down and provide power to charge the battery. This is called regenerative braking and is very effective at slowing the vehicle without using the brake pedal. In this regenerative state, the electric motor produces AC power and this is changed to DC by the inverter so the battery can be charged. For reference, the Toyota Prius battery is 210 volts DC. This is inverted to 750 volts, three phase AC, to power the mo- tor. To put that into perspective, an electric shock of between 70 and 90 volts DC is enough to cause a fatal injury. Many new electric vehicles for sale today operate at 400 volts DC, and the new Porsche platform, along with the new Kia/ Hyundai platform, operate at 800 volts DC – more than enough to kill! Below is a simplification of the layout for a Honda, with all the same components as the previous example, except this does not have the option for just electric motor running, or just engine running. All the components work together, so if the engine is running, the electric motor is also running. The layout above is for a typical range extender vehicle. In most (but not all) vehicles with this configuration, the drive train is driven by the electric motor and the gas engine drives a generator. This generator supplies electrical energy to the vehicle that is then used to drive the vehicle. The gas engine does not drive the vehicle. There are a few vehicles using this system besides the Volt. If you remove the gas engine and generator, and fit a bigger battery, you will have a full electric vehicle. The principle of DC power in the battery and AC power to drive the electric motor, with an inverter between the two, is the same irrespective of whichever type of electric or hybrid vehicle. HV Layouts The various different layout can equate to eight different layouts. On seven of them you will see two cables into the battery and three cables into the motors. The power into the battery is DC and the power into the motors is 3-phase AC. The difference is, the first example is the mild-hybrid, which uses an earth return for the battery due to the lower voltage. Mild hybrids still need to be treated with care. A 48-volt shock may not kill, but could cause other damage. consulab.com info@consulab.com 10 EV-601-TS_053322-96 Working on High Voltage Vehicles The layout above is for a typical range extender vehicle. In most (but not all) vehicles with this configuration, the drive train is driven by the electric motor and the gas engine drives a generator. This generator supplies electrical energy to the vehicle that is then used to drive the vehicle. The gas engine does not drive the vehicle. There are a few vehicles using this system besides the Volt. If you remove the gas engine and generator, and fit a bigger battery, you will have a full electric vehicle. The principle of DC power in the battery and AC power to drive the electric motor, with an inverter between the two, is the same irrespective of whichever type of electric or hybrid vehicle. HV Layouts The various different layout can equate to eight different layouts. On seven of them you will see two cables into the battery and three cables into the motors. The power into the battery is DC and the power into the motors is 3-phase AC. The difference is, the first example is the mild-hybrid, which uses an earth return for the battery due to the lower voltage. Mild hybrids still need to be treated with care. A 48-volt shock may not kill, but could cause other damage. Hydrogen Fuel Cells Hydrogen-powered vehicles are still high voltage and require care and consideration. Hydrogen from the tanks is mixed with air from the atmosphere in the fuel cell to generate electricity. This is inverted to high voltage to drive the vehicle via the electric motor. Hydrogen Fuel Cells Hydrogen-powered vehicles are still high voltage and require care and consideration. Hydrogen from the tanks is mixed with air from the atmosphere in the fuel cell to generate electricity. This is inverted to high voltage to drive the vehicle via the electric motor. A cooling system is required due to the heat generated in this process, and a small high-voltage battery is used to store energy, particularly from regenerative braking. The only emission from these vehicles is water. Understanding High Voltage Batteries Definition of High Voltage High voltage electricity refers to electrical potential large enough to cause injury or damage. In certain industries, high voltage refers to voltage above a certain threshold. The definition of high voltage in the automotive sector is > 60V DC or > 30V AC, as defined by UN ECE-R100 guidelines. A reminder that we cannot sense high voltage in the same way we can sense noise, heat, cold, or fire, which means that we have to be extra vigilant when working on high voltage vehicles. A cooling system is required due to the heat generated in this process, and a small high-voltage battery is used to store energy, particularly from regenerative braking. The only emission from these vehicles is water. Understanding High Voltage Batteries Definition of High Voltage High voltage electricity refers to electrical potential large enough to cause injury or damage. In certain industries, high voltage refers to voltage above a certain threshold. The definition of high voltage in the automotive sector is > 60V DC or > 30V AC, as defined by UN ECE-R100 guidelines. WARNING: A reminder that we cannot sense high voltage in the same way we can sense noise, heat, cold, or fire, which means that we have to be extra vigilant when working on high voltage vehicles. consulab.com info@consulab.com 11 EV-601-TS_053322-96 Maintenance and Safety Handling an EV: Best Practices It is important to recognize that hybrid electric and electric vehicles have unique high-voltage systems that are very dangerous if not handled properly. This danger can be higher yet if the vehicle’s high-voltage systems have been com- promised from an accident or aged components. Improper handling of these vehicles can easily lead to serious injury or death from electric shock, as well as increasing the risk of fire or health risks from leaking electrolyte. It is imperative that these vehicles are only serviced and processed by a facility that has received full training and has the necessary tools and personal protective equipment. Following these steps, these vehicles can be successfully and safely worked on. A Safety Reminder A reminder that these vehicles can carry and store extremely high voltage – the battery and capacitors store high volt- age everything else carries. When we make the vehicle safe the energy is then stored in the high voltage battery, making the vehicle safe DOES NOT discharge the battery, it just contains the energy within the battery. consulab.com info@consulab.com 12 EV-601-TS_053322-96 Maintenance and Safety Maintenance and Safety EV Maintenance: Myth vs Reality Some people think that owning a zero-emission vehicle means having zero maintenance to perform. While it is true that there are fewer mechanical parts compared to a conventional vehicle—they don’t have an engine or transmission and they don’t have a fuel tank, and on pure electric vehicles that run solely on electricity there is no exhaust system—they do have a cooling system and many of the same safety components as a conventional vehicle. So, even though you don’t need to take your car into the shop for things like oil changes, there are other things that you will need to attend to. Lack of regular maintenance on you EV could lead to more costly repairs down the road. ELIMINATED REPLACED No engine components and related parts Electric Motors and electronics No transmission or related parts Direct drive or gear reduction No Emission system or related parts Increased safety with HV components No Fuel Systems or related parts Batteries and HV cables No starter motor or alternator DC/DC and contactors and pre charge contactors Convertors, Invertors The Top EV Maintenance Items: Battery Care The number one maintenance consideration is the one that puts the “E” beside the “V” – the battery. The health of the battery lies at the heart of your car’s range and performance, as well as its residual resale value. Battery Health Report • Customer satisfaction with the charging and life of their battery • Repeat business every year (service) • Performance of the battery for the vehicle • Resale value of the vehicle • Warranty (Battery) battery. The health of the battery lies at the heart of your car’s range and performance, as well as its residual resale value. Battery Health Report You need to take care of your battery just as one would take care of an engine in a conventional vehicle. As you’ll learn in the section on charging, EV batteries should not be charged with DC fast chargers too often, as this puts extra stress on the battery. A level 2, or a slow, overnight charge are the best for battery health. WWhhaatt aabboouutt WWaarrrraanntt iieess?? HHOOWW LLOONNGG DDOOEESS TTHHEE BBAATT TTEERRYY LLAASSTT?? State of Health (SoH) SoH is the ultimate indicator of a battery’s degradation from the factory output. Some manufacturers’ batteries are known for degrading faster than what is normal, which makes this piece of information even more critical in determining the quality of the battery. SoH can • Customer satisfaction with the charging and life of their battery • Repeat business every year (service) • Performance of the battery for the vehicle • Resale value of the vehicle • Warranty (Battery) battery. The health of the battery lies at the heart of your car’s range and performance, as well as its residual resale value. Battery Health Report You need to take care of your battery just as one would take care of an engine in a conventional vehicle. As you’ll learn in the section on charging, EV batteries should not be charged with DC fast chargers too often, as this puts extra stress on the battery. A level 2, or a slow, overnight charge are the best for battery health. WWhhaatt aabboouutt WWaarrrraanntt iieess?? HHOOWW LLOONNGG DDOOEESS TTHHEE BBAATT TTEERRYY LLAASSTT?? State of Health (SoH) SoH is the ultimate indicator of a battery’s degradation from the factory output. Some manufacturers’ batteries are known for degrading faster than what is normal, which makes this piece of information even more critical in determining the quality of the battery. SoH can • Customer satisfaction with the charging and life of their battery • Repeat business every year (service) • Performance of the battery for the vehicle • Resale value of the vehicle • Warranty (Battery) consulab.com info@consulab.com 13 EV-601-TS_053322-96 Maintenance and Safety You need to take care of your battery just as one would take care of an engine in a conventional vehicle. As you’ll learn in the section on charging, EV batteries should not be charged with DC fast chargers too often, as this puts extra stress on the battery. A level 2, or a slow, overnight charge are the best for battery health. What about Warranties? How Long Does the Battery Last? State of Health (SoH) SoH is the ultimate indicator of a battery’s degradation from the factory output. Some manufacturers’ batteries are known for degrading faster than what is normal, which makes this piece of information even more critical in determining the quality of the battery. SoH can sometimes be displayed on the driver’s information display. For example, the driver screen on a Nissan Leaf displays a 12-bar gauge indicating the battery’s SoH. sometimes be displayed on the driver’s information display. For example, the driver screen on a Nissan Leaf displays a 12-bar gauge indicating the battery’s SoH. SoH can often be displayed in the Battery Energy Control Module (BECM) using a scan tool. On some models, a vehicle- specific scan tool must be used to retrieve the SoH information, but it can also be found using a generic scan tool that utilizes OEM functionality. This information will not be found using an OBD2 code reader. SoH is displayed as a percentage and does not exactly correspond with the information center’s bar graph gauge, or the predicted vehicle range. Obviously, if the percentage displayed is closer to 100%, the quality of the battery is excellent, but batteries at 80% or possibly even less may still be usable for some aftermarket users who do not require the full range of a new battery. Some excessively degraded batteries can be repurposed for non-automotive purposes, such as battery backups for housing and commercial uses. Predicted Vehicle Range (PVR) PVR is a way to determine the SoH when the technician has no access to the correct scan tool. The PVR is displayed on the driver’s information centre in kilometres or miles. The PVR is an estimated vehicle’s remaining driving distance range, based on the driving habits during the previous drive cycle. A fully charged battery’s PVR can be compared to the factory’s recorded expected range and from that a theoretical SoH of the battery can be calculated. SoH can often be displayed in the Battery Energy Control Module (BECM) using a scan tool. On some models, a vehicle-specific scan tool must be used to retrieve the SoH information, but it can also be found using a generic scan tool that utilizes OEM functionality. This information will not be found using an OBD2 code reader. SoH is displayed as a percentage and does not exactly correspond with the information center’s bar graph gauge, or the predicted vehicle range. Obviously, if the percentage displayed is closer to 100%, the quality of the battery is excellent, but batteries at 80% or possibly even less may still be usable for some aftermarket users who do not require the full range of a new battery. Some excessively degraded batteries can be repurposed for non-automotive purposes, such as battery backups for housing and commercial uses. Predicted Vehicle Range (PVR) PVR is a way to determine the SoH when the technician has no access to the correct scan tool. The PVR is displayed on the driver’s information centre in kilometres or miles. The PVR is an estimated vehicle’s remaining driving distance range, based on the driving habits during the previous drive cycle. A fully charged battery’s PVR can be compared to the facto- ry’s recorded expected range and from that a theoretical SoH of the battery can be calculated. sometimes be displayed on the driver’s information display. For example, the driver screen on a Nissan Leaf displays a 12-bar gauge indicating the battery’s SoH. SoH can often be displayed in the Battery Energy Control Module (BECM) using a scan tool. On some models, a vehicle- specific scan tool must be used to retrieve the SoH information, but it can also be found using a generic scan tool that utilizes OEM functionality. This information will not be found using an OBD2 code reader. SoH is displayed as a percentage and does not exactly correspond with the information center’s bar graph gauge, or the predicted vehicle range. Obviously, if the percentage displayed is closer to 100%, the quality of the battery is excellent, but batteries at 80% or possibly even less may still be usable for some aftermarket users who do not require the full range of a new battery. Some excessively degraded batteries can be repurposed for non-automotive purposes, such as battery backups for housing and commercial uses. Predicted Vehicle Range (PVR) PVR is a way to determine the SoH when the technician has no access to the correct scan tool. The PVR is displayed on the driver’s information centre in kilometres or miles. The PVR is an estimated vehicle’s remaining driving distance range, based on the driving habits during the previous drive cycle. A fully charged battery’s PVR can be compared to the factory’s recorded expected range and from that a theoretical SoH of the battery can be calculated. SoH is not a linear representation of the PVR and PVR will not behave the same from vehicle to vehicle. If the manufacturer’s rating is 130 km and the PVR displays 100Km after a charge, then the technician would know that a significant amount of degradation has occurred. Unfortunately, PVR is most useful for a fully charged battery and if the vehicle is beyond superficially damaged or is damaged in such a way that it will no longer take a charge, it becomes less accurate. Technicians should try to charge a vehicle before performing any tests. consulab.com info@consulab.com 14 EV-601-TS_053322-96 Maintenance and Safety State of Charge (SoC) The state of charge is the indicator of the level of energy a HV battery has stored in its capacity. The SoC can be dis- played on the driver’s information display as a percentage or a level gauge. A SoC can also be recorded via a scan tool through the BECM data list, near where you would find the SoH. Keep in mind the SoC displays the usable energy, from 0-100%, and even a battery that displays 0% will still have electrical potential. SoH is not a linear representation of the PVR and PVR will not behave the same from vehicle to vehicle. If the manufacturer’s rating is 130Km and the PVR displays 100Km after a charge, then the technician would know that a significant amount of degradation has occurred. Unfortunately, PVR is most useful for a fully charged battery and if the vehicle is beyond superficially damaged or is damaged in such a way that it will no longer take a charge, it becomes less accurate. Technicians should try to charge a vehicle before performing any tests. State of Charge (SoC) The state of charge is the indicator of the level of energy a HV battery has stored in its capacity. The SoC can be displayed on the driver’s information display as a percentage or a level gauge. A SoC can also be recorded via a scan tool through the BECM data list, near where you would find the SoH. Keep in mind the SoC displays the usable energy, from 0-100%, and even a battery that displays 0% will still have electrical potential. A HV battery’s SoC depreciates over time. A fully charged HV battery may be fully discharged and no longer usable after two years of inactivity. HV batteries will not be able to be charged by the vehicle once the SoC drops below 0%. The reason a vehicle is not able to charge a battery with 0% SoC is because the battery cells have been compromised once the cell voltages drop below a set point. Under no circumstance may a technician attempt to charge the battery without specialized equipment and training. In some cases a depleted HV battery can be saved by taking a battery apart and individually charging each cell. This is extremely time consuming and can only be done by trained technicians with the specialized equipment. The success rate and quality of the battery after resurrecting the charge level will always be unknown. This is why prevention of low SoC is the best path toward a healthy battery. TIPS: Avoid leaving your EV parked in extreme hot or cold temperatures. You also do not want to leave your EV parked for long periods if you’re not planning to drive it, as the battery can discharge. And keep in mind that your EV may also be equipped a 12-volt battery just like the A HV battery’s SoC depreciates over time. A fully charged HV battery may be fully discharged and no longer usable after two years of inactivity. HV batteries will not be able to be charged by the vehicle once the SoC drops below 0%. The reason a vehicle is not able to charge a battery with 0% SoC is because the battery cells have been compromised once the cell voltages drop below a set point. WARNING: Under no circumstance may a technician attempt to charge the battery without specialized equipment and training. In some cases a depleted HV battery can be saved by taking a battery apart and individually charging each cell. This is extremely time consuming and can only be done by trained technicians with the specialized equipment. The success rate and quality of the battery after resurrecting the charge level will always be unknown. This is why prevention of low SoC is the best path toward a healthy battery. TIPS: Avoid leaving your EV parked in extreme hot or cold temperatures. You also do not want to leave your EV parked for long periods if you’re not planning to drive it, as the battery can discharge. And keep in mind that your EV may also be equipped a 12-volt battery just like the ones in conventional vehicles. The 12-volt battery stores the power for the 12-volt system that runs components like the lights, entertainment system and the heating/cooling system. WARNING: The 12-volt battery can be a cause of problems and reliability issues for EVs and it is recommended to be inspected regularly and replaced every three years. Scan tool Challenges • Access to data ports • Some don’t use 16pin • Battery data • Reading new data pids • Proper balance of battery Vehicles like TESLA use unique locations such as under the center console tray or the rear console cover that needs a interface when using tools like SCAN MY TESLA. Other locations can include drivers side A pillar or completely wireless to the vehicle. NOTE: With the elimination of emission that these vehicles don’t have. The OBD port mandated under SAE and CARB don’t need to be in place. Making new adapters and locations for them. consulab.com info@consulab.com 15 EV-601-TS_053322-96 Maintenance and Safety consulab.com info@consulab.com 15 Battery Service and Repair Currently lots of opportunities for servicing batteries: • Prius and other Hybrids • Module style lipo batteries • Must balance cells and properly test others Lifting and Hoists for EV’s EVs will be required to have lifting equipment in place to be able to properly service electric vehicle models. In addition to lifting the vehicles for regular maintenance and service, when needed, electric vehicles will require lifting equipment that will allow the separation of the chassis from the battery packs(s). All lift equipment that must meet the minimum requirements (based on new OE requirements for lifts). At a minimum, 12,000 lb. capacity lifts equipped with three-stage arms will be needed to properly lift the Electric Vehicles. Be aware that inground lifts will not allow for proper clearance if the battery pack needs to be removed from the vehicle for service. While all lift options that fall into the specification range will work with the upcoming Electric Vehicles, it is recommend- ed that for shops/dealers purchasing new equipment to be used with some of the new GMC HUMMER, due to the extra width of the vehicle, that the wide lift option be selected on the 12,000 lb. to allow for the additional clearance while entering and exiting the vehicle. Brake Service These are the pads and rotors or the friction parts of the braking system. Brakes on an electric vehicle last longer due to the regenerative braking system, because most of the braking is done by the drag of regeneration when you lift your foot off the accelerator. EVs use regenerative braking, which uses electro- magnetic resistance that sends energy back into the battery. However, this will vary depending on the make and model of EV you’re driving. This is based on factors such as how many kilometres you drive, on average, your driving style or habits, the type of terrain you drive on, and the regenerative settings you select. Repairs could cost you more in the long run if these com- ponents are not regularly inspected. Probably the second biggest maintenance concerns of consumers when buying or selling their used EV is, how long before I have to replace the brakes? NOTE: If testing an earlier hybrid bat- tery, like a Toyota Prius, run the HV A/C compressor while watching cell voltage on a scan tool. Lifting and Hoists for EV’s EVs will be required to have lifting equipment in place to be able to properly service electric vehicle models. In addition to lifting the vehicles for regular maintenance and service, when needed, electric vehicles will require lifting equipment that will allow the separation of the chassis from the battery packs(s). All lift equipment that must meet the minimum requirements (based on new OE requirements for lifts). At a minimum, 12,000 lbs. capacity lifts equipped with three-stage arms will be needed to properly lift the Electric Vehicles. Be aware that inground lifts will not allow for proper clearance if the battery pack needs to be removed from the vehicle for service. While all lift options that fall into the specification range will work with the upcoming Electric Vehicles, it is recommended that for shops/dealers purchasing new equipment to be used with some of the new GMC HUMMER, due to the extra width of the vehicle, that the wide lift option be selected on the 12,000 lbs. to allow for the additional clearance while entering and exiting the vehicle. Lifting and Hoists for EV’s EVs will be required to have lifting equipment in place to be able to properly service electric vehicle models. In addition to lifting the vehicles for regular maintenance and service, when needed, electric vehicles will require lifting equipment that will allow the separation of the chassis from the battery packs(s). All lift equipment that must meet the minimum requirements (based on new OE requirements for lifts). At a minimum, 12,000 lbs. capacity lifts equipped with three-stage arms will be needed to properly lift the Electric Vehicles. Be aware that inground lifts will not allow for proper clearance if the battery pack needs to be removed from the vehicle for service. While all lift options that fall into the specification range will work with the upcoming Electric Vehicles, it is recommended that for shops/dealers purchasing new equipment to be used with some of the new GMC HUMMER, due to the extra width of the vehicle, that the wide lift option be selected on the 12,000 lbs. to allow for the additional clearance while entering and exiting the vehicle. Brake Service These are the pads and rotors or the friction parts of the braking system. Brakes on an electric vehicle last longer due to the regenerative braking system, because most of the braking is done by the drag of regeneration when you lift your foot off the accelerator. EVs use regenerative braking, which uses electromagnetic resistance that sends energy back into the battery. However, this will vary depending on the make and model of EV you’re driving. This is based on factors such as how many kilometres you drive, on average, your driving style or habits, the type of terrain you drive on, and the regenerative settings you select. Repairs could cost you more in the long run if these components are not regularly inspected. Probably the second biggest maintenance concerns of consumers when buying or selling their used EV is, how long before I have to replace the brakes? Cooling System Service There is no engine in an EV, but there is still a cooling system. If not kept cool, an EV battery can overheat, potentially leading to a fire. Maintenance intervals vary, but a few examples are: every 50,000 miles (80,000 Km) for the Tesla Model 3; 125,000 miles (200,000 Km) for the Nissan Leaf; and 150,000 miles (240,000 Km) for a Chevy Bolt. Brake fluid flush Not the braking system on your EV (the pads and rotors) but the fluid that applies pressure to pads to the rotors. If water or pollutants contaminate the fluid, this can cause the braking system to not function properly. You should service or inspect your fluids every 30,000 kilometres. consulab.com info@consulab.com 16 EV-601-TS_053322-96 Maintenance and Safety Cooling System Service There is no engine in an EV, but there is still a cooling system. If not kept cool, an EV battery can overheat, potentially leading to a fire. Maintenance intervals vary, but a few examples are: every 50,000 miles (80,000 km) for the Tesla Model 3; 125,000 miles (200,000 km) for the Nissan Leaf; and 150,000 miles (240,000 km) for a Chevy Bolt. Brake fluid flush Brake Service These are the pads and rotors or the friction parts of the braking system. Brakes on an electric vehicle last longer due to the regenerative braking system, because most of the braking is done by the drag of regeneration when you lift your foot off the accelerator. EVs use regenerative braking, which uses electromagnetic resistance that sends energy back into the battery. However, this will vary depending on the make and model of EV you’re driving. This is based on factors such as how many kilometres you drive, on average, your driving style or habits, the type of terrain you drive on, and the regenerative settings you select. Repairs could cost you more in the long run if these components are not regularly inspected. Probably the second biggest maintenance concerns of consumers when buying or selling their used EV is, how long before I have to replace the brakes? Cooling System Service There is no engine in an EV, but there is still a cooling system. If not kept cool, an EV battery can overheat, potentially leading to a fire. Maintenance intervals vary, but a few examples are: every 50,000 miles (80,000 Km) for the Tesla Model 3; 125,000 miles (200,000 Km) for the Nissan Leaf; and 150,000 miles (240,000 Km) for a Chevy Bolt. Brake fluid flush Not the braking system on your EV (the pads and rotors) but the fluid that applies pressure to pads to the rotors. If water or pollutants contaminate the fluid, this can cause the braking system to not function properly. You should service or inspect your fluids every 30,000 kilometres. Not the braking system on your EV (the pads and rotors) but the fluid that applies pressure to pads to the rotors. If water or pollutants contaminate the fluid, this can cause the braking system to not function properly. You should service or inspect your fluids every 30,000 kilometres. Most people know that by design EVs have a very effective braking system due to its regenerative braking capabilities. Because of this it also lends itself to having very specific brake issues with lack of use. Brakes that go unused are often noisy and an EV is no exception. During an EV service it is often recommended to burnish the rotors by doing some heavier braking on the road test to clean the rotors of rust. Depending on driving habits the brake pads will be used very little and the vehicle will only be stopped by regenerative braking. When select- ing brake parts it is recommended to use the highest quality available as lower quality parts have a more difficult time avoiding noise issues. Scan tool use will also be required to bleed the brakes as these are extremely sensitive to air being in the system. Tires and Rotation Tire rotation is important for all cars, but on an EV, even more so, because an engine is swapped out for a heavy battery, putting an added load onto the tires. Not only that, but EVs have considerably more torque, which can place added stress on the tires as you drive and manoeuvre the vehicle. So, you’ll want to get the maximum life out of the tires by moving them from wheel to wheel during your regular check-up. Tesla, for example, recommends rotating, balancing your tires and a wheel alignment 22000kms and every 10,000-12,000 kilometres for tire rotation. Aggressive driving can lead to premature tire wear and may require more frequent tire service. Tires are often the most neglected item on an EV. With so much time occurring between inspections a normal amount of air pressure will leak out of the tire. The customer may ignore TPMS warnings and continue driving on flat tires. It is not uncommon for an EV to show up in the bay for service to be done to something else and for the vehicle to have flat tires, but no concern from the customer. When selecting tires for an EV a tire with a “Leaf” rating and low rolling resis- tance should be considered because often the manufacturer requires this to achieve the maximum range of the battery. Also because of the added weight and higher air pressure XL or HC need to be used. Tires being low on air pressure will also affect the tire diameter which in turn will reduce the vehicles effective range. Another thing to keep in mind is often EVs do not come with spares in the vehicle, and only have cans of sealer to help keep the tire inflated. Brake Service These are the pads and rotors or the friction parts of the braking system. Brakes on an electric vehicle last longer due to the regenerative braking system, because most of the braking is done by the drag of regeneration when you lift your foot off the accelerator. EVs use regenerative braking, which uses electromagnetic resistance that sends energy back into the battery. However, this will vary depending on the make and model of EV you’re driving. This is based on factors such as how many kilometres you drive, on average, your driving style or habits, the type of terrain you drive on, and the regenerative settings you select. Repairs could cost you more in the long run if these components are not regularly inspected. Probably the second biggest maintenance concerns of consumers when buying or selling their used EV is, how long before I have to replace the brakes? Cooling System Service There is no engine in an EV, but there is still a cooling system. If not kept cool, an EV battery can overheat, potentially leading to a fire. Maintenance intervals vary, but a few examples are: every 50,000 miles (80,000 Km) for the Tesla Model 3; 125,000 miles (200,000 Km) for the Nissan Leaf; and 150,000 miles (240,000 Km) for a Chevy Bolt. Brake fluid flush Not the braking system on your EV (the pads and rotors) but the fluid that applies pressure to pads to the rotors. If water or pollutants contaminate the fluid, this can cause the braking system to not function properly. You should service or inspect your fluids every 30,000 kilometres. Most people know that by design EVs have a very effective braking system due to its regenerative braking capabilities. Because of this it also lends itself to having very specific brake issues with lack of use. Brakes that go unused are often noisy and an EV is no exception. During an EV service it is often recommended to burnish the rotors by doing some heavier braking on the road test to clean the rotors of rust. Depending on driving habits the brake pads will be used very little and the vehicle will only be stopped by regenerative braking. When selecting brake parts it is recommended to use the highest quality available as lower quality parts have a more difficult time avoiding noise issues. Scan tool use will also be required to bleed the brakes as these are extremely sensitive to air being in the system. Tires and Rotation Tire rotation is important for all cars, but on an EV, even more so, because an engine is swapped out for a heavy battery, putting an added load onto the tires. Not only that, but EVs have considerably more torque, which can place added stress on the tires as you drive and manoeuvre the vehicle. So, you’ll want to get the maximum life out of the tires by moving them from wheel to wheel during your regular check-up. Tesla, for example, recommends rotating, balancing your tires and a wheel alignment 22000kms and every 10,000-12,000 kilometres for tire rotation. Aggressive driving can lead to premature tire wear and may require more frequent tire service. Tires are often the most neglected item on an EV. With so much time occurring between inspections a normal amount of air pressure will leak out of the tire. The customer may ignore TPMS warnings and continue driving on flat tires. It is not uncommon for an EV to show up in the bay for service to be done to something else and for the vehicle to have flat tires, but no concern from the customer. When selecting tires for an EV a tire with a “Leaf” rating and low rolling resistance should be considered because often the manufacturer requires this to achieve the maximum range of the battery. Also because of the added weight and higher air pressure XL or HC need to be used. Tires being low on air pressure will also affect the tire diameter which in turn will reduce the vehicles effective range. Another thing to keep in mind is often EVs do not come with spares in the vehicle, and only have cans of sealer to help keep the tire inflated. Air Conditioning consulab.com info@consulab.com 17 EV-601-TS_053322-96 Maintenance and Safety Air Conditioning Apprentices recharging an A/C system need to keep in mind the A/C system uses a non-conductive POE based refrigerant oil. The A/C system lines need to be flushed when switching from PAG to POE oil in order to not contaminate the system. As well, air conditioning Systems should not only be serviced using the correct oil, but also with virgin refrigerant so that contamination form a previously recovered vehicle’s refrigerant does not contaminate the HVAC system. Typically, contaminating the system with conductive type oil will not cause serious issues, but if the A/C compressor de- velops a HV insulation leak the oil will allow HV to conduct to ground and the vehicle will trigger a code for an isolation fault and likely cause the vehicle to not go into “ready” mode and will need to be towed. Other EV Maintenance Items: • Undercoating • Under belly pan cleaning • Rocker guard and mud flap cleaning • Thorough inspection EV’s built-in safety features: To review: • HV batteries are protected by the vehicle’s structure or enclosed in a metal case. • HV system is controlled the by vehicle’s 12-volt, or low-volt battery. • When the 12-volt system is interrupted, by turning off the ignition, the relay opens and the HV system is shut down. • HV systems are isolated from the vehicle’s chassis. • High voltage system is shutdown in the event of a crash. • EV systems include fuses and fault protection. • If system detects a short circuit due to water intrusion, it is designed to immediately shutdown. • Remote operation keys should be kept away from vehicles. • EVs are quiet – others may not hear it approaching. • High voltage cables are usually coloured orange. • Pressure washing near orange-coloured HV components is not recommended. Apprentices recharging an AC system need to keep in mind the AC system uses a non- conductive POE based refrigerant oil. The AC system lines need to be flushed from switching from PAG to POE oil in order to not contaminate the system. As well, air conditioning Systems should not only be serviced using the correct oil, but also with virgin refrigerant so that contamination form a previously recovered vehicle’s refrigerant does not contaminate the HVAC system. Typically, contaminating the system with conductive type oil will not cause serious issues, but if the AC compressor develops a HV insulation leak the oil will allow HV to conduct to ground and the vehicle will trigger a code for an isolation fault and likely cause the vehicle to not go into “ready” mode and will need to be towed. Other EV Maintenance Items - Undercoating - Under belly pan cleaning - Rocker guard and mud flap cleaning - Thorough inspection EV's built-in safety features: To review: • HV batteries are protected by the vehicle’s structure or enclosed in a metal case • HV system is controlled the by vehicle’s 12-volt, or low-volt battery • When the 12-volt system is interrupted, by turning off the ignition, the relay opens and the HV system is shut down • HV systems are isolated from the vehicle’s chassis • High voltage system is shutdown in the event of a crash • EV systems include fuses and fault protection • If system detects a short circuit due to water intrusion, it is designed to immediately shutdown • Remote operation keys should be kept away from vehicles • EVs are quiet – others may not hear it approaching • High voltage cables are usually coloured orange • Pressure washing near orange-coloured HV components is not recommended Apprentices recharging an AC system need to keep in mind the AC system uses a non- conductive POE based refrigerant oil. The AC system lines need to be flushed from switching from PAG to POE oil in order to not contaminate the system. As well, air conditioning Systems should not only be serviced using the correct oil, but also with virgin refrigerant so that contamination form a previously recovered vehicle’s refrigerant does not contaminate the HVAC system. Typically, contaminating the system with conductive type oil will not cause serious issues, but if the AC compressor develops a HV insulation leak the oil will allow HV to conduct to ground and the vehicle will trigger a code for an isolation fault and likely cause the vehicle to not go into “ready” mode and will need to be towed. Other EV Maintenance Items - Undercoating - Under belly pan cleaning - Rocker guard and mud flap cleaning - Thorough inspection EV's built-in safety features: To review: • HV batteries are protected by the vehicle’s structure or enclosed in a metal case • HV system is controlled the by vehicle’s 12-volt, or low-volt battery • When the 12-volt system is interrupted, by turning off the ignition, the relay opens and the HV system is shut down • HV systems are isolated from the vehicle’s chassis • High voltage system is shutdown in the event of a crash • EV systems include fuses and fault protection • If system detects a short circuit due to water intrusion, it is designed to immediately shutdown • Remote operation keys should be kept away from vehicles • EVs are quiet – others may not hear it approaching • High voltage cables are usually coloured orange • Pressure washing near orange-coloured HV components is not recommended consulab.com info@consulab.com 18 EV-601-TS_053322-96 Maintenance and Safety Meters and Service Repairs This is the most critical area where PPE and equipment are critical for safety and proper repair. Once covers are removed and orange cables and contacts are exposed the risks are real. Different types of meters are used and can be used as long as they have the proper protection properties and can read high voltage lev- els.Different meters will serve different purpose such as insulation meters – these look for shorts in windings or cables in a vehicle. These meters are also capable of high voltage output and must be handled properly. Testing with a meter on high voltage is no different than 12 volt systems as long as you follow manufactures placement and use proper protec- tion items. If using a insulation tester know what your testing and become familiar with how it works when looking for a problem. A insulation tester strains the system by pushing higher voltage through the wires looking for a leak. Typical rule is to exceed 2x that of the voltage component being tested. For example if a battery HV cable is being checked and the cable carries 400 volts the most you need to test is 800 volts on the tester. Insulation testers use a high voltage, low current DC charge to measure the resistance within wires and motor windings to identify current leakage and faulty or damaged insulation, which can lead to arc faults, blown circuits, and risk of electrical shock or fire. State of Charge A technician needs to be mindful of the state of charge of an EV. If the vehicle is staying overnight at your shop, you may need to charge it so the customer has enough range to take the vehicle back home in the morning. Typically, after most repairs it would be common courtesy to start charging a vehicle after repair, unless the customer was waiting to pick up the vehicle. This would also depend on the amount of range left when the customer arrives which is something to consider before you start road testing a vehicle – never road test an EV more than what’s required during service. Giving a waiting customer their vehicle back with significantly less charge may cause an issue and depending on driving style it may be apparent that the vehicle was driven fairly aggressively as well. A Common Issue Customer complaints of an electric vehicle not charging – Often this is a user error as the owner does not realize there is a charge timer equipped on the vehicle. Vehicles come with charge timers to delay the charge time to the middle of the night as in some areas of the world energy is cheaper in less busy times. If a technician plugs in an EV and it does take a charge or doesn’t show the appropriate charge indicator the problem may be a charge timer set and can be turned off through the dash. Another thing to note is most EVs use lights on the dash to indicate the charge level or if there is an error with the onboard charger. What happens varies from vehicle to vehicle but be aware that those LEDs actually mean something and may help you figure out what is going on. Meters and service repairs This is the most critical arear where PPE and equipment are critical for safety and proper repair. Once covers are removed and orange cables and contacts are exposed the risks are real. Different types of meters are used and can be used as long as they have the proper protection properties and can read high voltage levels. Different meters will serve different purpose such as insulation meters – these look for shorts in windings or cables in a vehicle. These meters are also capable of high voltage output and must be handled properly. Testing with a meter on high voltage is no different than 12 volt systems as long as you follow manufactures placement and use proper protection items. If using a insulation tester know what your testing and become familiar with how it works when looking for a problem. A insulation tester strains the system by pushing higher voltage through the wires looking for a leak. Typical rule is to exceed 2x that of the voltage component being tested. For example if a battery HV cable is being checked and the cable carries 400volts the most you need to test is 800volts on the tester. Insulation testers use a high voltage, low current DC charge to measure the resistance within wires and motor windings to identify current leakage and faulty or damaged insulation, which can lead to arc faults, blown circuits, and risk of electrical shock or fire. State of Charge A technician needs to be mindful of the state of charge of an EV. If the vehicle is staying overnight at your shop, you may need to charge it so the customer has enough range to take the vehicle back home in the morning. Typically, after most repairs it would be common courtesy to start charging a vehicle after repair, unless the customer was waiting to pick up the vehicle. This would also depend on the amount of range left when the customer arrives which is something to consider before you start road testing a vehicle – never road test an EV more than what’s required during service. Giving a waiting customer their vehicle back with significantly less charge may cause an issue and depending on driving style it may be apparent that the vehicle was driven fairly aggressively as well. A Common Issue Customer complaints of an electric vehicle not charging – Often this is a user error as the owner does not realize there is a charge timer equipped on the vehicle. Vehicles come with charge timers to delay the charge time to the middle of the night as in some areas of the world energy is cheaper in less busy times. If a technician plugs in an EV and it does take a charge or doesn’t show the appropriate charge indicator the problem may be a charge timer set and can be turned off through the dash. Another thing to note is most EVs use lights on the dash to indicate the charge level or if there is an error with the onboard charger. What happens varies from vehicle to vehicle but be aware that those LEDs actually mean something and may help you figure out what is going on. Safety While working on EV vehicles you may come across orange cables while doing repairs on the vehicle. Orange cables contain HV electricity and you should not work with these cables. In most cases, this is nothing to be concerned with as long as you are not working directly near them. In circumstances where you are working near the orange cables you need to consult with the EV certified technician in the shop to see what safety steps need to be taken, if any. In most cases vehicles that are not in ready mode pose very little risk when you are working around orange cables. start charging a vehicle after repair, unless the customer was waiting to pick up the vehicle. This would also depend on the amount of range left when the customer arrives which is something to consider before you start road testing a vehicle – never road test an EV more than what’s required during service. Giving a waiting customer their vehicle back with significantly less charge may cause an issue and depending on driving style it may be apparent that the vehicle was driven fairly aggressively as well. A Common Issue Customer complaints of an electric vehicle not charging – Often this is a user error as the owner does not realize there is a charge timer equipped on the vehicle. Vehicles come with charge timers to delay the charge time to the middle of the night as in some areas of the world energy is cheaper in less busy times. If a technician plugs in an EV and it does take a charge or doesn’t show the appropriate charge indicator the problem may be a charge timer set and can be turned off through the dash. Another thing to note is most EVs use lights on the dash to indicate the charge level or if there is an error with the onboard charger. What happens varies from vehicle to vehicle but be aware that those LEDs actually mean something and may help you figure out what is going on. Safety While working on EV vehicles you may come across orange cables while doing repairs on the vehicle. Orange cables contain HV electricity and you should not work with these cables. In most cases, this is nothing to be concerned with as long as you are not working directly near them. In circumstances where you are working near the orange cables you need to consult with the EV certified technician in the shop to see what safety steps need to be taken, if any. In most cases vehicles that are not in ready mode pose very little risk when you are working around orange cables. Meters and service repairs This is the most critical arear where PPE and equipment are critical for safety and proper repair. Once covers are removed and orange cables and contacts are exposed the risks are real. Different types of meters are used and can be used as long as they have the proper protection properties and can read high voltage levels. Different meters will serve different purpose such as insulation meters – these look for shorts in windings or cables in a vehicle. These meters are also capable of high voltage output and must be handled properly. Testing with a meter on high voltage is no different than 12 volt systems as long as you follow manufactures placement and use proper protection items. If using a insulation tester know what your testing and become familiar with how it works when looking for a problem. A insulation tester strains the system by pushing higher voltage through the wires looking for a leak. Typical rule is to exceed 2x that of the voltage component being tested. For example if a battery HV cable is being checked and the cable carries 400volts the most you need to test is 800volts on the tester. Insulation testers use a high voltage, low current DC charge to measure the resistance within wires and motor windings to identify current leakage and faulty or damaged insulation, which can lead to arc faults, blown circuits, and risk of electrical shock or fire. State of Charge A technician needs to be mindful of the state of charge of an EV. If the vehicle is staying overnight at your shop, you may need to charge it so the customer has enough range to take the vehicle back home in the morning. Typically, after most repairs it would be common courtesy to consulab.com info@consulab.com 19 EV-601-TS_053322-96 Maintenance and Safety Safety While working on EV vehicles you may come across orange cables while doing repairs on the vehicle. Orange cables contain HV electricity and you should not work with these cables. In most cases, this is nothing to be concerned with as long as you are not working directly near them. In circumstances where you are working near the orange cables you need to consult with the EV certified technician in the shop to see what safety steps need to be taken, if any. In most cases vehicles that are not in ready mode pose very little risk when you are working around orange cables. What Can I Work On? Apprentices and entry-level technicians can work on most vehicle systems on an EV without special equipment and specific EV training. Refer to the service information provided. If there is no mention of disabling the HV system or warn- ings of touching orange cables, then it is generally appropriate to start work on the vehicle. It is always a good idea to consult with the EV certified technician in the shop. Items such as tires, brakes, suspension, lighting, infotainment, interior components, windshield wiper components, final drive services, and cabin filters do not require specific EV training, but the service information should still always be referred to prior to attempting the repairs. High Voltage Battery Testing and Quality Checks Importance of quality checks of HV Batteries With EVs, PHEVs, and Hybrid vehicles emerging as the standard platform for vehicles in the global market, demand for HV battery testing and quality checks will be increasing in the very near future. Now, more than ever, it is also important to ensure quality end-of-life HV batteries are being repurposed and that the end user is fully informed about the battery. We must raise the bar in terms of HV battery testing competencies in the automotive service and repair industry. Key Information There are a few items the automotive service technician needs to record before they can make a true evaluation of the quality of an HV battery. Specialized scan tools and training are required to be able to identify this information, and to determine the condition of the HV battery. In some cases, the information can be hard to find and may require vehicle specific type scan tools, but in most cases the information is readily available and can be identified on the driver’s vehi- cle information display. Codes in the Battery Energy Control Module Recording and investigating codes in the BECM is vital to understanding the condition of the HV battery. It is possible for codes related to a collision to be permanently stored in the BECM and make it unusable without specialized pro- gramming. The BECM will self diagnose the battery if any faults are present with its cells, contactors, and hardware components that are sealed inside the HV battery case. It is likely that codes will be present on a vehicle that is beyond superficially damaged and no longer drivable. Codes for lack of communication due to severed wires or faults with oth- er subsequent components are to be expected, but what is not expected are codes related to cell damage or contactor issues. Internal repair or parts harvesting of HV batteries should only be performed by qualified individuals with the correct equipment. What Can I Work On? Apprentices and entry-level technicians can work on most vehicle systems on an EV without special equipment and specific EV training. Refer to the service information provided. If there is no mention of disabling the HV system or warnings of touching orange cables, then it is generally appropriate to start work on the vehicle. It is always a good idea to consult with the EV certified technician in the shop. Items such as tires, brakes, suspension, lighting, infotainment, interior components, windshield wiper components, final drive services, and cabin filters do not require specific EV training, but the service information should still always be referred to prior to attempting the repairs. High Voltage Battery Testing and Quality Checks Importance of quality checks of HV Batteries With EVs, PHEVs, and Hybrid vehicles emerging as the standard platform for vehicles in the global market, demand for HV battery testing and quality checks will be increasing in the very near future. Now, more than ever, it is also important to ensure quality end-of-life HV batteries are being repurposed and that the end user is fully informed about the battery. We must raise the bar in terms of HV battery testing competencies in the automotive service and repair industry. Key Information There are a few items the automotive service technician needs to record before they can make a true evaluation of the quality of an HV battery. Specialized scan tools and training are required to be able to identify this information, and to determine the condition of the HV battery. In some cases, the information can be hard to find and may require vehicle specific type scan tools, but in most cases the information is readily available and can be identified on the driver’s vehicle information display. Codes in the Battery Energy Control Module Recording and investigating codes in the BECM is vital to understanding the condition of the HV battery. It is possible for codes related to a collision to be permanently stored in the BECM and make it unusable without specialized programming. The BECM will self diagnose the battery if any faults are present with its cells, contactors, and hardware components that are sealed inside the HV battery case. It is likely that codes will be present on a vehicle that is consulab.com info@consulab.com 20 EV-601-TS_053322-96 Educational Outcomes Educational Outcomes 1. Understanding of Electric Vehicle Technology: Students gain a comprehensive understanding of the key compo- nents and operation of electric vehicles, using a real-world Tesla Model 3 platform. 2. Hands-on Experience: The EV-601 provides practical, hands-on experience with electric vehicle systems, allowing students to engage directly with the components and understand their functions. 3. Safety Training: Students learn crucial safety protocols for handling high-voltage systems, fostering safe work prac- tices in an EV environment. 4. Diagnostic Skills Development: The EV-601 enables students to diagnose and troubleshoot various EV systems, enhancing their problem-solving and technical skills. 5. Real-world Scenario Simulation: Through the ConsuLab touchscreen and control system, students can simulate different scenarios, gaining experience in various operational states and fault conditions. 6. Technical Proficiency in EV Components: Students become familiar with specific EV components, such as battery management systems, electric motors, inverters, and cooling systems. 7. Collaborative Learning and Teamwork: The EV-601 encourages group work, promoting collaborative problem-solv- ing and communication skills essential in the automotive industry. 8. Industry-relevant Knowledge: Training with the EV-601 aligns with current industry standards and practices, ensur- ing students acquire relevant and up-to-date knowledge. 9. Enhanced Visual Learning: LED strip indicators and component cutaways provide visual learning aids, making com- plex concepts more accessible and easier to understand. 10. Adaptability and Versatility in Learning: The modular design of the EV-601 allows for tailored learning experiences, adaptable to various educational needs and curricula. 11. Sustainability Awareness: The EV-601 emphasizes the importance of sustainable technologies in automotive design, aligning with global trends towards environmentally conscious practices. consulab.com info@consulab.com 21 EV-601-TS_053322-96 Suggested Educational Materials Suggested Educational Materials EV Training Course Course Length: 10 Days Tools and Equipment: • Insulating gloves (recently certified), leather the protectors, safety glasses, insulated mats) • Insulation resistance tester (Fluke 1587 or equivalent) • Scan accessing EV-601 (ELM 327 with Scan My Tesla) • EV-601 • EV Tools and Safety Kit • Wheel chocks • Assorted hand tools as needed. Essential Skills Summary: 1. READING: Automotive service technicians must read and comprehend a variety of materials including repair manu- als, manufacturers’ bulletins and safety documents. They refer to government regulations, vehicle inspection proce- dures, hazardous material handling and disposal and safety requirements of vehicles. 2. DOCUMENT USE: Automotive service technicians interpret technical drawings and flowcharts. They locate data such as classifications, product and material specifications, identification numbers, quantities and costs. Automotive ser- vice technicians often use specification tables. They scan a variety of manufacturers’ labels for part numbers, serial numbers, sizes, colours and other information and adhere to hazard and safety icons. 3. WRITING: Automotive service technicians complete workplace documents such as written explanations to the client, work orders, inspection reports and incident reports. 4. ORAL COMMUNICATION: Automotive service technicians gather information from different sources about vehicle faults and needed repairs, explain the results of inspections and repairs, and discuss maintenance procedures. They exchange technical repair and troubleshooting information with others such as service managers, apprentices, co-workers, colleagues and suppliers. 5. NUMERACY: Automotive service technicians take a variety of measurements using digital and analog equipment. They estimate the amount of time required to complete repairs. Automotive service technicians compare measure- ments of energy, dimension, speed, horsepower, temperature and torque to specifications. They analyze pressure, power, torque, compression and electrical readings to assess vehicle performance and troubleshoot faults. 6. THINKING: Automotive service technicians use thinking skills and visual analysis to diagnose and repair problems. They evaluate the severity of vehicle defects and deficiencies and the quality of repairs. Automotive service techni- cians decide the most efficient course of action to complete a job. consulab.com info@consulab.com 22 EV-601-TS_053322-96 Suggested Educational Materials consulab.com info@consulab.com 22 7. WORKING WITH OTHERS: Most automotive service technicians work independently on jobs outlined in work orders. They may assist others with jobs that require two people or are within their specific area of expertise. They collabo- rate effectively with colleagues including salespersons, parts persons and management to resolve concerns, situa- tions and problems. 8. DIGITAL TECHNOLOGY: Automotive service technicians use computerized scanning equipment, onboard vehicle diagnostics and hand-held diagnostic tools to gain operational information about vehicles. They access the Internet and databases to retrieve repair information. Automotive service technicians use digital technology to exchange in- formation with other technicians, service managers, colleagues in other locations and manufacturer support special- ists. Keyboarding and basic computer skills are an asset. 9. CONTINUOUS LEARNING: Constant change in the industry makes it vital for automotive service technicians to stay current with the latest technology. They learn on the job, in organized information activities and in work discussion groups. Their training is provided by vehicle manufacturers, parts suppliers, employers, and associations. They also advance skills by reading work-related magazines, periodicals, and automotive websites. consulab.com info@consulab.com 23 EV-601-TS_053322-96 Suggested Educational Materials consulab.com info@consulab.com 23 Example Course Map and Task Matrix for Teaching EVs A. Safety and Related Tasks and Common Occupational Skills A-1: Recognizes Safety Considerations for High Voltage Vehicles - A-1.01: Identify safety hazards and maintain a safe workplace. - A-1.02: Different types of PPE and PPE storage and care. A-2: High Voltage System Identification - A-2.02: Identify components and characteristics of the high voltage system. A-3: Standards and Codes - A-3.01: Look up standards and codes that apply to Electric Vehicles. A-4: Uses Tools, Software, and Equipment - A-4.01: Service information. - A-4.02: Tools and equipment. A-5: Identification and Operation of Hybrid, Plug-in Hybrid, and Battery Electric Vehicle - A-5.01: Identification. B. Diagnose and Repair Battery Systems and Related Components B-1: Battery Systems - B-1.01: Recognizes battery components, locations, and hazards. - B-1.02: Battery Service. B-2: Diagnose Cables and Connectors - B-2.01: Cables and connectors. B-9: Battery Removal and Installation - B-9.01: Secure and isolate vehicle. - B-9.02: Follow manufacturers’ procedure information. - B-9.03: Use lifting devices and equipment. - B-9.04: Install HV battery. B-10: Battery Disposal - B-10.01: Safety and procedures. - B-10.02: Battery storage and securing. - B-10.03: Disposal and recycling of all types of EV batteries. consulab.com info@consulab.com 24 EV-601-TS_053322-96 Suggested Educational Materials consulab.com info@consulab.com 24 C. Charging Systems and Components C-11: Charging Systems - C-11.01: Levels of charging. - C-11.02: Charging equipment EVSE. - C-11.03: Charging connectors. C-12: Onboard Chargers - C-12.01: Charger types. - C-12.02: Function. C-13: Offboard Chargers - C-13.01: Charger types. - C-13.01: Function. D. High Voltage Drive Controllers, Inverters, Battery Management Systems, DC to DC Converters, and Cabling D-14: Drive Controllers, Inverters, DC/DC - D-14.01: Function and operation. - D-14.02: Inverters. - D-14.03: DC to DC converters. - D-14.04: Battery management systems. D-15: High Voltage Cables - D-15.01: Identification. - D-15.02: Cable shielding. - D-15.03: Cable Routing and securing. - D-15.04: Cable repair. E. Electric Drive Units and Reduction Gear Transmission E-15: Electric Motors - E-15.01: Types of motors. - E-15.02: Function and operation. - E-15.03: Testing and diagnostics. - E-15.04: Remove and replace. E-16: Reduction Gear and or Transmission - E-16.01: Reduction gear operation and function. - E-16.02: Servicing and maintenance. - E-16.03: Remove and replace. consulab.com info@consulab.com 25 EV-601-TS_053322-96 Suggested Educational Materials Complete Curriculum Guide (occupational standard) Major Work - Activity A: Safety and Related Tasks and Common Occupational Skills Task Description: Proper use of personal protective equipment (PPE) and safe work practices is essential due to the fact that automotive service technicians are exposed to hazardous materials and potentially dangerous equipment. Task A-1: Recognizes Safety Considerations for High Voltage Vehicles A-1.01: Identify safety hazards and maintains safe workplace Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-1.01a Identify workplace hazards with electric vehicles Understand safety regulations with electric vehicles including OSHA, ASTM, ANSI, CSA and other safety regulations. A-1.01b Apply safety standards when working with high voltage systems Know how to locate and apply and use standards when repairing or maintaining high voltage vehicles A-1.01c Maintain and secure area for electric vehicle servic- ing or maintaining Following safety standards and procedures for the workplace and regulations dealing with electric vehicles if available. A-1.01d Follow manufactures procedures when working with electric vehicles. Using service information to identify and properly repair electric vehicles. A-1.01e Identify damaged or otherwise unsafe condition of an electric vehicle Use original manufactures procedures in determin- ing non functioning, defective, or damaged compo- nents. A-1.01f Report any hazards and safety concerns with elec- tric vehicles. Notification to supervisor on an unsafe condition or hazards. Worksite hazards include spills, obstructions, defective equipment, batteries, various safety equipment, fluids, and chemicals. Safety regulations include Occupational Health and Safety (OH&S), Workplace Hazardous Materials, CSA, Workplace Hazardous Materials Informa- tion System (WHMIS)/Globally Harmonized System (GHS) provincial, federal regulations, CSA and SAE standards. Hazards include personal, environmental, shop/facility (fire, explosion, gases), vehicle restraint systems, high voltage systems, high pressure fuel systems (Hybrids). consulab.com info@consulab.com 26 EV-601-TS_053322-96 Suggested Educational Materials A-1.02: Different types of personal protection equipment (PPE), PPE storage and care Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-1.02a Identify different types of personal protection for high voltage servicing. Demonstrate and explain what the PPE does and how it serves to protect the user. A-1.02b Inspect and identify any damage to personal protec- tive equipment (PPE) before use. Following occupational health and Safety (OH&S) and other standards including manufactures specifi- cations on proper inspection of Personal protection equipment. A-1.02c Use personal protection equipment PPE properly for specific tasks. Demonstrate the Function and use of select PPE with understanding of its use for repairs or servicing. A-1.02d Read and understand the ratings and expiration dates on PPE. Location of safety information. A-1.02e Prepare and inspect PPE before and after use and properly store PPE. Demonstrate the requirements of the inspection and regulations of recertification of PPE equipment as well as maintaining PPE. A-1.02f Access and selection of proper PPE . Select proper PPE as required under manufactures service requirements and following not limited to provincial and federal regulations. A-1.02g Properly fit and adjust PPE. Using and guidelines by the manufacture and not limited to OH&S and others for fitment and secure- ment of PPE. Personal protection equipment for high voltage EVs include gloves, boots, shields, clothing, eye protection, insulating mats, head protection and breathing apparatus. Inspection visual, feel, function, recording and identifying expiration and could include these from standards with Occupational Health and Safety (OH&S), Workplace Hazardous Materials, CSA, Workplace Hazardous Materials Information System (WHMIS)/Globally Harmonized System (GHS) provincial, federal regulations, CSA and SAE standards. consulab.com info@consulab.com 27 EV-601-TS_053322-96 Suggested Educational Materials Task A-2: High Voltage System Identification A-2.01: Identify components and their characteristics to the high voltage systems Task Description: Identification of components that carry and store high voltage. This could include under hood and under vehicle components. Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-2.01a Locate components in an electric vehicle. Components are identified based on function. A-2.01b Demonstrate knowledge of the components and describe their operation. Explain the basic function and its relationship with each component to the high voltage system. A-2.01c Inspect and determine function of the high voltage components. using OE information to determine function. A-2.01d Determine flow of operation of high voltage systems in a HEV,PHEV and an BEV. Explain the differences between systems using man- ufactures or other information. Original Equipment information manufactures information, service repair information, technical service information, theory of operation manuals, owners manual, under hood labels. Inspection visual, feel, function, recording and identifying expiration and could include these from standards from Manufacture service information, Occupational Health and Safety (OH&S), Workplace Hazardous Materials, CSA, Workplace Hazardous Materials Information System (WHMIS)/Global- ly Harmonized System (GHS) provincial, federal regulations, CSA and SAE standards. Task A-3: Standards and Codes A-3.01: Standards and codes that apply to electric vehicles Task Description: Understand how to access, use and apply to ensure that standards are being meet for safety in a shop when working on electric vehicles. Essential Skills: Document Use, Thinking, Reading, Continuous Learning RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-3.01a Locate and use safety standards when working with PPE. Different documents that relate to high voltage EV safety systems. A-3.01b Apply safety standards when working on different services with high voltage. Explain and how they apply to jobs when working on high voltage vehicles. A-3.01c Describe the different standards that are used with electric vehicles. Identify tasks that relate to different standards. consulab.com info@consulab.com 28 EV-601-TS_053322-96 Suggested Educational Materials Task A-4: Uses Tools, Software and Equipment. A-4.01: Service information Task Description: To select proper tools for high voltage repair and servicing this could be in hand, shop equipment or specialty equipment. Access to service information on repair, maintenance, and diagnostics to determine process. Essential Skills: Reading, Document Use, Digital Technology, Thinking. RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-4.01a Access technical diagnostic and repair information for EV high voltage systems. Using different means to access both OE and aftermarket techni- cal information. A-4.01b Apply technical information to HV re- pairs and service. Information is used to diagnose, repair and maintain an EV. A-4.01c Use technical service bulletins and recalls for repairs on EVs. Identifies and validates if applicable to repair. A-4.02: Tools and equipment Essential Skills: Numeracy, Thinking, Document Use. RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-4.02a Store and organize high voltage tools. Follows manufactures recommendation shop policy and safety standards A-4.02b Demonstrate knowledge of HV tools and equipment, their applications, maintenance and procedures for use. Identify shop tools their use, function and applica- tion when working on HV systems. A-4.02c inspect tools and equipment regularly to recognize wear, damage, defects or expiry. Wear, damage, defects or expiry are identified according to safety regulations and manufacturers’ information. A-4.02d Operate and use tools when servicing HV vehicles Follow manufactures instructions A-4.02e identify, remove, repair or replace defective equip- ment. Defective equipment removed from service tagged and notified to supervisor. A-4.02f Meters and testing equipment for voltage testing on low and high voltage systems. Select proper tools and functions for manufactures required test. A-4.02g determine vehicle or item lifting points and required adapters and extensions for EVs. Vehicle or item lifting points and required adapters and extensions are used and determined according to manufacturers’ info. A-4.02h determine type and capacity of hoisting and lifting equipment required for EV’s. Refer to manufactures requirements. consulab.com info@consulab.com 29 EV-601-TS_053322-96 Suggested Educational Materials consulab.com info@consulab.com 29 Task A-5: Identification and Operation of a Hybrid, Plug-in Hybrid and Battery Electric Vehicle A-5.01: Identification Task Description: When differentiating between different types of high voltage vehicles. Each type offers a unique func- tion of operation. This function of operation effects repair and safety. Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence A-5.01a Explain the difference between different types of high voltage vehicles. Using manufactures information to describe the op- eration, components and functions of a HV vehicle. A-5.01b Explain the power flow of a hybrid vehicle. Describe the hybrid theory of operation. A-5.01c demonstrate high voltage vehicles identification. Identify different makes and models of HV vehicles. A-5.01d Describe the proper use of safety information be- fore servicing Hybrids, PHEV and BEV. Using manufactures information. consulab.com info@consulab.com 30 EV-601-TS_053322-96 Suggested Educational Materials Major Work - Activity B: Diagnose and Repair Battery Systems and Related Components Task Description: Technicians working with high voltage systems will diagnosis, replace and service battery system and components. Task B-1: Battery Systems B-1.01: Recognizes battery components locations and hazards Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence B-1.01a Select proper PPE Following manufactures service information and shop policies. Understand safety regulations with electric vehicles including OSHA, ASTM, ANSI, CSA and other safety provincial or federal regulations. B-1.01b Work with service information when testing high voltage batteries Using manufactures information when servicing B-1.01c Select proper meters and related service equipment when servicing a HV system Test are used in accordance with manufactures information B-1.01d Locate the high voltage battery’s location Identify battery location using manufactures infor- mation B-1.01e Identify lift points on a vehicle Following manufactures information consulab.com info@consulab.com 31 EV-601-TS_053322-96 Suggested Educational Materials Task B-2: Diagnose Battery System and Components. Storage, Transport and Disposal of HV Battery B-2.01: Battery service Essential Skills: Reading, Numeracy, Thinking, Document Use RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence B-2.01a Remove a HV battery. Following manufactures procedures. B-2.01b Set up work area and secure area. Using shop policies and manufactures procedures as well as standards to follow safe work practices. B-2.01c Retrieve codes and data related to battery. Codes and data are retrieved. B-2.01d Interpret and view DTC and data. Used to determine condition and fault-finding proce- dures for repair. B-2.01e Power down vehicle. Follow manufactures instructions in deactivating a high voltage vehicle. B-2.01f Select proper tools. Refer to manufactures procedures for repair tools. B-2.01g Interpret and preform a battery health check. Using manufactures information in procedures. B-2.01h Drain and refill the battery cooling system. Follow manufactures procedures. B-2.01i Verify repair. Repair is verified by retest. B-2.02: Battery storage out of vehicle Essential Skills: Numeracy, Thinking, Document Use RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence B-2.02a Store a HV battery. Following standards and manufactures procedures for storage. B-2.02b Deactivate (power down a battery). Manufactures procedures as well as local codes and standards. B-2.02c Retrieve and record information. Codes and data are retrieved and data is stored. B-2.02d Isolate high voltage terminals. Refer to manufactures procedures for storage. consulab.com info@consulab.com 32 EV-601-TS_053322-96 Suggested Educational Materials B-2.03: Battery transport Essential Skills: Numeracy, Thinking, Document Use RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence B-2.03a Prepare battery for shipping. Following manufactures procedures and follow TDG and other regulations. B-2.03b Package and identify battery. Forms and components for safe packaging as per TDG 5.12. B-2.03c Fill forms and contact shipper for transport. Follow TDG for information and procedures as well as policies on transport. B-2.03d Interpret and view DTC and data. Used to determine condition and fault-finding proce- dures for repair. B-2.04: Battery disposal Essential Skills: Numeracy, Thinking, Document Use RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence B-2.04a Prepare battery for disposal. Following standards and manufactures procedures for storage. B-2.04b Locate and verify procedures for disposal. Manufactures procedures as well as local codes and standards. B-2.04c Package and identify battery. Codes and data are retrieved and data is stored. B-2.04d Fill forms and contact shipper for transport. Refer to manufactures procedures for storage. Task B-3: Diagnose Cables and Connectors B-3.01: Cables and connectors Essential Skills: Numeracy, Thinking, Document Use RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence B-3.01a Locate types of cables. Identify cables based on manufactures information. B-3.01b Replace cables. Based on manufactures information. B-3.01c Test cables. Using repair procedures and toolfunction. B-3.01d Remove connectors. Follow manufactures instructions. B-3.01e Inspect, identify and verify connectors. Test connectors and functions according to manu- factures procedures. B-3.01f Verify repair. Repair is verified by retest. consulab.com info@consulab.com 33 EV-601-TS_053322-96 Suggested Educational Materials Major Work - Activity C: Diagnose and service high voltage electronic control systems and HVAC systems Task Description: Technicians working with high voltage systems will diagnosis, replace and service electronic control units. These may include and not limited to inverters, dc/dc convertors, chargers, and other systems that use high volt- age. Task C-1: High Voltage Systems C-1.01: Diagnosis and service high voltage controllers Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence C-1.01a Identify controllers for purpose and function. Explain the function and operation of control units using manufactures information. C-1.01b Inspect operation and measurements. Using manufactures information when servicing to inspect for function, wear, damage and failure. C-1.01c Remove and replace. In accordance with manufactures information. C-1.01d Select and use diagnostic tools and equipment. Used to pinpoint failures. C-1.01e interpret viewed values and DTCs. Viewed values and DTCs are interpreted to deter- mine condition of systems and component. C-1.01f Demonstrate knowledge of basic electrical and elec- tronic principles. Explain basic electrical theory. C-1.01g Use wiring diagrams and flow charts. Wiring diagrams are interpreted to determine the structure of circuits. consulab.com info@consulab.com 34 EV-601-TS_053322-96 Suggested Educational Materials C-1.02: Diagnosis and service charging stations Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence C-1.02a Identify the different levels of charging stations. Explain function in accordance of manufactures information. C-1.02b Identify components and connectors of the charging station. Referring to standards and manufactures informa- tion. C-1.02c Diagnose the operation of the charging station. In accordance with manufactures information. C-1.02d Test and diagnose charging station to vehicle. Used to pinpoint failures. C-1.02e Demonstrate knowledge of basic electrical and elec- tronic principles. Explain basic electrical theory. C-1.02f Demonstrate knowledge of basic electrical and elec- tronic principles. Explain basic electrical theory. C-1.03: Diagnosis and service air conditioning and related systems Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence C-1.03a Identify concern and components to HV compressor and heater system. Explain the function and operation of control units using manufactures information. C-1.03b Inspect operation and measurements. Using manufactures information inspect for function, wear, damage and failure. C-1.03c Remove and replace. In accordance with manufactures information C-1.03d Select and use diagnostic tools and equipment. Used to pinpoint failures. C-1.03e interpret viewed values and DTCs. Viewed values and DTCs are interpreted to deter- mine condition of systems and component. C-1.03f Preform safety related shutdown of system. Follow manufactures procedures in accordance to safety standards C-1.03g Use wiring diagrams and flow charts. wiring diagrams are interpreted to determine the structure of circuits. C-1.03h Follow refrigerant flow and control operation relat- ed to HV system. Using manufactures information to service HVAC systems. C-1.03i Verify concern and test . Accordance to manufacture information consulab.com info@consulab.com 35 EV-601-TS_053322-96 Suggested Educational Materials Major Work - Activity D: Diagnose and Service High Voltage Drive and Final Drive Units Task Description: In place of traditional transmissions, electric vehicles use a reduction type system for transfer of power to the final drive unit. Task D-1: Reduction Type Systems D-1.01: Diagnosis and service electric motors Essential Skills: Document Use, Thinking, Reading RANGE OF VARIABLES: Required Knowledge Demonstrative Evidence D-1.01a Demonstrate operation of motors and related com- ponents. Explain the function and operation of manufactures information. D-1.01b Inspect operation and measurements. Using manufactures information when servicing to inspect for function, wear, damage and failure. D-1.01c Remove and replace. In accordance with manufactures information. D-1.01d Select and use diagnostic tools and equipment. Used to pinpoint failures. D-1.01e Interpret viewed values and DTCs. viewed values and DTCs are interpreted to deter- mine condition of systems and component. D-1.01f Diagnose drive motors for proper function and performance Manufactures testing and related equipment. D-1.01g Use wiring diagrams and flow charts. Wiring diagrams are interpreted to determine the structure of circuits and operation. D-1.01h Select tools and equipment. Tools and equipment are selected according to task. D-1.01i Conduct tests of motor after repair. Motor assembly is tested after repair, connected and functions according to manufacturers specifica- tions. consulab.com info@consulab.com 36 EV-601-TS_053322-96 Student Assignments Student Assignments ANSWERS consulab.com info@consulab.com 37 EV-601-TS_053322-96 Student Learning Module 1 Student Learning Module 1 Component Identification This section requires students to find, locate, name the EV-601-TS key components, and identify their aspects. This can be used with resources found in books, online and during presentations. consulab.com info@consulab.com 38 EV-601-TS_053322-96 Module 1 — Trainer Layout and Familiarization Trainer Layout and Familiarization iDev Component locator 1 2 3 4 5 6 7 8 9 10 12 18 1415 11 24 16 17 2223 21 2019 25 1. Radiator 2. A/C Condensor 3. Power Steering rack & Pinion 4. Steering torque sensor 5. Power train coolant pump 6. Battery coolant pump 7. A/C Expansion valve 8. Chiller 9. Front Security loop 10. HV Contactor negative 11. HV Contactor positive 12. HV DCFC Contactor 13. Pyro-Fuse 14. PCS (Power Conversion System) 15. HV Controller 16. Motor assembly with gear reduction 17. Stator 18. Rotor 19. Three phase 20. Inverter 21. Inverter Cooler 22. Final Drive 23. Heat Exchanger oil 24. Resolver 25. Rear Security loop13 consulab.com info@consulab.com 39 EV-601-TS_053322-96 Module 1 — Trainer Layout and Familiarization Tesla Model 3 Components Front Trunk (Frunk): The front trunk, or “frunk,” is located at the front of the vehicle, where a traditional car’s engine would be. It houses items like the windshield washer fluid reservoir, HVAC (Heating, Ventilation, and Air Conditioning) components, and the 12V battery. Rear Trunk: The rear trunk is accessible from the outside of the car and contains the main cargo space. Depending on the model and configuration, it may also have a compartment for additional storage space or house components like the rear motor. Battery Pack: The battery pack, a crucial component in electric vehicles, is typically located underneath the vehicle, forming the car’s floor structure. Charging Port: The charging port is on the rear left side of the vehicle, near the tail light. This is where you would connect the charging cable for recharging the battery. Both L1, L2 and DCFC is all done from this port for charging. Electric Motors: The Tesla Model 3 is an electric car with dual-motor options. The motors are generally located at the front and rear of the vehicle to enable all-wheel drive capabilities. Inverter: The inverter, responsible for converting DC power from the battery to AC power for the electric motors, is often located close to the motors, either in the front or rear of the vehicle. consulab.com info@consulab.com 40 EV-601-TS_053322-96 Module 1 — Trainer Layout and Familiarization Power Electronics: This includes components like the onboard charger and DC-DC converter, which manage the flow of electricity within the vehicle. They may be inte- grated into the powertrain system. Center Console: Inside the cabin, the center console houses the infotainment system, climate controls, and other features. It is controlled by the Infotainment screen between the front seats. The center console behind the drink holders is the location for the key card. Firmware and Software Systems: The software that controls various vehicle functions, including Autopilot capabilities, is distributed throughout the car’s computer systems. High Voltage Battery Size of battery depends on the model of car typical LR car has an 82KWh pack with &75KWh usable. Battery is located under the passenger floor boards of the car. consulab.com info@consulab.com 41 EV-601-TS_053322-96 Module 1 — SA-1 SA-1 Component #1 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Radiator 2. What is the component function? To move coolant through the electronics and helps cool them 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Thermal transfer unit — Coolant radiator 5. Component location: Front of vehicle in front of condenser 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? Large coolant lines that attach each side and run to coolant tank 8. Would this component cause the vehicle not to turn on (ready mode)? No, but it would restrict power and charging speeds 9. Would this component prevent the vehicle from driving? Low coolant would cause error codes and limp mode (reduced power and charging) 10. Is this component cooled by or heated by coolant? It works in conjunction with the A/C system 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A — No warnings for high voltage 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: Part of the low voltage system run by two 12 volt pumps 13. Removing this component would it require disconnecting/disabling the HV system? Yes Disabling the HV controller and would have a special procedure using service information on draining and filling consulab.com info@consulab.com 42 EV-601-TS_053322-96 Module 1 — SA-2 SA-2 Component #2 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Condenser 2. What is the component function? To move heat that was captured by the refrigerant from the evaporator and chiller units in the vehicle 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Heat exchanger — Heat transfer unit 5. Component location: Front of vehicle 6. Does the component store or carry HV (if applicable)? None 7. Are their any identifiers that indicate what the component does? Has refrigerant lines running in and out of it as a conventional ICE vehicle has. The condenser is no different than a ICE powered vehicles condenser 8. Would this component cause the vehicle not to turn on (ready mode)? No, but could restrict DCFC charging 9. Would this component prevent the vehicle from driving? No, it would not effect operation of the vehicle 10. Is this component cooled by or heated by coolant? It is part of the thermal exchange system but needs air move- ment by fan and moving air to operate 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No Special procedures on removal and recharging of refrigerant requires the HV compressor to be operational consulab.com info@consulab.com 43 EV-601-TS_053322-96 Module 1 — SA-3 SA-3 Component #3 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Steering rack 2. What is the component function? To provide directional control to the vehicle 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Rack and pinion — Electric assist system 5. Component location: Front of vehicle below attached to the sub frame 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? Steering attaches to it and tie rod ends come out to the wheels 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? Yes, the vehicle would not be controllable 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 44 EV-601-TS_053322-96 Module 1 — SA-4 SA-4 Component #4 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Torque arm and sensor 2. What is the component function? To engage the electric assist to the wheels 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Torque arm — Torsional arm — Torque sensor 5. Component location: Input shaft of the steering rack 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? It shows that it is an input from the steering wheel 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system?No consulab.com info@consulab.com 45 EV-601-TS_053322-96 Module 1 — SA-5 SA-5 Component #5 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Coolant pump #1 2. What is the component function? It helps cool the electronics side of the system 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Coolant transfer — Water pump 5. Component location: It’s attached to coolant reservoir passenger side 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? Coolant tank and wires attached 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? It’s part of the thermal management system 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 46 EV-601-TS_053322-96 Module 1 — SA-6 SA-6 Component #6 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Coolant pump #2 2. What is the component function? It moves coolant for the HV battery 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Thermal pump 5. Component location: Driver’s side of coolant reservoir 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? Attached to coolant reservoir and wires going to it 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? It’s part of the thermal management system 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 47 EV-601-TS_053322-96 Module 1 — SA-7 SA-7 Component #7 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Expansion Valve 2. What is the component function? To control refrigerant into the chiller 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: H-Valve — Expansion device 5. Component location: Before the battery chiller 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? Refrigerant lines going into a small chiller unit to help remove heat from the coolant 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? It’s part of the thermal management system 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 48 EV-601-TS_053322-96 Module 1 — SA-8 SA-8 Component #8 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Battery coolant chiller 2. What is the component function? To move heated coolant from the battery and to transfer heat to the refrigerant 3. High Voltage or Low Voltage? N/A 4. Other names for component: Chiller — Battery cooler 5. Component location: Driver’s side attached to the expansion valve part of the AC system and cooling system 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? Attached by coolant lines and A/C lines 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? It’s part of the thermal management system 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 49 EV-601-TS_053322-96 Module 1 — SA-9 SA-9 Component #9 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: First responder cut loop 2. What is the component function? First responder disconnect gives first responders the ability to disable the high voltage part of the system 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Cut loop — Firefighter loop 5. Component location: Driver’s side firewall 6. Does the component store or carry HV (if applicable)? N/A 7. Are their any identifiers that indicate what the component does? Labels and orange tags 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? Yes Explain: Orange colour indicates controls HV 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 50 EV-601-TS_053322-96 Module 1 — SA-10 SA-10 Component #10 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: HV contactor 2. What is the component function? To supply high voltage isolated negative 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Solenoid — HV switch 5. Component location: Inside penthouse driver’s side 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? High voltage lines in and out not coloured 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV DC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 51 EV-601-TS_053322-96 Module 1 — SA-11 SA-11 Component #11 — Answers SA-11 HV contactor positive 11. A. Name of component ____HV Contactor_____________________ B. What is the component function __ To supply high voltage isolated Positive_______________________ C. High Voltage or Low Voltage _____High Voltage______________ D. Other names for component ____ Solenoid __HV switch _______________ __________________ ________________ ________________ _______________ E. Component location _____Inside penthouse passenger side______________________ F. Does the component Store or carry HV (if applicable) Carry G. Are their any identifiers that indicate what the component does __ High voltage lines in and out not coloured heavy gauge bus bars_________________ H. Would this component cause the vehicle not to turn on (ready mode)_ _____yes__________________ I. Would this component prevent the vehicle from driving. ___Yes______________________ J. Is this component cooled by or heated by coolant ____No_____________________________________ K. Does the component have a “high voltage” warning sign or icon on it __Yes / no__X_ if it does what does it say. ______No____________________________ L. Is the component HV DC or AC powered (2 or 3 leads on the cable) ______HV DC______________ M. Removing this component would it require disconnecting/disabling the HV system ____Yes __________ Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: HV contactor (positive) 2. What is the component function? To supply high voltage isolated positive 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Solenoid — HV switch 5. Component location: Inside penthouse passenger’s side 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? High voltage lines in and out not coloured heavy gauge bus bars 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV DC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 52 EV-601-TS_053322-96 Module 1 — SA-12 SA-12 Component #12 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: DCFC contactors 2. What is the component function? They control power during supercharging 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Fast charge contactors 5. Component location: Inside penthouse direct to battery 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? Orange High Voltage 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? Yes Explain: Orange 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV DC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 53 EV-601-TS_053322-96 Module 1 — SA-13 SA-13 Component #13 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Pyro fuse 2. What is the component function? Safety disconnect in the event of a collision 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: HV fuse 5. Component location: Inside battery case in between modules 2 and 3 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? No 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV DC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 54 EV-601-TS_053322-96 Module 1 — SA-14 SA-14 Component #14 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Power conversion system 2. What is the component function? It’s used in charging to convert 120/240 into DC voltage 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Charger 5. Component location: Under penthouse rear of vehicle 6. Does the component store or carry HV (if applicable)? Carry and convert 7. Are their any identifiers that indicate what the component does? High voltage AC in DC out 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? Cooled by coolant 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: Only orange cables 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV AC and DC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 55 EV-601-TS_053322-96 Module 1 — SA-15 SA-15 Component #15 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: High voltage controller 2. What is the component function? It controls power and charging for the HV battery and components associated to it 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Controller 5. Component location: Rear under penthouse right rear of vehicle 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? No 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 56 EV-601-TS_053322-96 Module 1 — SA-16 SA-16 Component #16 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Motor assembly 2. What is the component function? It holds the final drive, stator and rotor 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Gear reduction unit — Drive unit 5. Component location: Rear of vehicle 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? Axles are attached 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? Cooled by coolant 11. Does the component have a “high voltage” warning sign or icon on it? Yes Explain: Labels and orange cables 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV DC and three phase AC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 57 EV-601-TS_053322-96 Module 1 — SA-17 SA-17 Component #17 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Stator 2. What is the component function? It provides the windings for the magnetic field for the rotor 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Stator coil 5. Component location: Inside reduction unit or motor housing 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? Windings inside 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? Yes, but cooled by oil 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: Inside motor housing 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV three phase AC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 58 EV-601-TS_053322-96 Module 1 — SA-18 SA-18 Component #18 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Rotor 2. What is the component function? In a PM motor inboard it holds the neodymium 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Rotor coil 5. Component location: Inside stator 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? No 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? Yes, but cooled by oil 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: Inside motor housing 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV AC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 59 EV-601-TS_053322-96 Module 1 — SA-19 SA-19 Component #19 — Answers L. Is the component HV DC or AC powered (2 or 3 leads on the cable) ___HV AC_________________ M. Removing this component would it require disconnecting/disabling the HV system ___Yes___________ SA-19 Cables for stator 19. A. Name of component ___Cables for Stator______________________ B. What is the component function ___Supply 3 phase AC power to the stator______________________ C. High Voltage or Low Voltage ____High Voltage_______________ D. Other names for component ___________________ __________________ ________________ ________________ _______________ E. Component location ____Attached to the stator inside motor assymbly _______________________ F. Does the component Store or carry HV (if applicable) carry AC Voltage G. Are their any identifiers that indicate what the component does __Supply power to run motor_________________ H. Would this component cause the vehicle not to turn on (ready mode)_ _______Yes________________ Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Cables for stator 2. What is the component function? They supply three phase AC power to the stator 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: N/A 5. Component location: Attached to the stator inside motor assembly 6. Does the component store or carry HV (if applicable)? Carry AC Voltage 7. Are their any identifiers that indicate what the component does? Supply power to run motor 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV AC 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 60 EV-601-TS_053322-96 Module 1 — SA-20 SA-20 Component #20 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Inverter 2. What is the component function? It inverts DC to AC to drive the electric motor 3. High Voltage or Low Voltage? High Voltage 4. Other names for component: Controller 5. Component location: Inside the motor assembly attached to the stator 6. Does the component store or carry HV (if applicable)? Carry 7. Are their any identifiers that indicate what the component does? No 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? Cooled by coolant 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: However it has orange cables going into its DC 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: HV DC in HV AC out 13. Removing this component would it require disconnecting/disabling the HV system? Yes consulab.com info@consulab.com 61 EV-601-TS_053322-96 Module 1 — SA-21 SA-21 Component #21 — Answers M. Removing this component would it require disconnecting/disabling the HV system ____Yes__________ SA-21 Inverter cooling 21. A. Name of component __Inverter cooling_______________________ B. What is the component function __Keeps electronics of the inverter cooled_______________________ C. High Voltage or Low Voltage ____NA_______________ D. Other names for component ___________________ __________________ ________________ ________________ _______________ E. Component location ____Side of inverter _______________________ F. Does the component Store or carry HV (if applicable) NA G. Are their any identifiers that indicate what the component does __Coolant lines going in and out of device_________________ H. Would this component cause the vehicle not to turn on (ready mode)_ _______YES________________ I. Would this component prevent the vehicle from driving. ___Yes______________________ J. Is this component cooled by or heated by coolant ____Uses coolant to cool_____________________________________ Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Inverter cooling 2. What is the component function? It keeps electronics of the inverter cooled 3. High Voltage or Low Voltage? N/A 4. Other names for component: None 5. Component location: Side of inverter 6. Does the component store or carry HV (if applicable)? N/A 7. Are their any identifiers that indicate what the component does? Coolant lines going in and out of device 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? Yes, coolant is used to cool 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 62 EV-601-TS_053322-96 Module 1 — SA-22 SA-22 Component #22 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Final drive 2. What is the component function? It transfers power to the axles 3. High Voltage or Low Voltage? N/A 4. Other names for component: Carrier — Ring and pinion — Differential 5. Component location: Rear of motor housing 6. Does the component store or carry HV (if applicable)? N/A 7. Are their any identifiers that indicate what the component does? Axles are attached to it 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? N/A 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 63 EV-601-TS_053322-96 Module 1 — SA-23 SA-23 Component #23 — Answers H. Would this component cause the vehicle not to turn on (ready mode)_ ______No_________________ I. Would this component prevent the vehicle from driving. __Yes_______________________ J. Is this component cooled by or heated by coolant ________NA_________________________________ K. Does the component have a “high voltage” warning sign or icon on it __Yes / no___ if it does what does it say. ________NA__________________________ L. Is the component HV DC or AC powered (2 or 3 leads on the cable) ___NA_________________ M. Removing this component would it require disconnecting/disabling the HV system _____No_________ SA-23 Oil cooler 23. A. Name of component ___Oil Cooler______________________ B. What is the component function To transfer heat to the coolant from the oil in the motor assembly C. High Voltage or Low Voltage ______NA_____________ D. Other names for component ___________________ __________________ ________________ ________________ _______________ E. Component location _Rear of drive unit__________________________ F. Does the component Store or carry HV (if applicable) NA Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Oil cooler 2. What is the component function? It transfers heat to the coolant from the oil in the motor assembly 3. High Voltage or Low Voltage? N/A 4. Other names for component: None 5. Component location: Rear of drive unit 6. Does the component store or carry HV (if applicable)? N/A 7. Are their any identifiers that indicate what the component does? Yes, coolant lines going in and out 8. Would this component cause the vehicle not to turn on (ready mode)? No 9. Would this component prevent the vehicle from driving? No 10. Is this component cooled by or heated by coolant? It’s part of the thermal system 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 64 EV-601-TS_053322-96 Module 1 — SA-24 SA-24 Component #24 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: Resolver 2. What is the component function? A resolver is a type of rotation angle sensor for controlling the drive motor 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Motor position sensor 5. Component location: End of drive unit 6. Does the component store or carry HV (if applicable)? No 7. Are their any identifiers that indicate what the component does? It’s attached to the end of the rotor 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? No Explain: N/A 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes Explain: It creates a low voltage AC signal used for position and rotation 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 65 EV-601-TS_053322-96 Module 1 — SA-25 SA-25 Component #25 — Answers Objective: To find, locate, name the component, and identify its aspects. Procedure: This can be used with resources found in books, online and during presentations. 1. Name of component: First responder cut loop 2. What is the component function? It gives first responders the ability to disable the high voltage part of the system 3. High Voltage or Low Voltage? Low Voltage 4. Other names for component: Disconnect — Firefighter loop 5. Component location: Right rear window 6. Does the component store or carry HV (if applicable)? N/A 7. Are their any identifiers that indicate what the component does? Yes, labels and orange tags 8. Would this component cause the vehicle not to turn on (ready mode)? Yes 9. Would this component prevent the vehicle from driving? Yes 10. Is this component cooled by or heated by coolant? No 11. Does the component have a “high voltage” warning sign or icon on it? Yes Explain: Orange colour indicates controls HV 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? No Explain: N/A 13. Removing this component would it require disconnecting/disabling the HV system? No consulab.com info@consulab.com 66 EV-601-TS_053322-96 Module 1 — Power Flow Power Flow of an Electric SystemPower flow of an Electric system (could use pictures from Megan?) Ba7ery Pack: The ba7ery pack serves as the energy storage / reservoir of an electric vehicle. It comprises mulCple lithium-ion cells connected in series and parallel to achieve the desired voltage and capacity. The ba7ery pack stores electrical energy, typically in the form of DC electricity. The stored energy is essenCal for powering the vehicle's electric motor and various onboard systems. The capacity and energy density of the ba7ery pack significantly impact the range and performance of the electric vehicle. As the primary source of energy, the ba7ery pack undergoes constant monitoring by the vehicle's power management system to ensure opCmal operaCon and longevity. (601 picture of ba7ery) Power Management System: The power distribuCon system is responsible for regulaCng and managing the flow of electricity within the electric vehicle. It serves as the brain of the vehicle's electrical system, coordinaCng the distribuCon of power from the ba7ery pack to other components. The power management system monitors various parameters, including ba7ery voltage, current, temperature, and state of charge, to opCmize energy usage and ensure safety. It controls the charging and discharging of the ba7ery pack, manages power delivery to the electric motor and accessory systems, and coordinates energy flow during regeneraCve braking. Through sophisCcated algorithms and sensors, the power management system maximizes the efficiency and performance of the electric vehicle while protecCng its components from damage or overuse. (601 picture) Battery Pack The battery pack serves as the energy storage / reservoir of an electric vehicle. It comprises multiple lithium-ion cells connected in series and parallel to achieve the desired voltage and capacity. The battery pack stores electrical energy, typically in the form of DC electricity. The stored energy is essential for powering the vehicle’s electric motor and various onboard systems. The capacity and energy density of the battery pack significantly impact the range and performance of the electric vehicle. As the primary source of energy, the battery pack undergoes constant monitoring by the vehicle’s power management system to ensure optimal opera- tion and longevity. Power Management System The power distribution system is responsible for regulating and managing the flow of electricity within the electric vehicle. It serves as the brain of the vehicle’s electrical sys- tem, coordinating the distribution of power from the battery pack to other components. The power management system monitors various parameters, including battery voltage, current, temperature, and state of charge, to optimize energy usage and ensure safety. It controls the charging and discharging of the battery pack, manages power delivery to the electric motor and accessory systems, and coordinates energy flow during regenera- tive braking. Through sophisticated algorithms and sensors, the power management system maximizes the efficiency and perfor- mance of the electric vehicle while protecting its components from damage or overuse. HVDC relay The HVDC Relay, applied to an electric vehicle, is installed between the vehicle battery and the inverter to cut off the charge and to discharge the DC power of the battery. It is also used between the external charger and the vehicle battery. A reminder that these vehicles can carry and store extremely high voltage – the battery and capacitors store high voltage everything else carries. When we make the vehicle safe the energy is then stored in the high voltage battery, making the vehicle safe DOES NOT discharge the battery, it just contains the energy within the battery. Now that you’ve been introduced to the components of an EV, let’s look at where they are located. Component Locations High voltage battery – this could be in the trunk floor, underneath the back seat, behind the back seat, in the transmission tunnel or under the floor of the vehicle – there is no consistency across vehicle manufacturers. Battery cooling – every battery has some form of battery cooling, be it air cooling, water cooling or full climate control – in the photo above, the battery is air cooled. consulab.com info@consulab.com 67 EV-601-TS_053322-96 Module 1 — Power Flow Inverter The power inverter is a critical component that converts DC electricity from the battery pack into AC electricity for the electric motor. Since most electric motors operate on AC power, the inverter plays a crucial role in facilitating power delivery. It converts the fixed voltage and current from the battery pack into variable-frequency and variable-amplitude AC signals required by the electric motor. Additionally, the power inverter controls the speed and torque of the electric motor by adjusting the frequency and amplitude of the AC power. Through pulse-width modulation (PWM) techniques, the inverter regulates the flow of electricity to the motor, enabling precise control over the vehicle’s acceleration and perfor- mance. The efficiency and reliability of the power inverter significantly impact the overall efficiency and drivability of the electric vehicle. Electric Motor The electric motor is the heart of the electric vehicle’s propulsion system. It con- verts electrical energy from the power inverter into mechanical energy to drive the wheels. Electric motors come in various types, including AC induction motors, per- manent magnet motors, and synchronous reluctance motors, each offering unique characteristics in terms of efficiency, torque, and power output. The electric motor consists of a rotor and stator, with the rotor connected to the vehicle’s drivetrain and the stator connected to the power inverter. When AC electricity is supplied to the motor, electromagnetic forces induce rotational motion in the rotor, generating torque to propel the vehicle forward. The electric motor’s efficiency, power density, and responsiveness significantly influence the vehicle’s acceleration, top speed, and overall driving experience. Transmission (if equipped) While many electric vehicles utilize a single-speed transmission due to the wide torque range of electric motors, some models incorporate multi-speed transmis- sions for improved efficiency and performance. The transmission serves to op- timize power delivery from the electric motor to the wheels, particularly during acceleration and cruising. By selecting appropriate gear ratios, the transmission adjusts the rotational speed and torque output of the electric motor to match the vehicle’s speed and load conditions. This optimization ensures efficient power uti- lization and enhances the driving dynamics of the electric vehicle. However, not all electric vehicles require a transmission, as the inherent characteristics of electric motors, such as high torque at low speeds and smooth power delivery, may negate the need for gear shifting. Inverter: The power inverter is a criCcal component that converts DC electricity from the ba7ery pack into AC electricity for the electric motor. Since most electric motors operate on AC power, the inverter plays a crucial role in facilitaCng power delivery. It converts the fixed voltage and current from the ba7ery pack into variable-frequency and variable-amplitude AC signals required by the electric motor. AddiConally, the power inverter controls the speed and torque of the electric motor by adjusCng the frequency and amplitude of the AC power. Through pulse-width modulaCon (PWM) techniques, the inverter regulates the flow of electricity to the motor, enabling precise control over the vehicle's acceleraCon and performance. The efficiency and reliability of the power inverter significantly impact the overall efficiency and drivability of the electric vehicle. (601 Picture) Electric Motor: The electric motor is the heart of the electric vehicle's propulsion system. It converts electrical energy from the power inverter into mechanical energy to drive the wheels. Electric motors come in various types, including AC inducCon motors, permanent magnet motors, and synchronous reluctance motors, each offering unique characterisCcs in terms of efficiency, torque, and power output. The electric motor consists of a rotor and stator, with the rotor connected to the vehicle's drivetrain and the stator connected to the power inverter. When AC electricity is supplied to the motor, electromagneCc forces induce rotaConal moCon in the rotor, generaCng torque to propel the vehicle forward. The electric motor's efficiency, power density, and responsiveness significantly influence the vehicle's acceleraCon, top speed, and overall driving experience. (601 Picture) Transmission (if equipped): While many electric vehicles uClize a single-speed transmission due to the wide torque range of electric motors, some models incorporate mulC-speed transmissions for improved efficiency and performance. The transmission serves to opCmize power delivery from the electric motor to the wheels, parCcularly during acceleraCon and cruising. By selecCng appropriate gear raCos, the transmission adjusts the rotaConal speed and torque output of the electric motor to match the vehicle's speed and load condiCons. This opCmizaCon ensures efficient power uClizaCon and enhances the driving dynamics of the electric vehicle. However, not all electric vehicles require a transmission, as the inherent characterisCcs of electric motors, such as high torque at low speeds and smooth power delivery, may negate the need for gear shiZing. consulab.com info@consulab.com 68 EV-601-TS_053322-96 Module 1 — Power Flow Axles and Wheels The axles and wheels transmit mechanical energy from the electric motor to the ground, propelling the vehicle forward. As the electric motor rotates, it generates torque that is transferred through the drivetrain to the axles. The axles, in turn, transmit this torque to the wheels, causing them to rotate. The rotational motion of the wheels creates traction with the road surface, enabling the vehicle to move. Axles are typically equipped with differential gears to distribute torque evenly between the wheels and allow for smooth cornering. The size, design, and material composition of the wheels affect the vehicle’s handling, ride comfort, and energy efficiency. Additionally, advanced traction control systems and electronic stability control help optimize the distribution of power to the wheels, enhancing traction and stability under various driving conditions. Regenerative Braking System Regenerative braking is a unique feature of electric vehicles that allows them to recover kinetic energy during decelera- tion and braking. When the driver applies the brakes, the electric motor operates in reverse mode, acting as a generator to convert the vehicle’s kinetic energy into electrical energy. This regenerative braking energy is then sent back to the battery pack for storage and later use. By harnessing energy that would otherwise be lost as heat during traditional braking, regenerative braking improves the overall efficiency and range of the electric vehicle. Advanced regenerative braking systems feature adjustable regenerative braking levels, allowing drivers to customize their driving experience and maximize energy recuperation. Additionally, regenerative braking systems work in conjunction with traditional fric- tion brakes to provide smooth and consistent braking performance, enhancing safety and control. Electric vehicles also rely on various accessory systems to provide comfort, convenience, and safety features for pas- sengers. These accessory systems draw electrical power from the battery pack to operate functions such as lighting, climate control, infotainment, and onboard electronics. LED lighting systems offer energy-efficient illumination, while electric heating and cooling systems provide climate control without relying on an internal combustion engine. Infotain- ment systems feature touchscreen displays, navigation, and connectivity options, enhancing the driving experience. Ad- vanced driver-assistance systems (ADAS), including adaptive cruise control, lane-keeping assist, and collision avoidance, rely on sensor data and onboard processing to enhance safety and driver awareness. Efficient management of accesso- ry system power consumption is essential to maximize the electric vehicle’s range and optimize overall energy efficiency Overall Performance of the Vehicle The startup process of energy in the pre-charge circuit of an electric vehicle (EV) involves several steps to ensure the safe and controlled initialization of the high-voltage system. consulab.com info@consulab.com 69 EV-601-TS_053322-96 Module 1 — Power Flow The Startup Procedure • Initial Power-On: When the EV is powered on, the pre-charge circuit is activated. This typically occurs when the driver initiates the vehicle’s startup sequence, such as turning the ignition key or pressing the power button. • Low-Voltage Activation: Initially, the pre-charge circuit applies a low-level voltage to the high-voltage capacitors or bus bars in the EV’s powertrain. This voltage is significantly lower than the nominal operating voltage of the system, typically ranging from a few volts to a fraction of the full voltage. • Voltage Ramp-Up: With the low-level voltage applied, the pre-charge circuit begins the gradual ramp-up process. It controls the rate at which the voltage increases, ensuring a smooth and controlled buildup of energy in the system. The ramp-up duration can vary depending on factors such as the size of the capacitors, the capacity of the battery pack, and the specifications of the powertrain components. Once the ignition is pressed the negative contactor on the high voltage side closes as well the pre-charge circuit contactor or relay closes supplying energy to “pre charge” the capacitors in the inverter. This is done through a resister in the circuit to keep voltage and current low. This pre charge circuit can pre charge the capacitors fairly quickly. (1-7 pre-charge circuit operation) The startup process of energy in the pre-charge circuit of an electric vehicle (EV) involves several steps to ensure the safe and controlled iniCalizaCon of the high-voltage system. The startup procedure: IniCal Power-On: When the EV is powered on, the pre-charge circuit is acCvated. This typically occurs when the driver iniCates the vehicle's startup sequence, such as turning the igniCon key or pressing the power bu7on. Low-Voltage AcCvaCon: IniCally, the pre-charge circuit applies a low-level voltage to the high-voltage capacitors or bus bars in the EV's powertrain. This voltage is significantly lower than the nominal operaCng voltage of the system, typically ranging from a few volts to a fracCon of the full voltage. Voltage Ramp-Up: With the low-level voltage applied, the pre-charge circuit begins the gradual ramp-up process. It controls the rate at which the voltage increases, ensuring a smooth and controlled buildup of energy in the system. The ramp-up duraCon can vary depending on factors such as the size of the capacitors, the capacity of the ba7ery pack, and the specificaCons of the powertrain components. Once the igniCon is pressed the negaCve contactor on the high voltage side closes as well the pre-charge Instructor manual Note: Monitoring and Regulation happens throughout the voltage ramp-up process, the pre-charge circuit continuously monitors the voltage levels in the system. It regulates the voltage increase to prevent sudden spikes or fluctuations that could potentially damage electronic components or pose safety risks. The circuit may incorporate feedback mechanisms to adjust the ramp-up rate based on real-time measurements and system conditions. • Current Limiting: In addition to controlling voltage levels, the pre-charge circuit may also limit the flow of current during startup. This helps to minimize inrush current, which is the initial surge of current that occurs when power is applied to capacitive loads. By limiting inrush current, the circuit reduces stress on electrical components and ensures a more stable startup process. This is usually done with a high wattage resistor • Safety Checks: As part of the startup procedure, the pre-charge circuit may perform various safety checks to verify the integrity of the high-voltage system. This could include checking for short circuits, open circuits, or other faults that could affect the operation of the powertrain. If any abnormalities are detected, the circuit may initiate protec- tive measures, such as interrupting the startup sequence or triggering warning indicators for diagnostics. This is to prevent high voltage at full strength and does the HVIL and LOI test during this stage. • Completion and Transition: Once the capacitors or bus bars reach the nominal operating voltage, the pre-charge circuit completes the startup process. At this point, the high-voltage system is ready for normal operation, and the main power source or load can be connected to the system. The transition from pre-charge mode to full operation is seamless, ensuring efficient power delivery without any sudden disruptions. consulab.com info@consulab.com 70 EV-601-TS_053322-96 Module 1 — SA-26 SA-26 Quiz on Power Flow Use the answer sheet for your answers. 1. During vehicle start up what component stores the high voltage energy for the system? A. Power distribution unit B. Capacitors C. HV Battery D. Contactors 2. The purpose of the pre-charge circuit is to... A. Protect the resistor B. Protect the capacitors C. Protect the inverter electronics D. Protect the contactors 3. Electric motors can come in a variety of configurations what is the most common type of electric motor? A. Permanent magnet B. Induction C. Sleeve outrunner D. Variable magnet 4. The resistor found in the pre-charge circuit is used for? A. To protect the pre-charge contactor from damage B. To slow down the current and voltage C. To change the voltage to enhance the motor D. To store extra energy for the capacitors 5. If a main contactor was welded closed what could be the most likely problem? A. Voltage is to high from the battery B. The pre-charge contactor is stuck closed C. The pre-charge contactor is stuck open D. The main contactor primary circuit is defective 6. List in order each step of the pre-charge circuit operation. Use the answer sheet. consulab.com info@consulab.com 71 EV-601-TS_053322-96 Module 1 — SA-26 SA-26 Quiz on Power Flow — Answer Sheet Name : Group : Date : Use an “X” to indicate the correct answer. 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. List in order the operation steps using the diagram circles. List in order of operaCon of each of the circles in the diagram Instructor grade : Comments : consulab.com info@consulab.com 72 EV-601-TS_053322-96 Module 1 — SA-26 SA-26 Quiz on Power Flow — Answers 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. circuit contactor or relay closes supplying energy to the “pre charge” the capacitors in the inverter. This is done through a resister in the circuit to keep voltage and current low. This pre charge circuit can pre charge the capacitors fairly quickly. (1-7 pre charge circuit operaCon) Note: Monitoring and RegulaCon happens throughout the voltage ramp-up process, the pre-charge circuit conCnuously monitors the voltage levels in the system. It regulates the voltage increase to prevent sudden spikes or fluctuaCons that could potenCally damage electronic components or pose safety risks. The circuit may incorporate feedback mechanisms to adjust the ramp-up rate based on real-Cme measurements and system condiCons. Current LimiCng: In addiCon to controlling voltage levels, the pre-charge circuit may also limit the flow of current during startup. This helps to minimize inrush current, which is the iniCal surge of current that occurs when power is applied to capaciCve loads. By limiCng inrush current, the circuit reduces stress on electrical components and ensures a more stable startup process. This is usually done with a high wa7age resistor Safety Checks: As part of the startup procedure, the pre-charge circuit may perform various safety checks to verify the integrity of the high-voltage system. This could include checking for short circuits, open circuits, or other faults that could affect the operaCon of the powertrain. If any abnormaliCes are detected, the circuit may iniCate protecCve measures, such as interrupCng the startup sequence or triggering warning indicators for diagnosCcs. This is to prevent high voltage at full strength and does the HVIL and LOI test during this stage. CompleCon and TransiCon: Once the capacitors or bus bars reach the nominal operaCng voltage, the pre-charge circuit completes the startup process. At this point, the high-voltage system is ready for normal operaCon, and the main power source or load can be connected to the system. The transiCon from pre-charge mode to full operaCon is seamless, ensuring efficient power delivery without any sudden disrupCons. Instructor manual consulab.com info@consulab.com 73 EV-601-TS_053322-96 Student Learning Module 2 Student Learning Module 2 High Voltage Battery Construction This section requires students to see how the battery voltages and energy storage are used during different drive situations. Also, they will learn about how a battery is put together to create high voltage. consulab.com info@consulab.com 74 EV-601-TS_053322-96 Module 2 — High Voltage Battery Construction High Voltage Battery Construction The battery pack of an electric vehicle consists of individual cells, each featuring an anode (negative electrode) and a cathode (positive electrode), separated by a plastic-like material. Connecting the positive and negative terminals initiates the flow of ions between the electrodes through a liquid electrolyte inside the cell. Simultaneously, electrons released by these electrodes travel through an external wire. During discharging, when the battery powers a device such as a flashlight, ions move from the anode to the cathode through the separator, while electrons travel along the wire from the negative to the positive terminal, providing power to an external load. Over time, the cell’s energy depletes as it fuels the connected device. Conversely, during charging, electrons flow from an external energy source in the opposite direction (from positive to negative). The process reverses as electrons move from the cathode back to the anode, replenishing the cell’s energy. In the construction of electric vehicle batteries, unlike the single-cell concept of AA or AAA batteries, EV batteries consist of numerous individual cells, often grouped into modules. These modules, numbering several dozen, collectively form the complete EV battery pack. Electric vehicle cells can be small cylindrical units with standardized dimensions, resembling AA or AAA cells. Companies like Tesla, Rivian, and Lucid often utilize this approach, connect- ing thousands of small cells to form their battery packs. Some manufacturers advocate for the cost-effectiveness of small cells produced in large volumes. However, Tesla, for example, plans to transition to fewer but larger cylindrical cells to reduce the number of connections within their EV battery packs Electric vehicle cells are also available in two alternative configurations: prismatic, characterized by a rigid and rectangular shape, or pouch, featuring a soft aluminum case that permits slight expansion in the cell walls during intense heat. Unlike cylindrical cells, there are limited stan- dardized dimensions for prismatic and pouch cells. Major automakers like General Motors and Ford collaborate with cell manufacturers such as China’s CATL, Japan’s Panasonic, or Korea’s LG Chem to specify their own dimensions for prismatic or pouch cells, ensuring compatibility with their electric vehicle designs. Variations in Electric Vehicle Battery Chemistry The composition of an electric vehicle (EV) battery, specifically the materials present in its cathode, can differ among various cell types. Presently, there are primarily two categories of battery chemistry, both falling under the lithium-ion umbrella, denoting the utilization of lithium in conjunction with other metals. Conversely, during charging, electrons flow from an external energy source in the opposite direction (from positive to negative). The process reverses as electrons move from the cathode back to the anode, replenishing the cell's energy. In the construction of electric vehicle batteries, unlike the single-cell concept of AA or AAA batteries, EV batteries consist of numerous individual cells, often grouped into modules. These modules, numbering several dozen, collectively form the complete EV battery pack. Electric vehicle cells can be small cylindrical units with standardized dimensions, resembling AA or AAA cells. Companies like Tesla, Rivian, and Lucid often utilize this approach, connecting thousands of small cells to form their battery packs. Some manufacturers advocate for the cost-effectiveness of small cells produced in large volumes. However, Tesla, for example, plans to transition to fewer but larger cylindrical cells to reduce the number of connections within their EV battery packs Electric vehicle cells are also available in two alternative configurations: prismatic, characterized by a rigid and rectangular shape, or pouch, featuring a soft aluminum case that permits slight expansion in the cell walls during intense heat. Unlike cylindrical cells, there are limited standardized dimensions for prismatic and pouch cells. Major automakers like General Motors and Ford collaborate with cell manufacturers such as China's CATL, Japan's Panasonic, or Korea's LG Chem to specify their own dimensions for prismatic or pouch cells, ensuring compatibility with their electric vehicle designs. Variations in Electric Vehicle Battery Chemistry Conversely, during charging, electrons flow from an external energy source in the opposite direction (from positive to negative). The process reverses as electrons move from the cathode back to the anode, replenishing the cell's energy. In the construction of electric vehicle batteries, unlike the single-cell concept of AA or AAA batteries, EV batteries consist of numerous individual cells, often grouped into modules. These modules, numbering several dozen, collectively form the complete EV battery pack. Electric vehicle cells can be small cylindrical units with standardized dimensions, resembling AA or AAA cells. Companies like Tesla, Rivian, and Lucid often utilize this approach, connecting thousands of small cells to form their battery packs. Some manufacturers advocate for the cost-effectiveness of small cells produced in large volumes. However, Tesla, for example, plans to transition to fewer but larger cylindrical cells to reduce the number of connections within their EV battery packs Electric vehicle cells are also available in two alternative configurations: prismatic, characterized by a rigid and rectangular shape, or pouch, featuring a soft aluminum case that permits slight expansion in the cell walls during intense heat. Unlike cylindrical cells, there are limited standardized dimensions for prismatic and pouch cells. Major automakers like General Motors and Ford collaborate with cell manufacturers such as China's CATL, Japan's Panasonic, or Korea's LG Chem to specify their own dimensions for prismatic or pouch cells, ensuring compatibility with their electric vehicle designs. Variations in Electric Vehicle Battery Chemistry consulab.com info@consulab.com 75 EV-601-TS_053322-96 Module 2 — High Voltage Battery Construction Categorization of Lithium-Ion Batteries The prevalent type in North America and Europe integrates a mixture of nickel, manganese, and cobalt (NMC) or nickel, manganese, cobalt, and aluminum (NMCA). These batteries boast higher energy densities, referring to energy per weight or volume. However, they also exhibit a heightened susceptibility to oxidation (fire risk) in the event of a severe short circuit or impact. Manufacturers and battery experts dedicate significant efforts to closely monitor cells and modules throughout production and the vehicle’s lifespan to mitigate the risk of oxidation for various applications: • Land Vehicle • Vehicle • Car • Luxury Vehicle • Motor Vehicle • Automotive Design • Performance Car • Porsche Panamera • Porsche • Supercar • TESLA Conversely, the second type, more prevalent in China, is identified as lithium-iron-phosphate (LFP), despite the periodic table symbol for iron being Fe, not F. Iron-phosphate cells possess notably lower energy density, necessitating larger batteries to deliver equivalent energy and driving range compared to NMC-based batteries. consulab.com info@consulab.com 76 EV-601-TS_053322-96 Module 2 — SA-27 SA-27 High Voltage Battery Specifications — Answers Objective: To see how the battery voltages and energy storage are used during different drive situations. Requirements: • EV-601 vehicle powered ON • Work sheet • Pen or pencil • Appropriate PPE • Multimeter • Old 9 volt battery – take apart 1. What is the battery packs full voltage stationary? 400 volts 2. Is this AC or DC volts? DC volts 3. Now using the Consulab touch screen, put the vehicle into ready mode. 4. What is the voltage at battery when vehicle is in ready mode? 400 volts 5. Accelerating vehicle using the touch screen to 100 km/h (62 mph), what is the voltage at? 360 volts Hint: Use steady state to hold the speed. 6. Now let off the accelerator and let it coast down to 0 kmph what is the voltage during deceleration? 402 volts 7. What is the voltage at stop? 400 volts 8. What did you observe that was different during deceleration to vehicle stopped? Used energy, captured energy and stored 9. Why did this happen? The motor is also a generator (regenerative) 10. Turn off the vehicle and place vehicle off mode. Student assignment 2 This assignment you will need the following items • EV-601 vehicle powered on • Work sheet • Pen or pencil • Appropriate PPE The purpose of the Battery construction assignment is to see how the battery voltages and energy storage are used during different drive situations. Also you will learn about how a battery is put together to create high voltage EV-601a What is the battery packs full voltage stationary? ________ volts Is this AC or DC volts ____ volts Now using the Consulab Touch screen put the vehicle into ready mode. What is the voltage at battery when vehicle is in ready mode? _____ volts Accelerating vehicle using the touch screen to 100kmph what is the voltage at? ____ volts (hint use steady state to hold the speed) Now let off the accelerator and let it coast down to 0kmph what is the voltage during deceleration? _____ volts What is the voltage at stop? ____ volts What did you observe that was different during deceleration to vehicle stopped? ________________________________________________ Why did this happen? ________________________________________________ Turn off the vehicle and place vehicle off mode EV-601b How many modules are in this high voltage battery pack? __________ What is the average voltage in each module? ____________ Can you calculate how many cells are in each module if each battery cell is 4.00 volts? ______ consulab.com info@consulab.com 77 EV-601-TS_053322-96 Module 2 — SA-28 SA-28 High Voltage Battery Modules — Answers Objective: To see how a battery is put together in modules to create high voltage. 1. How many modules are in this high voltage battery pack? 4 2. What is the average voltage in each module? 100 volts 3. Can you calculate how many cells are in each module if each battery cell is 4.00 volts? 25 4. Would you say this is capacity or potential of energy? Potential 5. If I wanted to increase capacity, what would you have to do? To add more battery cells in series 6. If I wanted to Increase Potential of energy, you would have to? To add more cells to each group consulab.com info@consulab.com 78 EV-601-TS_053322-96 Module 2 — SA-29 SA-29 High Voltage Battery Configuration — Answers Objective: To show how battery technology for different chemistry can have an impact on power and energy storage of in a battery. 1. How many cell groups are in a 9 volt battery? 6 How many cell groups are in a 9 volt battery? ___6________ How many cell groups are in a 12 volt battery? ___6________ 2. How many cell groups are in a 12 volt battery? 6 How many cell groups are in a 9 volt battery? ___6________ How many cell groups are in a 12 volt battery? ___6________ 3. How many cell groups are in a 12volt lithium Ion battery? 4 How many cell groups are in a 9 volt battery? ___6________ How many cell groups are in a 12 volt battery? ___6________ 4. The picture below is a 400volt battery pack. Count the modules in the pack and calculate the voltage in each module. Each module is: volts How many cell groups are in a 12 volt Lithium Ion battery? ______4_________ The picture below is a 400volt battery pack. Count the modules in the pack and calculate the voltage in each module Each module is _________volts The voltage of this module is ACvolts or DCvolts? _________ 5. The voltage of this module is ACvolts or DCvolts? volts consulab.com info@consulab.com 79 EV-601-TS_053322-96 Student Learning Module 3 Student Learning Module 3 EV Charging Systems and Operation Drive Modes This section comprises assignments which are designed to. consulab.com info@consulab.com 80 EV-601-TS_053322-96 Module 3 — EV Charging Systems EV Charging Systems Level 1 Charging: Level 1 (L1) charging represents the fundamental and universally accessible approach to charging electric vehicles (EVs). This method utilizes a standard 120-Volt household outlet and is facilitated by a universal L1 charge cable compatible with all EVs (using J1772 or NACS J3400 standard cable). With a power rating of up to 2.4 kW, L1 chargers provide a gradual restoration of around 5 miles of range per hour of charging. Charging costs for L1 charging, dependent on electricity prices and EV efficiency. Although commonly referred to as an «emergency charger» or «trickle charger,» L1 charging is best suited for overnight charging and may not be ideal for longer commutes or extended journeys. Level 2 Charging: Level 2 (L2) charging operates at a higher input voltage of 240 Volts and is typically installed in residential garages, driveways, or public charging stations otherwise known as “home chargers”. L2 chargers, available in both permanent and portable models, can be connected to standard 240-Volt dryer or welder receptacles. The cost of L2 chargers varies, ranging from $500 to $2,000, taking into account factors such as brand, power rating, and installation requirements. Charging costs for L2 charging align with those of L1, spanning from 2¢ to 6¢ per mile. L2 charging stations adhere to the SAE J1772 or «J-plug» standard, ensuring compatibility with a broad range of EVs. Public-access L2 chargers are commonly found in parking garages, parking lots, and businesses, offering a charging rate of up to 12 miles of range per hour. Direct Current Fast Charging (DCFC): DCFC charging stands out as the fastest option, typically deployed in high-traffic areas like highway rest stops and commercial districts. DCFC chargers operate at elevated voltages (480 V or 1,000 V) and are not intended for residential use. Charging fees for fast charging, which may be structured as an hourly rate or per kilowatt-hour (kWh). Unlike lower levels, DCFC chargers lack a universal standard. Notable types include Superchargers (for specific Tesla models), SAE CCS (compatible with certain European EVs), and CHAdeMO (suited for select Asian EVs). DCFC stations commence at 50 kW and can exceed 400 kW, offering a rapid top-up. However, high-speed charging is typically available only up to 80% battery capacity to ensure the battery’s longevity. SA-30 charge modes Charging systems Level 1 Charging: Level 1 (L1) charging represents the fundamental and universally accessible approach to charging electric vehicles (EVs). This method utilizes a standard 120-Volt household outlet and is facilitated by a universal L1 charge cable compatible with all EVs (using J1772 or NACS J3400 standard cable). With a power rating of up to 2.4 kW, L1 chargers provide a gradual restoration of around 5 miles of range per hour of charging. Charging costs for L1 charging, dependent on electricity prices and EV efficiency. Although commonly referred to as an "emergency charger" or "trickle charger," L1 charging is best suited for overnight charging and may not be ideal for longer commutes or extended journeys. Level 2 Charging: Level 2 (L2) charging operates at a higher input voltage of 240 Volts and is typically installed in residential garages, driveways, or public charging stations otherwise known as “home chargers”. L2 chargers, available in both permanent and portable models, can be connected to standard 240-Volt dryer or welder receptacles. The cost of L2 chargers varies, ranging from $500 to $2,000, taking into account factors such as brand, power rating, and installation requirements. Charging costs for L2 charging align with those of L1, spanning from 2¢ to 6¢ per mile. L2 charging stations adhere to the SAE J1772 or "J- plug" standard, ensuring compatibility with a broad range of EVs. Public-access L2 chargers are commonly found in parking garages, parking lots, and businesses, offering a charging rate of up to 12 miles of range per hour. SA-30 charge modes Charging systems Level 1 Charging: Level 1 (L1) charging represents the fundamental and universally accessible approach to charging electric vehicles (EVs). This method utilizes a standard 120-Volt household outlet and is facilitated by a universal L1 charge cable compatible with all EVs (using J1772 or NACS J3400 standard cable). With a power rating of up to 2.4 kW, L1 chargers provide a gradual restoration of around 5 miles of range per hour of charging. Charging costs for L1 charging, dependent on electricity prices and EV efficiency. Although commonly referred to as an "emergency charger" or "trickle charger," L1 charging is best suited for overnight charging and may not be ideal for longer commutes or extended journeys. Level 2 Charging: Level 2 (L2) charging operates at a higher input voltage of 240 Volts and is typically installed in residential garages, driveways, or public charging stations otherwise known as “home chargers”. L2 chargers, available in both permanent and portable models, can be connected to standard 240-Volt dryer or welder receptacles. The cost of L2 chargers varies, ranging from $500 to $2,000, taking into account factors such as brand, power rating, and installation requirements. Charging costs for L2 charging align with those of L1, spanning from 2¢ to 6¢ per mile. L2 charging stations adhere to the SAE J1772 or "J- plug" standard, ensuring compatibility with a broad range of EVs. Public-access L2 chargers are commonly found in parking garages, parking lots, and businesses, offering a charging rate of up to 12 miles of range per hour. Direct Current Fast Charging (DCFC): DCFC charging stands out as the fastest option, typically deployed in high-traffic areas like highway rest stops and commercial districts. DCFC chargers operate at elevated voltages (480 V or 1,000 V) and are not intended for residential use. Charging fees for fast charging, which may be structured as an hourly rate or per kilowatt-hour (kWh). Unlike lower levels, DCFC chargers lack a universal standard. Notable types include Superchargers (for specific Tesla models), SAE CCS (compatible with certain European EVs), and CHAdeMO (suited for select Asian EVs). DCFC stations commence at 50 kW and can exceed 400 kW, offering a rapid top-up. However, high-speed charging is typically available only up to 80% battery capacity to ensure the battery's longevity. How to charge an Electric Vehicle (EV) To initiate the electric vehicle (EV) charging process, several steps need to be followed, providing a seamless experience for users. First and foremost, ensure that the EV is parked near the charging station, whether it be at home, a public charging point, or a dedicated charging station. Once parked, the driver should locate the charging port on the EV, which is typically located on the front fender or rear of the vehicle. Modern EVs often have a prominently marked charging port, making it easily identifiable. Next, retrieve the appropriate charging cable for the charging station being used. Different charging levels (L1, L2, or DCFC) and connector types may require specific cables. It's crucial to match the cable with both the EV's charging port and the charging station to ensure compatibility. Direct Current Fast Charging (DCFC): DCFC charging stands out as the fastest option, typically deployed in high-traffic areas like highway rest stops and commercial districts. DCFC chargers operate at elevated voltages (480 V or 1,000 V) and are not intended for residential use. Charging fees for fast charging, which may be structured as an hourly rate or per kilowatt-hour (kWh). Unlike lower levels, DCFC chargers lack a universal standard. Notable types include Superchargers (for specific Tesla models), SAE CCS (compatible with certain European EVs), and CHAdeMO (suited for select Asian EVs). DCFC stations commence at 50 kW and can exceed 400 kW, offering a rapid top-up. However, high-speed charging is typically available only up to 80% battery capacity to ensure the battery's longevity. How to charge an Electric Vehicle (EV) To initiate the electric vehicle (EV) charging process, several steps need to be followed, providing a seamless experience for users. First and foremost, ensure that the EV is parked near the charging station, whether it be at home, a public charging point, or a dedicated charging station. Once parked, the driver should locate the charging port on the EV, which is typically located on the front fender or rear of the vehicle. Modern EVs often have a prominently marked charging port, making it easily identifiable. Next, retrieve the appropriate charging cable for the charging station being used. Different charging levels (L1, L2, or DCFC) and connector types may require specific cables. It's crucial to match the cable with both the EV's charging port and the charging station to ensure compatibility. consulab.com info@consulab.com 81 EV-601-TS_053322-96 Module 3 — EV Charging Systems How to charge an Electric Vehicle (EV): To initiate the electric vehicle (EV) charging process, several steps need to be followed, providing a seamless experience for users. First and foremost, ensure that the EV is parked near the charging station, whether it be at home, a public charging point, or a dedicated charging station. Once parked, the driver should locate the charging port on the EV, which is typically locat- ed on the front fender or rear of the vehicle. Modern EVs often have a prominently marked charging port, making it easily identifiable. Next, retrieve the appropriate charging cable for the charging station being used. Different charging levels (L1, L2, or DCFC) and connector types may require specific cables. It’s crucial to match the cable with both the EV’s charging port and the charging station to ensure compatibility. If charging at home or at a private location, plug the charging cable into the EV’s charging port. For public charging stations, users may need to use a membership card, smartphone app, or RFID card to initiate the charging process. Follow the instructions provided by the charging station, which may include authentication steps and payment methods if applicable. After securely connecting the cable, the EV and charging station will communicate to establish a connection. Many EVs have an indicator light on the dashboard or near the charging port, signaling that the vehicle is actively charging. Addi- tionally, charging stations often have visual indicators to show the status of the charging process. It’s important for EV owners to be mindful of the charging time needed to achieve their desired range. Charging times vary depending on the charging level and the capacity of the battery. Some EVs may offer the option to schedule charging during off-peak hours, optimizing energy consumption and potentially reducing charging costs. In conclusion, starting the EV charging sequence involves parking near a charging station, identifying the charging port, selecting the appropriate cable, and following the specific instructions provided by the charging station. With these steps, EV users can efficiently and effectively initiate the charging process, contributing to the widespread adoption of electric vehicles. Direct Current Fast Charging (DCFC): DCFC charging stands out as the fastest option, typically deployed in high-traffic areas like highway rest stops and commercial districts. DCFC chargers operate at elevated voltages (480 V or 1,000 V) and are not intended for residential use. Charging fees for fast charging, which may be structured as an hourly rate or per kilowatt-hour (kWh). Unlike lower levels, DCFC chargers lack a universal standard. Notable types include Superchargers (for specific Tesla models), SAE CCS (compatible with certain European EVs), and CHAdeMO (suited for select Asian EVs). DCFC stations commence at 50 kW and can exceed 400 kW, offering a rapid top-up. However, high-speed charging is typically available only up to 80% battery capacity to ensure the battery's longevity. How to charge an Electric Vehicle (EV) To initiate the electric vehicle (EV) charging process, several steps need to be followed, providing a seamless experience for users. First and foremost, ensure that the EV is parked near the charging station, whether it be at home, a public charging point, or a dedicated charging station. Once parked, the driver should locate the charging port on the EV, which is typically located on the front fender or rear of the vehicle. Modern EVs often have a prominently marked charging port, making it easily identifiable. Next, retrieve the appropriate charging cable for the charging station being used. Different charging levels (L1, L2, or DCFC) and connector types may require specific cables. It's crucial to match the cable with both the EV's charging port and the charging station to ensure compatibility. consulab.com info@consulab.com 82 EV-601-TS_053322-96 Module 3 — SA-30 SA-30 Opening the Charge Port — Answers Objective: To identify the charging port, select the appropriate cable, and follow the specific instructions provided by the charging station. Note: The charge port is located on the left side of Model 3, behind a door that is part of the rear tail light assembly. 1. Park Model 3 to ensure that the charge cable easily reaches the charge port. 2. With Model 3 in Park, press and release the button on the Tesla charge cable to open the charge port door. You can also open the charge port door using any of these methods if not using the TESLA NACS adapter: • On the touchscreen, touch CCoonnttrroollss and touch the Charge Port icon (lightning bolt). • On the touchscreen, navigate to CCoonnttrroollss > > CChhaarrggiinngg > > OOppeenn CChhaarrggee PPoorrtt. • Press the bottom of the charge port door when Model 3 is unlocked. • On the key fob accessory (sold separately), hold down the rear trunk button for 1-2 seconds. • Use voice commands to open the charge port door. You can also use voice commands to close the charge port door and begin or stop charging. NNoottee:: sslliigghhttllyy ttoouucchh tthhee bboottttoomm ooff tthhee cchhaarrggee ddoooorr aanndd sshhoouulldd ooppeenn aauuttoommaattiiccaallllyy nneevveerr ffoorrccee tthhee ddoooorr ooppeenn oorr cclloosseedd Note 3. You can also open the charge port door using any of these methods if not using the TESLA NACS adapter: - On the touchscreen, touch Controls and touch the Charge Port icon (lightning bolt). - On the touchscreen, navigate to Controls > Charging > Open Charge Port. - Press the bottom of the charge port door when Model 3 is unlocked. - On the key fob accessory (sold separately), hold down the rear trunk button for 1-2 seconds. - Use voice commands to open the charge port door. You can also use voice commands to close the charge port door and begin or stop charging. Note: Slightly touch the bottom of the charge door and should open automatically never force the door open or closed. You can also open the charge port door using any of these methods if not using the TESLA NACS adapter: • On the touchscreen, touch CCoonnttrroollss and touch the Charge Port icon (lightning bolt). • On the touchscreen, navigate to CCoonnttrroollss > > CChhaarrggiinngg > > OOppeenn CChhaarrggee PPoorrtt. • Press the bottom of the charge port door when Model 3 is unlocked. • On the key fob accessory (sold separately), hold down the rear trunk button for 1-2 seconds. • Use voice commands to open the charge port door. You can also use voice commands to close the charge port door and begin or stop charging. NNoottee:: sslliigghhttllyy ttoouucchh tthhee bboottttoomm ooff tthhee cchhaarrggee ddoooorr aanndd sshhoouulldd ooppeenn aauuttoommaattiiccaallllyy nneevveerr ffoorrccee tthhee ddoooorr ooppeenn oorr cclloosseedd Note Note: The Tesla «T» lights up when you open the charge port door. If you do not insert a charge cable into the charge port within a few minutes after opening the charge port door, the charge port door closes. If this happens, use the touchscreen to open the charge port door again. consulab.com info@consulab.com 83 EV-601-TS_053322-96 Module 3 — SA-30 4. Plug in the EV-601 using the supplied level 1 cable. Note: The button on top of the charge connector will open the charge port door. Light will be red. The Tesla "T" lights up when you open the charge port door. If you do not insert a charge cable into the charge port within a few minutes after opening the charge port door, the charge port door closes. If this happens, use the touchscreen to open the charge port door again. PPlluugg iinn tthhee EEVV--660011 uussiinngg tthhee ssuupppplliieedd lleevveell 11 ccaabbllee.. NNoottee:: tthhee bbuuttttoonn oonn ttoopp ooff tthhee cchhaarrggee ccoonnnneeccttoorr wwiillll ooppeenn tthhee cchhaarrggee ppoorrtt ddoooorr Light will be red Set up screen to show charging selected the different types of charging on an EV-601 5. Set up the screen to show charging. Then select the different types of charging on the EV-601. The Tesla "T" lights up when you open the charge port door. If you do not insert a charge cable into the charge port within a few minutes after opening the charge port door, the charge port door closes. If this happens, use the touchscreen to open the charge port door again. PPlluugg iinn tthhee EEVV--660011 uussiinngg tthhee ssuupppplliieedd lleevveell 11 ccaabbllee.. NNoottee:: tthhee bbuuttttoonn oonn ttoopp ooff tthhee cchhaarrggee ccoonnnneeccttoorr wwiillll ooppeenn tthhee cchhaarrggee ppoorrtt ddoooorr Light will be red Set up screen to show charging selected the different types of charging on an EV-601 6. The EV-601 is in need of battery charging. What are the three types of High Voltage battery charging? A. Level 1 B. Level 2 C. Direct current fast charging DCFC 7. Locate what components turn on and off during each level of charging. A. Contactors B. DC / DC C. Coolant pumps D. Charger E. conditioning compressor consulab.com info@consulab.com 84 EV-601-TS_053322-96 Module 3 — SA-30 8. What is the difference between the different types of charging? A. Voltage B. Connector for some C. AC or DC D. Thermal management 9. What is the voltage when Level 1 is plugged in and the cabin A/C cabin is set to cool? 398 volts 10. Why is there a difference when charging on level 1 with the A/C on? Charging keeping up with the power from the wall 11. What happens when you switch to Level 2 or DCFC charging? Voltage goes to 400 volts 12. Why is the charging not effected by these two? Power input is greater than the A/C system consulab.com info@consulab.com 85 EV-601-TS_053322-96 Module 3 — SA-31 SA-31 Charging with Battery Temperature Hot — Answers Objective: To monitor the active battery management system and other systems when DCFC is selected on the EV-601 and the battery is hot. When DCFC is selected on the EV-601 and the battery is hot what happens with the battery management system and what other systems become active? . Select the above screen and watch which systems are active on during charging. 1. __Coolant pumps 2. __Contactors 3. ___AC compressor 4. ____DC/DC___________________________________________________________ SA-34 On board Charger and how it works 1. Select the above screen and watch which systems are active on during charging: A. Coolant pumps B. Contactors C. A/C compressor D. DC / DC consulab.com info@consulab.com 86 EV-601-TS_053322-96 Module 3 — SA-32 SA-32 Onboard Charger and How it Works — Answers Objective: To know how an EV onboard charger works. When an EV is plugged into an AC charging station, the onboard charger within the EV communicates with the electric car charging station to determine the available power, voltage, and charging capacity. It then converts AC into DC power before regulating the flow of electricity into the battery, successfully charging your electric car. Each electric vehicle’s onboard charger has a maximum charging rate – the fastest it can charge with alternating current. For example, if your EV has a maximum charging rate of 7kW, you won’t be able to charge any faster than 7kW, even if you used a 22kW AC charger. Maximum charging rates depend on the EV make and model. The EV-601 has a on board 11Kw charger. When DCFC is selected on the EV-601 and the battery is hot what happens with the battery management system and what other systems become active? . Select the above screen and watch which systems are active on during charging. 1. __Coolant pumps 2. __Contactors 3. ___AC compressor 4. ____DC/DC___________________________________________________________ SA-34 On board Charger and how it works 1. What happens during level 1 and 2 charging for AC power flow?: A. Power in from connector B. AC power is sent to the charger (PCS) C. AC is converted to DC D. Contactors turn on to supply voltage to the battery When an EV is plugged into an AC charging station, the onboard charger within the EV communicates with the electric car charging station to determine the available power, voltage, and charging capacity. It then converts AC into DC power before regulating the flow of electricity into the battery, successfully charging your electric car. Each electric vehicle’s onboard charger has a maximum charging rate – the fastest it can charge with alternating current. For example, if your EV has a maximum charging rate of 7kW, you won’t be able to charge any faster than 7kW, even if you used a 22kW AC charger. Maximum charging rates depend on the EV make and model. The EV-601 has a on board 11Kw charger. What happens during level 1 and 2 charging for AC power flow? 1. ___Power in from connector 2. ___AC power is sent to the charger (PCS)_ 3. ____AC is converted to DC 4. Contactors turn on to supply voltage to the battery consulab.com info@consulab.com 87 EV-601-TS_053322-96 Module 3 — Operation Drive Modes Drive mode of the EV-601 An inverter serves as a crucial component in the functionality of an electric vehicle by trans- forming direct current (DC) power into the alternating current (AC) power required for the vehicle’s motor operation. This device not only facilitates the conversion of power but also plays a pivotal role in controlling the motor’s performance. One of the primary functions of the inverter is to modulate the speed of the electric mo- tor by manipulating the frequency of the generated alternating current. By adjusting this frequency, the inverter effectively governs the rotational speed of the motor, allowing for precise control over the vehicle’s movement. Furthermore, the inverter has the capability to influence the power and torque output of the motor. This is achieved by fine-tuning the amplitude of the AC signal produced. In essence, the inverter serves as a sophisticated control unit, enabling dynamic adjustments to the motor’s operational parameters, enhancing the overall efficiency and performance of the electric vehicle. Drive mode of the EV-601 An inverter serves as a crucial component in the functionality of an electric vehicle by transforming direct current (DC) power into the alternating current (AC) power required for the vehicle's motor operation. This device not only facilitates the conversion of power but also plays a pivotal role in controlling the motor's performance. One of the primary functions of the inverter is to modulate the speed of the electric motor by manipulating the frequency of the generated alternating current. By adjusting this frequency, the inverter effectively governs the rotational speed of the motor, allowing for precise control over the vehicle's movement. Furthermore, the inverter has the capability to influence the power and torque output of the motor. This is achieved by fine-tuning the amplitude of the AC signal produced. In essence, the inverter serves as a sophisticated control unit, enabling dynamic adjustments to the motor's https://youtu.be/oVge8I6kxPY?si=8clTcjWZEEUsg-ST – Video on motor tear down Also, Inverters serve as the control from captured energy called regenerative braking and convert the energy back into the HV battery. Regenerative braking is a sophisticated kinetic energy recovery system integrated into electric and hybrid vehicles. When the driver engages the braking mechanism, this technology exploits the electric motor’s capacity to operate as a generator, transforming kinetic energy into electrical energy. The conversion process involves the electric motor gener- ating alternating current (AC), which is subsequently rectified into direct current (DC) by power electronics. The rectified electrical energy is then fed back into the vehicle’s energy storage system, typically a high-voltage battery pack. This recuperative process not only contributes to slowing down the vehicle but also serves to recharge the battery, enhanc- ing overall energy efficiency and promoting sustainable practices in electric and hybrid vehicle operations. Drive mode of the EV-601 An inverter serves as a crucial component in the functionality of an electric vehicle by transforming direct current (DC) power into the alternating current (AC) power required for the vehicle's motor operation. This device not only facilitates the conversion of power but also plays a pivotal role in controlling the motor's performance. One of the primary functions of the inverter is to modulate the speed of the electric motor by manipulating the frequency of the generated alternating current. By adjusting this frequency, the inverter effectively governs the rotational speed of the motor, allowing for precise control over the vehicle's movement. Furthermore, the inverter has the capability to influence the power and torque output of the motor. This is achieved by fine-tuning the amplitude of the AC signal produced. In essence, the inverter serves as a sophisticated control unit, enabling dynamic adjustments to the motor's https://youtu.be/oVge8I6kxPY?si=8clTcjWZEEUsg-ST consulab.com info@consulab.com 88 EV-601-TS_053322-96 Module 3 — SA-33 SA-33 Touchscreen Drive Mode A — Answers Objective: To have action reaction type of testing and to demonstrate different things that happen in an EV during differ- ent scenarios. STARTING: 1. What is the step 1 in starting an EV? Ignition ON to power the 12 volt system 2. What is the battery voltage when the vehicle is at 0% charge? 272 volts 3. What is the battery voltage when the vehicle is at 50% charge? 340 volts 4. What is the battery voltage when the vehicle is at 100% charge? 400 volts 5. In order to put the vehicle into drive what must be displayed on the dashboard? Ready light 6. Why is this mode (Icon) important in order to operate the drive function of the vehicle? It ensures all safety systems are in place and working interlock and isolation 7. What checks are done to ensure the high voltage system is safe? HVIL — Isolation — Voltage HV 8. Set “ EV-601 Consulab touch screen” as shown below. c. __Negative contactors__________________________________ d. ____________________________________ e. ____________________________________ What colour is the ready mode light? _______Green___________________________ What would prevent the “ready mode” from turning on? ______Charger plugged in___________________ Now select the 0% charge what components are on? a. _Same no change just reduced range___________________________________ SA-29 – Drive mode B Set “ EV-601 Consulab touch screen” as shown below Now let’s get the vehicle ready to move and drive forward. Setting up screen as shown below put the vehicle into drive. What needs to be on, in order for the vehicle to be put into drive or reverse? __Ready Light______________ What need to be on, in order for the vehicle to be put into drive or reverse ? Ready Light consulab.com info@consulab.com 89 EV-601-TS_053322-96 Module 3 — SA-33 9. What components are now ON? A. DC/DC converter B. Positive contactors C. Negative contactors 10. What colour is the ready mode light? Green 11. What would prevent the “ready mode” from turning ON? Charger plugged in 12. Now select the 0% charge what components are ON? Same ones as Step 9 (no change just reduced range) A. DC/DC converter B. Positive contactors C. Negative contactors consulab.com info@consulab.com 90 EV-601-TS_053322-96 Module 3 — SA-34 SA-34 Touchscreen Drive Mode B — Answers Objective: To have action reaction type of testing and to demonstrate different things that happen in an EV during differ- ent scenarios. 1. Set “ EV-601 Consulab touch screen” as shown below. c. __Negative contactors__________________________________ d. ____________________________________ e. ____________________________________ What colour is the ready mode light? _______Green___________________________ What would prevent the “ready mode” from turning on? ______Charger plugged in___________________ Now select the 0% charge what components are on? a. _Same no change just reduced range___________________________________ SA-29 – Drive mode B Set “ EV-601 Consulab touch screen” as shown below Now let’s get the vehicle ready to move and drive forward. Setting up screen as shown below put the vehicle into drive. What needs to be on, in order for the vehicle to be put into drive or reverse? __Ready Light______________ 2. Now let’s get the vehicle ready to move and drive forward. Put the vehicle into drive. 3. What needs to be ON, in order for the vehicle to be put into drive or reverse? Ready light 4. Using the accelerator what is the battery voltage reading at 60 km/h (37 mph) ? 280 volts 5. Using the accelerator what is the battery voltage reading at 100 km/h (62 mph) ? 280 volts 6. Using the accelerator what is the battery voltage reading at 210 km/h (130 mph) ? 280 volts 7. Now when releasing accelerator what happens to the voltage on deceleration? It goes up 8. What is this called? Regeneration 9. Why does this happen? Motor acts as a generator 10. What would prevent this from happening? A. Battery too cold B. Battery too hot C. Battery at 100 % consulab.com info@consulab.com 91 EV-601-TS_053322-96 Module 3 — SA-35 SA-35 Watching the Power Drive to the Rear Drive Unit — Answers Objective: To monitor the rear power drive DC-AC conversion. Note: Accelerating the vehicle up to about 100 km/h (62 mph) what can we see with the rear power is the conversion from DC to AC current to the Permanent Magnet Synchronous Reluctance Motor (PMSRM). Accelerating the vehicle up to about 100Kmph what can we see with the rear power is the conversion from DC to AC current to the Permanent magnet synchronous reluctance motor (PMSRM) What do we see in the coloured cable strip of LEDs? ____3 colour LED lights ____________________ What happens when we accelerate the vehicle to 100 Kmph? ___Increase speed ______________ What happens when we let off the accelerator with the lights? __lights reverse_______________ What is this called? _EMF_______________________________ What effect would this have on a vehicle slowing down? __capturing energy___________________ What is this effect used for? ___Regeneration__________________________________________ How does the vehicle increase this effect while slowing down? __by applying more load on the sator ______________ 1. What do we see in the colored cable strip of LEDs? 3 color LED lights 2. What happens when we accelerate the vehicle to 100 km/h (62 mph) ? We increase speed 3. What happens when we let off the accelerator with the lights? Lights are reversed 4. What is this called? EMF (electromotive force) 5. What effect would this have on a vehicle slowing down? Capturing energy 6. What is this effect used for? Regeneration 7. How does the vehicle increase this effect while slowing down? By applying more load on the stator consulab.com info@consulab.com 92 EV-601-TS_053322-96 Student Learning Module 4 Student Learning Module 4 First Responder Training This section comprises assignments which are designed to provide a first responder training dedicated for emergency personnel to quickly and safely disable the high-voltage electrical system in the event of an accident or emergency situation. consulab.com info@consulab.com 93 EV-601-TS_053322-96 Module 4 — First Responder Training First responder Training for EV’s with the EV-601-TS Introduction Electric vehicles (EVs) are revolutionizing the automotive industry, offering a cleaner and more sustainable mode of trans- portation. As their popularity continues to soar, it’s imperative that first responders — paramedics, firefighters, and law enforcement officers—are adequately trained to handle incidents involving these vehicles. This training is essential due to the unique challenges and safety considerations associated with EVs. One of the primary reasons for first responders to undergo specialized training in dealing with electric vehicles is safety. Unlike traditional internal combustion engine vehicles, EVs are powered by high-voltage batteries, which can pose sig- nificant risks if mishandled. Understanding how to safely approach and interact with these vehicles is crucial to prevent accidents, electrocutions, or other hazards, especially during emergencies such as accidents or fires. Moreover, dealing with electric vehicles requires specialized knowledge and techniques that differ from those used for conventional vehicles. First responders must familiarize themselves with the location of high-voltage components, such as the battery pack, inverters, and electric motors. They need to know how to safely disable power systems and isolate electrical circuits to minimize risks to themselves, bystanders, and the environment. Emergency response protocols play a vital role in ensuring effective handling of incidents involving electric vehicles. First responders must be able to quickly assess the situation, secure the scene, and implement appropriate safety measures. Standardized protocols help streamline response efforts and ensure that responders can efficiently manage any scenar- io they encounter, promoting public safety and confidence in emergency services. Fire safety is another critical aspect of first responder training with electric vehicles. Lithium-ion batteries, commonly used in EVs, present unique challenges in the event of a fire. They can reignite even after being extinguished, and certain firefighting methods may exacerbate the situation. Proper training equips responders with the knowledge and techniques to safely manage EV-related fires while minimizing risks to themselves and others. Extrication techniques are essential skills that first responders must possess when dealing with accidents involving electric vehicles. Rescuing occupants from damaged EVs may require different approaches compared to tradi- tional vehicles due to the vehicle’s structure and power systems. Understanding how to safely extricate individuals while avoiding further harm is crucial for a successful rescue operation. The environmental impact of accidents involving electric vehicles is another factor that first responders must consider. EVs contain hazardous materials that can leak or contaminate the environment, posing risks to ecosystems and public health. Proper training ensures that responders can effectively mitigate these environmental risks and prevent further harm during emergency situations. consulab.com info@consulab.com 94 As electric vehicle adoption continues to grow, encounters with these vehicles in emergency situations will become more common. Therefore, it is essential to provide first responders with comprehensive training to handle any scenario they may encounter. By equipping them with the necessary knowledge and skills, we can ensure timely and competent responses to emergencies, ultimately saving lives and protecting communities. What is the Emergency Responder Guide book? The Emergency Response Guidebook was developed by Transport Canada and the US Department of Transportation. The information in the first responders guide (FRG) can help first responders in learning about the hybrid and electric systems so that they can perform necessary rescue actions quickly and proper- ly in an emergency situation. The First Responder Guides provide an overview of how vehicle systems oper- ate and how to identify a hybrid or electric vehicle from a conventional vehicle. This guidebook is for firefighters, police, and other emergency responders who are often the first to arrive at a transportation incident involving dangerous goods. Its important to understand the hazards around electric vehicles and placement of components and warnings in a vehicle after an upset. The First Responders guide will help first responders: • Identify hazards based on the material involved in a transportation incident • Protect themselves and the public during the initial response to an incident The first responders guide is designed for dangerous goods incidents on a highway or rail line, in the case of this course directed at electric and hybrid vehicles. This First responders guide does not: • Include information on the physical or chemical properties of dangerous goods • Replace emergency response training, knowledge, and good judgment • Address every possible factor related to a dangerous goods incident Understanding the first responder’s guidebook and reviewing it will help quickly help identify in electric vehicles. These items are not limited to all vehicles and some responders guides will include more information: • Identification • Warning label locations • Prevention measures for High Voltage EV-601-TS_053322-96 Module 4 — First Responder Training What is the Emergency Responder Guide book? The Emergency Response Guidebook was developed by Transport Canada, the US Department of Transportation. The information in the first responders guide (FRG) can help first responders in learning about the hybrid and electric systems so that they can perform necessary rescue actions quickly and properly in an emergency situation. The First Responder Guides provide an overview of how vehicle systems operate and how to identify a hybrid or electric vehicle from a conventional vehicle. This guidebook is for firefighters, police, and other emergency responders who are often the first to arrive at a transportation incident involving dangerous goods. Its important to understand the hazards around electric vehicles and placement of components and warnings in a vehicle after an upset. The First Responders guide will help first responders: • Identify hazards based on the material involved in a transportation incident • protect themselves and the public during the initial response to an incident The first responders guide is designed for dangerous goods incidents on a highway or rail line, in the case of this course directed at electric and hybrid vehicles. This First responders guide does not: • include information on the physical or chemical properties of dangerous goods • replace emergency response training, knowledge, and good judgment • address every possible factor related to a dangerous goods incident Understanding the first responder’s guidebook and reviewing it will help quickly help identify in electric vehicles. These items are not limited to all vehicles and some responders guides will include more information. • Identification • Warning label locations • Prevention measures for High Voltage • Battery position both high voltage and low voltage • Component location • First responders cut loop • Depowering vehicles • Securing vehicles • Cut points in a vehicle body • SIR component locations • High Voltage cables and hazards • Fire fighting techniques • Submersion How to navigate the first responders guide, is a challenge for many first responders as some guides can be up to a 100 pages long and not always easily to come by. Especially in a vehicle emergency and the first responder is trying to consulab.com info@consulab.com 95 EV-601-TS_053322-96 Module 4 — First Responder Training • Battery position both high voltage and low voltage • Component location • First responders cut loop • Depowering vehicles • Securing vehicles • Cut points in a vehicle body • SIR component locations • High Voltage cables and hazards • Fire fighting techniques • Submersion How to navigate the first responder guide, is a challenge for many first responders as some guides can be up to a 100 pages long and not always easily to come by. Especially in a vehicle emergency and the first responder is trying to identi- fy the vehicle and then trying to locate the information relevant to the vehicle, incident, and protective measures. So it becomes important for all first responders to understand how a EV first responder guide works to navigate it quickly. Location of First Responders Guides can be found in various areas online. Its also important to know that the first responders’ guides are written by the manufacture and finding the guide in one place is the same document as every- where else. Understanding how to use the guide is just as important as putting it into practice. High voltage vehicles pose different hazards than conventional vehicles both to passengers and first responder personal dealing with a EV vehicle at a accident scene. Let’s start with location of the guides, many guides can be found on manufacture websites. A direct link to all OEM ser- vice websites that offer first responders guides for free. But in many cases, you have to search websites to access the guides and can be time consuming. Sites like the National Fire Prevention Association has a direct links to all response guides for electric vehicles. NFPA - Emergency Response Guides for Alternative Fuel Vehicles Most important part of the emergency response guides is general understanding and review of the important information. identify the vehicle and then trying to locate the information relevant to the vehicle, incident, and protective measures. So it becomes important for all first responders to understand how a EV first responder guide works to navigate it quickly. Location of First Responders Guides can be found in various areas online. Its also important to know that the first responders’ guides are written by the manufacture and finding the guide in one place is the same document as everywhere else. Understanding how to use the guide is just as important as putting it into practice. High voltage vehicles pose different hazards than conventional vehicles both to passengers and first responder personal dealing with a EV vehicle at a accident scene. Let’s start with location of the guides, many guides can be found on manufacture websites. A direct link to all OEM service websites that offer first responders guides for free. But in many cases, you have to search websites to access the guides and can be time consuming. Sites like the National Fire Prevention Association has a direct links to all response guides for electric vehicles. NFPA - Emergency Response Guides for Alternative Fuel Vehicles Most important part of the emergency response guides is general understanding and review of the important information. The First Responders guide will help first responders: • Identify hazards based on the material involved in a transportation incident • protect themselves and the public during the initial response to an incident The first responders guide is designed for dangerous goods incidents on a highway or rail line, in the case of this course directed at electric and hybrid vehicles. This First responders guide does not: • include information on the physical or chemical properties of dangerous goods • replace emergency response training, knowledge, and good judgment • address every possible factor related to a dangerous goods incident Understanding the first responder’s guidebook and reviewing it will help quickly help identify in electric vehicles. These items are not limited to all vehicles and some responders guides will include more information. • Identification • Warning label locations • Prevention measures for High Voltage • Battery position both high voltage and low voltage • Component location • First responders cut loop • Depowering vehicles • Securing vehicles • Cut points in a vehicle body • SIR component locations • High Voltage cables and hazards • Fire fighting techniques • Submersion How to navigate the first responders guide, is a challenge for many first responders as some guides can be up to a 100 pages long and not always easily to come by. Especially in a vehicle emergency and the first responder is trying to http://NFPA - Emergency Response Guides for Alternative Fuel Vehicles http://NFPA - Emergency Response Guides for Alternative Fuel Vehicles consulab.com info@consulab.com 96 First Responder “Quick Guides” or “Rescue Sheets” Information can be overwhelming and very in depth and the required information that is needed in the event of an elec- tric vehicle situation at an accident must be easily accessible. So recent most manufactures have added Quick Guides. These are similar information to a first responders guide but concentrate on specific “need to know” information. The quick guides do not replace the first responders guide but act as a supplement to the guide. First Responders “Quick Guides” or “Rescue Sheets” Information can be overwhelming and very in depth and the required information that is needed in the event of an electric vehicle situation at an accident must be easily accessible. So recent most manufactures have added Quick Guides. These are similar information to a first responders guide but concentrate on specific “need to know” information. The quick guides do not replace the first responders guide but act as a supplement to the guide. Other valuable apps that can be downloaded for free to all students and they should Quick response guide or rescue sheets First Responders “Quick Guides” or “Rescue Sheets” Information can be overwhelming and very in depth and the required information that is needed in the event of an electric vehicle situation at an accident must be easily accessible. So recent most manufactures have added Quick Guides. These are similar information to a first responders guide but concentrate on specific “need to know” information. The quick guides do not replace the first responders guide but act as a supplement to the guide. Other valuable apps that can be downloaded for free to all students and they should Quick response guide or rescue sheets First Responders “Quick Guides” or “Rescue Sheets” Information can be overwhelming and very in depth and the required information that is needed in the event of an electric vehicle situation at an accident must be easily accessible. So recent most manufactures have added Quick Guides. These are similar information to a first responders guide but concentrate on specific “need to know” information. The quick guides do not replace the first responders guide but act as a supplement to the guide. Other valuable apps that can be downloaded for free to all students and they should Quick response guide or rescue sheets Other valuable apps that can be downloaded for free to all students and they should. EV RESCUE Emergency Response Guides for Electric & Hybrid Vehicles First Responders “Quick Guides” or “Rescue Sheets” Information can be overwhelming and very in depth and the required information that is needed in the event of an electric vehicle situation at an accident must be easily accessible. So recent most manufactures have added Quick Guides. These are similar information to a first responders guide but concentrate on specific “need to know” information. The quick guides do not replace the first responders guide but act as a supplement to the guide. Other valuable apps that can be downloaded for free to all students and they should Quick response guide or rescue sheets EV-601-TS_053322-96 Module 4 — First Responder Training consulab.com info@consulab.com 97 EV-601-TS_053322-96 Module 4 — First Responder Training 1.3 How to utilize a response guide in the event of an accident. This involves police, fire and paramedics that have considerations when approaching a vehicle during an accident and incident. Each division is outlined in how to handle a scene involving a motor vehicle. Law Enforcement, Medical teams and Fire Fighting Services. Access to ALL EV systems including cars, trucks, busses and charging stations. consulab.com info@consulab.com 98 EV-601-TS_053322-96 Module 4 — Law Enforcement Law Enforcement Law Enforcement ------------------------------------------------------------------------------------------------------------- ------------------------ Electric and Hybrid-Electric Vehicles Equipped with High Voltage Batteries – ELECTRIC AND HYBRID-ELECTRIC VEHICLE CONSIDERATIONS In the event of damage to or fire involving an electric vehicle (EV) or hybrid- electric vehicle (HEV): • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. • Physical damage to the vehicle or HV battery may result in immediate or delayed release of toxic and/or flammable gases and fire. ------------------------------------------------------------------------------------------------------------- -------------------------- IDENTIFY VEHICLE • Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise Dispatch and all responders that an electric or hybrid-electric vehicle is involved. ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH VOLTAGE BATTERIES Electric and Hybrid-Electric Vehicle Considerations In the event of damage to or fire involving an electric vehicle (EV) or hybrid-electric vehicle (HEV): • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. • Physical damage to the vehicle or HV battery may result in immediate or delayed release of toxic and/or flammable gases and fire. Identify Vehicle: • Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise dispatch and all responders that an electric or hybrid-electric vehicle is involved. Immobilize Vehicle: • Always approach vehicle from the sides to stay out of potential travel path. It may be difficult to determine if the vehicle is running due to lack of engine noise. • If possible: 1. Chock the tires 2. Place the vehicle into Park 3. Set the parking brake. Law Enforcement ------------------------------------------------------------------------------------------------------------- ------------------------ Electric and Hybrid-Electric Vehicles Equipped with High Voltage Batteries – ELECTRIC AND HYBRID-ELECTRIC VEHICLE CONSIDERATIONS In the event of damage to or fire involving an electric vehicle (EV) or hybrid- electric vehicle (HEV): • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. • Physical damage to the vehicle or HV battery may result in immediate or delayed release of toxic and/or flammable gases and fire. ------------------------------------------------------------------------------------------------------------- -------------------------- IDENTIFY VEHICLE • Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise Dispatch and all responders that an electric or hybrid-electric vehicle is involved. consulab.com info@consulab.com 99 EV-601-TS_053322-96 Module 4 — Law Enforcement Disable Vehicle: • Place vehicle in Park, set parking brake, turn off the vehicle, activate hazard lights, and move vehicle keys at least 16 feet away from vehicle. • If your local standard operating procedures (SOPs) allow, and if you are properly trained and equipped, disconnect the 12-volt battery. CAUTION: Safety restraints, air bags and other safety systems may be active for up to five minutes after discon- necting the 12-volt battery. EMERGENCIES Crash: • If you detect leaking fluids, sparks, smoke, flames, increased temperature, gurgling, popping or hissing noises from the HV battery compartment, ventilate passenger area (i.e., roll down windows or open doors) and request fire de- partment response. • Request Emergency Medical Services if there are injuries as a result of the crash. • If you detect any unusual odors or experience eye, nose, or throat irritation, move away from the vehicle and evacu- ate others from the immediate area. • Avoid contact with orange high voltage cabling and areas identified as high voltage risk by warning labels. • Remain a safe distance upwind and uphill from the vehicle and stay out of the way of oncoming traffic until other appropriately equipped emergency responders arrive. • Be alert. There is a potential for delayed fire with damaged lithium-ion batteries. Listen for hissing or popping sounds. Fire: • If you are unable to quickly remove the occupants, use a fire extinguisher to protect them from the flames. • As with any vehicle fire, the by-products of combustion can be toxic and all individuals should be directed to move to a safe distance upwind and uphill from the vehicle fire and out of the way of oncoming traffic. Post-incident: • Always assume the HV battery and associated components are energized and fully charged during investigation and storage. • Ensure that passenger and cargo compartment remain ventilated, i.e., open window, door, or trunk during investiga- tion and storage. • Notify an authorized service center or vehicle manufacturer representative as soon as possible as there may be other steps they can take to secure and discharge the HV battery. • Do not store a severely damaged vehicle with a lithium-ion battery inside a structure or within 50 feet of any struc- ture or vehicle. • Request fire department if you observe leaking fluids, sparks, smoke, flames, or hear gurgling, popping or bubbling from the HV battery consulab.com info@consulab.com 100 EV-601-TS_053322-96 Module 4 — Medical Staff Medical Staff — EMT’s Medical Staff – EMT’s ------------------------------------------------------------------------------------------------------------- ------------------------ Electric and Hybrid-Electric Vehicles Equipped with High Voltage Batteries – ELECTRIC AND HYBRID-ELECTRIC VEHICLE CONSIDERATIONS • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. • Physical damage to the vehicle or HV battery may result in immediate or delayed release of toxic and/or flammable gases and fire. ------------------------------------------------------------------------------------------------------------- -------------------------- IDENTIFY VEHICLE Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise dispatch and all responders that an electric or hybrid-electric vehicle is involved. IMMOBILIZE VEHICLE • Always approach vehicle from the sides to stay out of potential travel path. It may be difficult to determine if the vehicle is on due to lack of engine noise. • If possible, chock the tires, place the vehicle into Park and set the parking brake ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH VOLTAGE BATTERIES Electric and Hybrid-Electric Vehicle Considerations In the event of damage to or fire involving an electric vehicle (EV) or hybrid-electric vehicle (HEV): • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. • Physical damage to the vehicle or HV battery may result in immediate or delayed release of toxic and/or flammable gases and fire. Identify Vehicle: • Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise dispatch and all responders that an electric or hybrid-electric vehicle is involved. Immobilize Vehicle: • Always approach vehicle from the sides to stay out of potential travel path. It may be difficult to determine if the vehicle is running due to lack of engine noise. • If possible: 1. Chock the tires 2. Place the vehicle into Park 3. Set the parking brake. consulab.com info@consulab.com 101 EV-601-TS_053322-96 Module 4 — Medical Staff Disable Vehicle: • Place vehicle in Park, set parking brake, turn off the vehicle, activate hazard lights, and move vehicle keys at least 16 feet away from vehicle. • If your local standard operating procedures (SOPs) allow, and if you are properly trained and equipped, disconnect the 12-volt battery. CAUTION: Safety restraints, air bags and other safety systems may be active for up to five minutes after discon- necting the 12-volt battery. EMERGENCIES Crash: • Request law enforcement response if you need assistance with traffic control or scene safety. • If you detect leaking fluids, sparks, smoke, flames, increased temperature, gurgling, popping or hissing noises from the HV battery compartment, ventilate passenger area (i.e., roll down windows or open doors) and request fire de- partment response. • Avoid contact with orange high voltage cabling and areas identified as high voltage risk by warning labels. • Move away from the vehicle and evacuate others from the immediate area if you detect any unusual odors or expe- rience eye, nose, or throat irritation. Rapid extrication may be needed for injured or trapped occupants. • Remain a safe distance upwind and uphill from the vehicle and out of the way of oncoming traffic until other appro- priately equipped emergency responders arrive. • Be alert. There is a potential for delayed fire with damaged lithium-ion batteries. Fire: • If you are unable to quickly remove the occupants, use a fire extinguisher to protect them from the flames. • As with any vehicle fire, the by-products of combustion can be toxic and all individuals should be directed a safe distance upwind and uphill from the vehicle fire and out of the way of oncoming traffic. Post-incident: • Always assume the HV battery and associated components are energized and fully charged. • Ensure that passenger and cargo compartment remain ventilated, i.e., open window, door, or trunk if and when inside vehicle providing patient care. • Notify authorized service center or vehicle manufacturer representative as soon as possible as there may be other steps they can take to secure and discharge the HV battery. • Do not store a severely damaged vehicle with a lithium-ion battery inside a structure or within 50 feet of any struc- ture or vehicle. • Request fire department if you observe leaking fluids, sparks, smoke, flames, or hear gurgling or popping and hissing sounds. consulab.com info@consulab.com 102 EV-601-TS_053322-96 Module 4 — Fire Fighters Fire Fighters • As with any vehicle fire, the by-products of combustion can be toxic and all individuals should be directed a safe distance upwind and uphill from the vehicle fire and out of the way of oncoming traffic. POST-INCIDENT • Always assume the HV battery and associated components are energized and fully charged. • Ensure that passenger and cargo compartment remain ventilated, i.e., open window, door, or trunk if and when inside vehicle providing patient care. • Notify authorized service center or vehicle manufacturer representative as soon as possible as there may be other steps they can take to secure and discharge the HV battery. • Do not store a severely damaged vehicle with a lithium-ion battery inside a structure or within 50 feet of any structure or vehicle. • Request fire department if you observe leaking fluids, sparks, smoke, flames, or hear gurgling or popping and hissing sounds. Fire Fighters ------------------------------------------------------------------------------------------------------------- ------------------------ Electric and Hybrid-Electric Vehicles Equipped with High Voltage Batteries – ELECTRIC AND HYBRID-ELECTRIC VEHICLE CONSIDERATIONS In the event of damage to or fire involving an electric vehicle (EV) or hybrid- electric vehicle (HEV): • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH VOLTAGE BATTERIES Electric and Hybrid-Electric Vehicle Considerations In the event of damage to or fire involving an electric vehicle (EV) or hybrid-electric vehicle (HEV): • Always assume the high voltage (HV) battery and associated components are energized and fully charged. • Exposed electrical components, wires, and HV batteries present potential HV shock hazards. • Venting/off-gassing HV battery vapors are potentially toxic and flammable. • Physical damage to the vehicle or HV battery may result in immediate or delayed release of toxic and/or flammable gases and fire. Identify Vehicle: • Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise dispatch and all responders that an electric or hybrid-electric vehicle is involved. Immobilize Vehicle: • Always approach vehicle from the sides to stay out of potential travel path. It may be difficult to determine if the vehicle is running due to lack of engine noise. • If possible: 1. Chock the tires 2. Place the vehicle into Park 3. Set the parking brake. consulab.com info@consulab.com 103 EV-601-TS_053322-96 Module 4 — Fire Fighters Disable Vehicle: • Place vehicle in Park, set parking brake, turn off the vehicle, activate hazard lights, and move vehicle keys at least 16 feet away from the vehicle. • If your local standard operating procedures (SOPs) allow and if you are properly trained and equipped, disconnect the 12-volt battery. CAUTION: Safety restraints, air bags and other safety systems may be active for up to five minutes after discon- necting the 12-volt battery. EMERGENCIES Crash: • If you detect leaking fluids, sparks, smoke, flames, increased temperature, gurgling or bubbling sounds from the HV battery compartment, assume there is a battery fire and ventilate the passenger area (i.e., roll down windows, or open doors). • If there is fire, and occupants are still inside the vehicle or are trapped, use a fire extinguisher to protect the occu- pants until a hose line is available or until the occupants are removed.. • Request Emergency Medical Services if there are injuries as a result of the crash. • Request law enforcement if you need assistance with traffic control or scene safety. • Move away from the vehicle and evacuate others from the immediate area if you detect any unusual odors or ex- perience eye, nose, or throat irritation. Wear full Personal Protective Equipment (PPE) and Self-Contained Breathing Apparatus (SCBA) if rapid extrication is necessary for injured or trapped occupants. • Be alert. TThere is a potential for delayed fire with damaged lithium-ion batteries. Fire: • NOTE: If the fire involves a lithium-ion battery, it will require large, sustained volumes of water for extinguishment. If there is no immediate threat to life or property, consider defensive tactics and allow fire to burn out. • If there is active fire, follow local SOP for vehicle fires. Wear appropriate Personal Protective Equipment (PPE) and Self Contained Breathing Apparatus (SCBA) at all times. • If occupants are still inside the vehicle or are trapped, use a fire extinguisher to protect the occupants until a hose line is available or until the occupants are removed. • Establish a safe perimeter around the vehicle. • Consider establishing a water supply to support long-term operation. • Use a hose line to apply water to extinguish the fire while continuing to cool the HV battery and its casing. Never attempt to penetrate the HV battery or its casing to apply water. • Avoid contact with orange high voltage cabling and areas identified as high voltage risk by warning labels. • Be alert. There is a potential for delayed ignition or re-ignition of a lithium-ion battery fire even after it is believed to be extinguished. This may remain an issue until the lithium-ion battery is properly discharged. • As with any vehicle fire, the by-products of combustion can be toxic and all individuals not properly trained, dressed, and equipped to fight the fire should be directed a safe distance upwind and uphill from the vehicle fire and out of the way of oncoming traffic. consulab.com info@consulab.com 104 EV-601-TS_053322-96 Module 4 — Fire Fighters Post-incident: • Always assume the HV battery and associated components are energized and fully charged. • Ensure that passenger and cargo compartments remain ventilated, i.e., open window, door or trunk if and when inside vehicle providing patient care. • Notify an authorized service center or vehicle manufacturer representative (dealer) as soon as possible as there may be additional steps they can take to secure and discharge the HV battery. • Do not store a severely damaged vehicle with a lithium-ion battery inside a structure or within 50 feet of any struc- ture or vehicle. • Vehicle should be monitored for leaking fluids, sparks, smoke, flames, gurgling or bubbling sounds from the HV bat- tery, and if detected, assume the HV battery is burning and follow above guidance to extinguish the fire. consulab.com info@consulab.com 105 EV-601-TS_053322-96 Module 4 — First Responder Loop First Responder Loop How does the First Responder Loop Work? For auto service technicians, understanding the functionality of the first re- sponder loop on electric vehicles (EVs) is crucial for ensuring safety during maintenance and repair tasks. The first responder loop serves as a safety feature designed to quickly disable the high-voltage power systems of an EV in emergency situations, reducing the risk of electric shock or other hazards. Typ- ically located in easily accessible areas such as the trunk or near the battery compartment and marked with standardized symbols or labels, the activation of this loop isolates the high-voltage systems, preventing electrical current flow. This ensures that technicians can safely work on the vehicle without the risk of electrocution. Familiarity with the location, activation, and purpose of the first responder loop is essential for auto service technicians to carry out their duties effectively and safely when handling EVs. The first responder loop is typically located in an easily accessible area of the vehicle, such as the trunk or near the battery compartment. Its location may vary depending on the vehicle make and model, but it is usually marked with a standardized symbol or label to assist first responders in locating it quickly. Also not that the first responder loop may have a primary and secondary loop present on the vehicle. The EV-601 demonstrates the primary and secondary cut loops: 1. In the event of an emergency, first responders can activate the first responder loop to safely disable the high-volt- age power systems of the EV. This is typically done by pulling a designated lever or cutting two points in the loop. 2. When the first responder loop is activated, it effectively isolates the high-voltage systems of the vehicle, preventing electrical current from flowing through them. This reduces the risk of electric shock to responders and bystanders and allows emergency personnel to safely perform their duties, such as extrication of occupants or firefighting. Important: Note the low voltage systems are not disabled but the Air bag system is and power to the contactors. Once the first responder loop is activated, emergency responders can proceed with their tasks knowing that the high-voltage systems of the vehicle have been safely disabled. This enables them to work more effectively and efficiently to mitigate the incident and ensure the safety of everyone involved. When using the EV-601 it utilizes two cut points in the HV circuit. These are to ensure in the event of a frontal collision or rear collision they are always accessible. When demonstrating the first responder loop make sure the vehicle is in drive then have a student unplug one of the “loops” its not necessary to “cut” the loop but unplug the circuit. consulab.com info@consulab.com 106 Its important to explain the circuit and the direct interruption to the contactors and SIR system. But also note that the low voltage system in not effected and all low voltage items will remain powered until the negative and positive termi- nals of the battery are disconnected. The First responders cut loop provides direct power and pass thru power to components that control HV circuits. By cutting power to the contactors ensures that they cannot power back up again. Also, the power to the restraint module is also cut when the first responder loop is cut. The wires located usually in a red loom are always low voltage positive wires. This way cutting the harness thru does not create a spark or short in the circuit when cutting the 3 wires. The First responders cut loop provides direct power and pass thru power to components that control HV circuits. By cutting power to the contactors ensures that they cannot power back up again. Also, the power to the restraint module is also cut when the first responders loop is cut. The wires located usually in a red loom are always low voltage positive wires. This way cutting the harness thru does not create a spark or short in the circuit when cutting the 3 wires. Its important that cutting through the wires of the first responders loop on an electric vehicle (EV) is important for safety reasons. The first responders loop, also known as the high-voltage electrical safety disconnect, is designed to allow emergency personnel to quickly and safely disable the high-voltage power system of an EV in the event of an accident or emergency situation. Here are some reasons why cutting through these wires is important: Preventing Electric Shock: Electric vehicles have high-voltage systems that can pose serious risks of electric shock if not properly disabled. Cutting through the first responders loop helps to ensure that the high-voltage system is safely deactivated, reducing the risk of electric shock to first responders and others at the scene. Proper procedures is to cut thru the cable in two spots removing a section to ensure reconnection is impossible CUT CU T Proper procedures is to cut thru the cable in two spots removing a section to ensure reconnection is impossible. EV-601-TS_053322-96 Module 4 — First Responder Loop consulab.com info@consulab.com 107 EV-601-TS_053322-96 Module 4 — First Responder Loop It’s important to cut through the wires of the first responder loop on an electric vehicle (EV) for safety reasons. The first responder loop, also known as the high-voltage electrical safety disconnect, is designed to allow emergency personnel to quickly and safely disable the high-voltage power system of an EV in the event of an accident or emergency situation. Here are some reasons why cutting through these wires is important: Preventing Electric Shock: Electric vehicles have high-voltage systems that can pose serious risks of electric shock if not properly disabled. Cutting through the first responder loop helps to ensure that the high-voltage system is safely deactivated, reducing the risk of electric shock to first responders and others at the scene. Preventing Fire: In the event of a severe accident or damage to the EV, there’s a risk of electrical arcing or short circuits that could lead to a fire. Cutting through the wires of the first responder loop helps to mitigate this risk by preventing the flow of electricity through the vehicle’s high-voltage system. Facilitating Rescue Operations: By disabling the high-voltage system, cutting through the first responder loop makes it safer and easier for emergency personnel to extract occupants from the vehicle, particularly if they are trapped or injured. Avoiding Further Damage: Leaving the high-voltage system active could potentially cause further damage to the vehicle or escalate the severity of the situation. Cutting through the first responder loop helps to prevent such scenarios. Standard Procedure: Cutting through the wires of the first responder loop is often a standard procedure recommended by EV manufacturers and emergency response organizations to ensure the safety of both responders and bystanders. consulab.com info@consulab.com 108 EV-601-TS_053322-96 Module 4 — SA-36 SA-36 First responder loop Function — Answers Objective: To demonstrate the function of the first responder loops during an event that the high voltage system needs to be powered down. 1. 1. Set up the first responder loop touchscreen as below: This will demonstrate the function of the first responders’ loop during an event that the high voltage system needs to be powered down. Setting up the first responder screen Location of the disconnects for first responders 1. ___Underhood firewall __________________________ 2. ____Passanger rear window_ ________________________ 2. Where are located the disconnects for the first responders on the EV-601? A. Underhood firewall B. Passanger rear window 3. What systems are affected by the unplugging of the first responders disconnect? All high voltage systems 4. Why are some systems still active even with the loop unplugged? To keep vehicle mobile and open and close doors windows 5. What happens if the first responder loops are reconnected? High voltage remains off 6. What must be done in order to restore the vehicle? To reset vehicle consulab.com info@consulab.com 109 EV-601-TS_053322-96 Module 4 — Quiz Quiz on First Responder for EV-601 Use the answer sheet for your answers. 1. Hybrid electric vehicles incorporate what power systems for a true hybrid? A. HV battery and transmission B. ICE engine and transmission C. ICE engine and electric motors D. ICE engine and differential 2. Hybrid vehicles can be identified by... A. Badges B. Size of wheels C. Lack of door handles D. Red high voltage cables 3. What was called the first production car that was all electric in 1990? A. Toyota Prius B. Honda Insite C. Chevrolet EV1 D. Nissan Pulsar 4. Why cutting the first responder loop in the event of a accident is important? A. Disables the 12-volt system B. Prevents electric shock C. Identifies vehicle is disabled D. Discharges the HV battery 5. What are the three steps in securing an electric vehicle? A. Chock the wheels, disconnect the 12-volt battery and make sure the vehicle is in park B. Chock the wheels, make sure the vehicle is in park and disable the high voltage system C. Chock the wheels, make sure the vehicle is in park, and apply the park brake D. Apply the park brake, disable the ignition and roll up the windows consulab.com info@consulab.com 110 EV-601-TS_053322-96 Module 4 — Quiz 6. When dealing with a lithium vehicle battery fire, the best method to extinguish the fire is to use... A. Class B extinguisher B. Class ABC extinguisher C. Lots of water D. First use an ABC extinguisher then water 7. A vehicle battery fire requires over how many gallons of water? A. 1500 gallons B. 2000 gallons C. 2200 gallons D. 2600 gallons 8. When dealing with a leakage from damaged lithium battery and electrolyte gets on your skin, the proper clean up procedure is to use... A. Lots of water and seek medical attention B. Bleach and water C. Dilute boric acid or vinegar D. Soap and water 9. A thermal image camera (TIC) can be used to check a battery an hour after a fire to check for? A. Damage to the battery B. If the fire is out C. Reduce the risk thermal runaway D. Temperature of the case of the battery 10. The term kWh is a way to identify the size of the... A. Drive motor B. Charging speed at level 3 C. Size of the battery D. Energy type for the battery 11. The first responder disconnect or cut point is designed to... A. Power off only the high voltage system B. Completely power off the vehicle by disabling the 12-volt system C. Completely power off the vehicle by disabling the high voltage system D. Disable SIR and HV systems consulab.com info@consulab.com 111 EV-601-TS_053322-96 Module 4 — Quiz 12. Most of today’s electric vehicles HV BEV battery voltage will be... A. 201 DC volts B. 300 DC volts C. 400 DC volts D. 800 AC volts 13. How many wires are found in the front cut loop circuit? A. 1 B. 2 C. 3 D. 4 14. In the event of a submerged vehicle the term “microbubbling” is used to describe... A. The energy stored to create a barrier around the battery to protect it B. The gassing of the battery creating small bubbles containing hydrogen and oxygen from battery discharge C. Small pieces of metal from the electric motor containing small bubbles D. Small bubbles of fluid from the battery that contain alkaline substance 15. After a collision and the airbags have deployed, why the vehicle will not start or drive? A. HV battery has been shorted out B. A built-in protection device has disconnected the HV battery C. The vehicle software will not allow the vehicle to start D. Drive motor is disengaged 16. If a BEV vehicle is involved in a fire and is plugged into a Level 2 home charger, the first step is to... A. Unplug the connector immediately from the vehicle B. Disconnect source power from the charger C. Use lots of water to put out the fire first D. Call power company to shut power off to entire home 17. Most first responder cut loop is coloured in... A. Blue B. Orange C. Red D. Yellow consulab.com info@consulab.com 112 EV-601-TS_053322-96 Module 4 — Quiz 18. On a HV BEV vehicle what components carry High Voltage? A. Inverter, battery and cables B. Inverter, capacitors and battery C. Cables, inverter and contactors D. Cables, motor and battery 19. The first responder under hood label has what information in it? A. Battery voltage, battery location and cut point for first responder loop B. Year of production, battery voltage and 12-volt battery location C. High voltage cable diagram, year of production and HV battery location D. Motor type, battery location and tire sizes 20. The first responder cut loop controls what side(s) of the circuit? A. Positive control to key components B. Positive and Negative power to key components C. Controls the CAN bus communication to key components D. Negative control to key components consulab.com info@consulab.com 113 EV-601-TS_053322-96 Module 4 — Quiz Answer Sheet Quiz on First Responder for EV-601 Answer Sheet Name : Group : Date : Use an “X” to indicate the correct answer. 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D 11. A B C D 12. A B C D 13. A B C D 14. A B C D 15. A B C D 16. A B C D 17. A B C D 18. A B C D 19. A B C D 20. A B C D Instructor grade : Comments : consulab.com info@consulab.com 114 EV-601-TS_053322-96 Module 4 — Quiz Answers Quiz on First Responder for EV-601 — Answers 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D 11. A B C D 12. A B C D 13. A B C D 14. A B C D 15. A B C D 16. A B C D 17. A B C D 18. A B C D 19. A B C D 20. A B C D consulab.com info@consulab.com 115 EV-601-TS_053322-96 Student Learning Module 5 Student Learning Module 5 Autopilot (ADAS) consulab.com info@consulab.com 116 EV-601-TS_053322-96 Student Learning Module 5 STUDENT ASSIGNMENTS FOR MODULE 5 ANSWERS COMING SOON consulab.com info@consulab.com 117 EV-601-TS_053322-96 Student Learning Module 6 Student Learning Module 6 Isolation Testing – Loss of Isolation (LOI) This section comprises assignments which are designed to conduct an insulation test on the EV-601, to identify high voltage components and circuits, and to be prepared for high voltage safety certification. consulab.com info@consulab.com 118 EV-601-TS_053322-96 Module 6 — Isolation Testing Isolation Testing – Loss of Isolation (LOI) Testing the insulation of high-voltage cables on electric vehicles is a critical aspect of ensuring electrical safety and reliable performance. Various methods are employed to assess the integrity of the insulation system. The “Dielectric Withstand Voltage”, or Hipot Test, involves subjecting the cables to voltages higher than normal operational levels to evaluate the insulation’s breakdown strength. Insulation Resistance Tests measure the resistance between conductors and between conductors and ground, providing insight into the insulation’s quality and detecting potential issues like moisture ingress. Cable Capacitance Measurement assesses changes in capacitance, which can indicate insulation deg- radation. To follow safety standards and manufacturer guidelines, along with testing by qualified personnel, is essential for accurate and reliable results in assessing high-voltage cable insulation on electric vehicles. Performing an insulation test on the EV-601, or any electric vehicle, is a critical step in ensuring the safety and reliabil- ity of the high-voltage system. Please note that any procedures should be conducted by qualified personnel, and it’s important to follow specific guidelines and recommendations. General Outline for Conducting an Insulation Test on the EV-601: Before proceeding with any testing, thoroughly review the vehicle’s service manual, technical documentation, and safety guidelines provided. information will guide you on the correct procedures, specifications, and safety precautions specific to Tesla vehicles. Prepare the Vehicle: • Ensure the vehicle is powered off and that the high-voltage system is properly isolated. Done • If necessary, disconnect the high-voltage battery. This step may involve disabling the vehicle’s high voltage system and taking appropriate safety measures. Done Identify Test Points: • Identify the test points for the insulation test. These are typically specified in the vehicle documentation and may include points for testing between conductors and between conductors and the vehicle chassis (ground). Done Select Testing Equipment: • Choose the appropriate insulation testing equipment, such as a high-voltage insulation tester (megohmmeter). Ensure the equipment is calibrated and in good working condition. Done consulab.com info@consulab.com 119 EV-601-TS_053322-96 Module 6 — Isolation Testing Perform Dielectric Withstand Voltage Test (Hipot Test): Note: A Hipot Test is an abbreviation of High Potential Test. • Connect the insulation tester to the identified test points. Done • Apply a test voltage as specified in the Tesla documentation. This is typically a voltage higher than the normal oper- ating voltage to check the insulation’s ability to withstand stress. Done • Monitor for any breakdown or leakage current. The insulation should not exhibit failure during the test. Done Perform Insulation Resistance Test: • Insulation resistance testing must be done between conductors and between conductors and ground. • Measure and record the insulation resistance values. A high insulation resistance indicates good insulation. Done Perform Partial Discharge Test (if applicable): • If partial discharge testing is recommended or required, follow the specified procedures in the documentation. Done • Monitor for any partial discharges that could indicate localized breakdowns in insulation. Done Record and Analyze Results: • Document all test results, including any deviations from expected values. Done • Analyze the results to identify potential issues or areas of concern. Done Reconnect and Verify: • After completing the insulation test, reconnect any disconnected components, ensuring proper reassembly. Done • Verify that the vehicle operates normally, and there are no adverse effects from the testing. Done Comply with Safety Procedures: • Always follow proper safety procedures, including the use of personal protective equipment and adherence to elec- trical safety standards. • Remember that working with high-voltage systems poses inherent risks, and testing should only be performed by individuals with the necessary training and qualifications. • If you are not familiar with high-voltage systems or testing procedures, it is recommended to seek assistance from qualified professionals or contact Tesla for guidance. • Perform the isolation/insulation test when diagnosis requires verification that a circuit or component is properly isolated, or a cable has sufficient insulation. Done consulab.com info@consulab.com 120 EV-601-TS_053322-96 Module 6 — Isolation Testing Warning: When measuring isolation/insulation, the tester will generate high DC voltage up to 1000V. Proper HV PPE must be worn when performing an isolation/insulation test. Warning: Residual voltage may still be present in the component after performing an isolation/insulation test – DO NOT TOUCH THE COMPONENT WITHOUT FIRST CHECKING THE VOLTAGE after an isolation/insulation test. Warning: Make sure that the insulation meter and leads are capable of handling at least 1000V DC. Warning: Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage. Warning: If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off. Warning: Always wear High Voltage (HV) gloves and safety glasses when handling any high voltage component, in- cluding test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired. Warning: All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment. Warning: Assume that high voltage is always present when working on a Tesla vehicle, associated high voltage com- ponents, or associated high voltage test equipment until proven otherwise. Be aware that energy states can change during testing, so err on the side of caution. Warning: Always have an electrical safety hook in the area when working with HV components. Electrical safety hooks are used to remove an injured person from a live high voltage circuit without risking additional injury. Warning: Obey all instructions when using test equipment or servicing a Tesla vehicle or associated high voltage components. If repair instructions are not clear or if there are any questions about how to use the test equipment, escalate a Toolbox session before proceeding. Warning: If any test equipment fails to operate as expected, do not attempt to diagnose or repair the vehicle. Follow the appropriate lock out – tag out procedure for the equipment, notify your manager. Warning: When using test equipment, make sure that all cables are connected before turning equipment on or other- wise initiating use. Warning: Only technicians who have been trained in High Voltage Awareness and have completed all required certi- fication courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be always worn a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information. • Inspect the condition of the HV rubber gloves and protective outer gloves. Done • Do not use any PPE that is out of date, leaking, or otherwise compromised. Inspect the condition of the isolation/ insulation tester that it is fit and functional. Do not use any equipment that has frayed or damaged probes, leads, connectors, or exposed metal. consulab.com info@consulab.com 121 EV-601-TS_053322-96 Module 6 — Isolation Testing • Install the probes to the tester. Done • Set the tester to measure isolation/insulation MOhms (MΩ) scale. Done • Set the tester to the test voltage appropriate for the component being measured. Done HVAC PTC heaters and refrigerant compressors - 250V Caution: • Test voltages greater than 250V will damage PTC heaters and compressors. • Charge ports only - 1000V • All other components - 500V Note: 1. Put on the PPE. Done 2. Set and hold the probe ends to the locations to be tested. Done 3. Press the START/TEST button on the tester to begin the test. Done Note: The measured value will increment and then stabilize. • Observe and remember the measured isolation resistance/insulation resistance in MOhms (MΩ). Done Warning: Do not remove the probes from the test locations. Release the START/TEST button, or press a second time, (as appropriate) to end the test. Warning: Do not remove the probes from the test locations. Removing the probes prematurely prevents the tester from discharging the circuit under test. These videos demonstrate that without proper discharge, high voltages are present and dangerous. Allow the tester to discharge the circuit under test. Note: For some testers, a measured value will decrement to zero. This video demonstrates proper discharge after mea- surement. Verify that there is no indication on the tester of high voltage present in the circuit under test. Note: Indicators on the tester display might be: 1. Lightning bolt icon 2. TEST icon 3. HV icon 4. Attention icon 5. LED lit — or a combination of these indicators. • Remove the probes from the test locations. Done • Set the tester to measure high voltage DC. Done Warning: The tester must not be set to measure isolation/insulation MOhms (MΩ). Set the probe ends to the same locations previously tested. If the voltage is greater than 10V continue to hold the probes to the test locations for an additional minute. Warning: Do not touch the component until the voltage is verified to be safe (10V or less). The voltage is gradually decreasing - Continue to hold the probes to the test locations until the displayed voltage is 10V or less. Remove the probes from the test locations. Remove the HV PPE. consulab.com info@consulab.com 122 EV-601-TS_053322-96 Module 6 — SA-37 SA-37 A/C Compressor Testing – Component Side for Loss of Isolation (LOI) - Answers Objective: To perform a LOI test on the EV-601 air conditioning compressor. 1. Max applied voltage: 250 V or damage to component: 2. Insulation expected resistance: greater than 18 MΩ. 3. Ground to case of component. 4. 10 second applied test (TESLA). 5. Before any testing proper PPE MUST be worn at all times. 6. What voltage do you set the insulation tester to test the insulation? 250 volts 7. Where is the best place to put the insulation tester ground for testing? Chassis 8. Why is this important? Monitoring is with chassis 9. How long should you leave the test go for? 10 seconds 10. What is the meter display value? 270 megaohms 11. Is this within specification? Yes 12. Before removing probe after testing what must you do? A. Press button to stop test B. Wait to remove consulab.com info@consulab.com 123 EV-601-TS_053322-96 Module 6 — SA-38 SA-38 PTC Heater Testing – Component Side for Loss of Isolation (LOI) - Answers Objective: To perform a LOI test on the EV-601 positive temperature coefficient heater. 1. Max applied voltage: 250 V or damage to component: 2. Insulation expected resistance: greater than 18 MΩ. 3. Ground to case of component. 4. 10 second applied test (TESLA). 5. Before any testing proper PPE MUST be worn at all times. 6. What voltage do you set the insulation tester to test the insulation? 250 volts 7. Where is the best place to put the insulation tester ground for testing? Chassis 8. Why is this important? Monitoring is with chassis 9. How long should you leave the test go for? 10 seconds 10. What is the meter display value? 270 megaohms 11. Is this within specification? Yes 12. Before removing probe after testing what must you do? A. Press button to stop test B. Wait to remove consulab.com info@consulab.com 124 EV-601-TS_053322-96 Module 6 — SA-39 SA-39 High Voltage Safety Fundamentals — Answers Objective: To learn the EV-601 high voltage safety fondamentals for the Tesla Model 3. 1. Open the owner’s manual available for the Tesla Model 3 and review the EV section. 2. At what voltage does the lithium-ion battery in the EV operate? volts NOTE: Although nominal lithium-ion battery voltage for the EV is 360+ volts, it may be as high as 400+ volts with a full state of charge (SOC). 3. What color are the high voltage harnesses? Yellow X Orange Red Brown 4. According to the EV Overview, what injuries could result from disassembling, removing or replacing high voltage parts or harnesses? Burns, electric shock, injury and or death 5. Refer to the HIGH-VOLTAGE COMPONENTS section in the owner’s manual. Write the letter for each component called out in the graphic below, next to its name in the following table According to the EV Overview, what injuries could result from disassembling, removing or replacing high voltage parts or harnesses? Burns, electric shock, injury and or death Refer to the HIGH-VOLTAGE COMPONENTS section. Write the letter for each component called out in the graphic below, next to its name in the following table. Lithium-ion Battery D High Voltage Harness I Power Delivery Module E Traction Motor G Traction Motor Inverter S Service Plug N Lithium-ion Battery D High Voltage Harness I Power Delivery Module E Traction Motor G Traction Motor Inverter S Service Plug N consulab.com info@consulab.com 125 EV-601-TS_053322-96 Module 6 — SA-39 6. According to the owner’s manual, if a fire should occur in an electric vehicle what type of fire extinguisher must you use? Check your answer: X ABC X BC X C X All of them 7. What does the owner’s manual state the lithium-ion battery will experience if exposed to heat such as a paint booth? Damage battery reduce capacity 8. When will the emergency shut-off system be activated and high voltage systems turned off? Check all that apply: X Front/side collisions in which the air bags are deployed X Certain rear collisions X Certain EV system malfunctions Motor overheating Hard braking 9. The emergency shut-off system activates for what purpose? To minimize risk in the event that could cause injury 10. Review the CAUTIONS TO HIGH VOLTAGE subsection of the GENERAL INFORMATION EV service manual to answer the following questions. 11. Refer to the PROCEDURE FOR DISCONNECTING HIGH VOLTAGE and place a number beside each step so they are numbered in the correct order of performance. Turn the ignition OFF. Remove the service plug. Wait a minimum of 10 minutes. Disconnect the 12V battery negative cable. 12. Where does the procedure indicate you should secure the vehicles key? Check the correct answer: In the glove box In his/her tool box In a safe X On his/her person 13. What are you instructed to do to any high voltage connectors or terminals after disconnecting? Insulate the connectors with insulating tape 14. Why does the service manual direct you to put the service plug in your pocket or lock it in your tool box? To prevent plug from being put in 15. What does the service manual state are the risks if high voltage components and vehicle are mishandled? Risk of electric shock consulab.com info@consulab.com 126 EV-601-TS_053322-96 Module 6 — SA-39 16. Which component is designed to be removed to disconnect the high voltage circuits before performing inspection or maintenance? Check the correct answer: System main relay Inverter X Service plug Pre-charge relay 17. What does this section indicate might happen if the vehicle is set to READY status with the service plug removed? A malfunction will occur 18. What points does the service manual direct you to check before starting maintenance work? Check all that apply: X Charge cable (including EVSE) is not connected X Charge timer is not set X Air conditioner timer is not set Maintenance reminder is set 19. How are hazardous high voltage devices and components identified? Orange cables 20. Should a person who wears an electronic pacemaker or other medical electronics work on an electric vehicle? Check the correct answer: No 21. The service manual states that you should never carry metal products and magnetic recording media (cash/credit cards, prepaid cards, items with a magnetic strip, etc.) when repairing or inspecting high voltage parts. What reasons does it give for this warning? A. Metal products: They may cause a short B. Magnetic recording media: Magnetism may cause the device to become damaged 22. What must be posted to alert others that work is being performed on the high voltage system? High voltage warning signs 23. What type of personal protection equipment does the service manual indicate to use when working on high voltage systems? Gloves, glasses and boots 24. What are the service manual instructions regarding a peeling or damaged high voltage label? Replace and make sure in correct position and place 25. What should be done to the personal protection equipment daily and before and after every use? Inspect from damage and wear consulab.com info@consulab.com 127 EV-601-TS_053322-96 Module 6 — SA-39 26. What is being done in the graphics below? Daily use check for leaks Read HANDLING OF INSULATION RESISTANCE TESTER. How many volts can the tester generate? Volts 1000 What are the dangers of using the tester incorrectly? You can get shocked Before using the insulation tester how can the insolation tester be tested to ensure it is functioning correctly? Test it with another meter CAT rated for the voltage Should the insulation resistance tester be used on a 12 volt circuit? (Circle one) YES / NO CAUTION: Using the insulation resistance tester to inspect 12 volt circuits can damage control units, processors, and components. The tester applies up to 1000 volts to the circuit during testing, depending upon the setting of the tester. A B C 27. Read HANDLING OF INSULATION RESISTANCE TESTER. How many volts can the tester generate? 1000 volts 28. What are the dangers of using the tester incorrectly? You can get shocked 29. Before using the insulation tester how can the insolation tester be tested to ensure it is functioning correctly? Test it with another meter CAT rated for the voltage 30. Should the insulation resistance tester be used on a 12 volt circuit? Check the correct answer: No CAUTION: Using the insulation resistance tester to inspect 12 volt circuits can damage control units, processors, and components. The tester applies up to 1000 volts to the circuit during testing, depending upon the setting of the tester. 31. Refer to the Handling of Damaged Vehicles subsection. What is the required voltage rating for the insulated gloves? Class 0-1000volts 32. If the vehicle must be scrapped for any reason, what must be done with the Lithium-ion battery? State of charge needs to be at an acceptable level consulab.com info@consulab.com 128 EV-601-TS_053322-96 Module 6 — SA-40 SA-40 Identifying High Voltage Components and Circuits Answers Objective: To Identifying the EV-601 high voltage components and circuits. NOTE: Do not touch ANY high voltage components or orange wiring harnesses without first putting on personal protec- tion equipment. Technicians who are not certified to work on high voltage systems should not touch any high voltage harnesses or components. 1. Confirm that the Power switch is OFF. 2. Remove the I-Key from the inside of the vehicle. 3. Open the hood and inspect the motor compartment. 4. If applicable, three high-voltage harnesses should be visible. To which high-voltage components do they connect? Power delivery, A/C compressor, heaters and charging 5. Refer to the AIR CONDITIONER label under the hood. Should refrigerant oil with fluorescent dye be used in this refrigerant system? Check the correct answer: No 6. Note the high voltage warning label located on the power delivery module. What warning does it give? High voltage inside 7. Locate and remove the HV service plug. 8. If applicable, is there any voltage warning label attached to the metal access plate over the service plug? Yes and No. If so, what does it indicate: Qualified technicians only 9. What would you say is the potential voltage at the terminals of ANY orange connector on this vehicle? 400 volts consulab.com info@consulab.com 129 EV-601-TS_053322-96 Module 6 — SA-40 10. Replace the service plug access cover. 11. To which high-voltage components do they connect? Needs to be reinstalled from anything getting into it CAUTION: During this module, and any time you service an electric vehicle, you must wear Personal Protection Equipment BEFORE accessing the service plug. 12. Return the workstation to its original condition. Outcomes: You have now completed this worksheet. You should be able to: • List personal protection equipment and indicate when it is required. • Identify the procedures to follow when shutting off the high voltage systems. • Identify harnesses and components that have high voltage! If you would like to check your understanding of the procedures and your skills in completing this worksheet, return to the first step and review your work. Once you are confident with your skills, have the instructor check your answers. Have the instructor sign this worksheet and your sign-off sheet. consulab.com info@consulab.com 130 EV-601-TS_053322-96 Certification Test High Voltage Safety Certification Testing Beta This section is an example of generic testing that can be performed on an EV. This was designed to be used as a generic document but with service information can be added to the EV service shop. consulab.com info@consulab.com 131 EV-601-TS_053322-96 Certification Test High Voltage Safety Certification — Answers Objective: Given an EV the appropriate reference material, and an appropriate meter you will be able to cut off the high voltage system and inspect it to determine if conditions are safe to conduct repairs. Relevance: An electric vehicle with system voltages that can be as high as 400 VDC. This exercise is used to certify your ability to cut off the high voltage system properly, and verify it is safe to perform service or repairs on the high voltage components. Resources: • EV Service Manual to match the Vehicle • EV Vehicle • Personal Protection Equipment • Insulation resistance tester (FLUKE 1587) Skill Check: Follow the steps of this worksheet to properly cut off the high voltage and inspect the system to verify it is safe to perform high voltage service or repairs. You will also perform an insulation resistance test, and a bonding integri- ty inspection What to expect: Follow the steps of this worksheet to properly cut off the high voltage and inspect the system to verify it is safe to perform high voltage service or repairs. You will also perform an insulation resistance test, and a bonding integrity inspection. Electric Vehicle 1. Open the service manual for the EV at your bay to the HV general information. 2. Review the CAUTIONS AS TO HIGH VOLTAGE sub-section carefully. There are several warnings concerning persons who use implantable medical devices such as a pacemaker or cardiac defibrillator. 3. What condition generated in an EV could affect the operation of these devices? Electro magnetic EMF fields 4. Should a technician who uses such an implanted medical device perform service or repairs on a high voltage sys- tems when operating or charging? Check the correct answer: No 5. What point should be checked by ALL technicians before beginning any maintenance or repairs on an EV? The key must stay with the working technician and or placed in a lock out box 6. Step 1 of the PROCEDURE FOR DISCONNECTING HIGH VOLTAGE is Turn power switch OFF. 7. What must be done with the key? The key must stay with the working technician and or placed in a lock out box consulab.com info@consulab.com 132 EV-601-TS_053322-96 Certification Test 8. How long should you wait after the service plug is removed or power down is preformed? Check the correct answer: X 2 minutes 5 minutes 10 minutes 30 minutes 9. What color are high voltage harnesses? Check the correct answer: Red Yellow X Orange 10. What should be done immediately with disconnected high voltage connectors and terminals? Cover with insulating tape 11. What should be done to the PROTECTIVE WEAR daily? Inspected 12. Why can an INSULATION RESISTANCE TESTER be dangerous? Check the correct answer: The probe tips are very sharp X It applies 500 V or more to the circuit it is testing It contains alkaline electrolyte It weighs over 100 lb 13. Can an INSULATION RESISTANCE TEST be used to inspect a 12 V circuit? No CAUTION: Using the insulation resistance tester to inspect 12 volt circuits can damage control units, processors, and components. The tester applies up to 1000 volts to the circuit during testing, depending upon the setting of the tester. High Voltage Shut Off Procedure 14. If necessary, secure the vehicle 15. Power the vehicle to READY mode and inspect the dash. 16. Is the master warning lamp or any other warning lamp illuminated that would indicate a concern with the high voltage systems? Check the correct answer: Yes and No See your instructor if any abnormal or unusual warning lamps are illuminated. NOTE: Whenever service or maintenance procedures are performed on the EV’s, the charge timers and climate control timers should be turned OFF. They can activate and energize the high voltage system. Remember to turn them back ON when service is complete. consulab.com info@consulab.com 133 EV-601-TS_053322-96 Certification Test 17. Turn off the vehicle and ensure the keys are secure if applicable. Done 18. Disconnect the 12 V battery negative cable and wrap the cable end with tape so it is fully insulated. Done 19. Prepare a piece of insulating tape for use by unrolling a 10 inch length and folding each end over about 1/2 inch onto itself, sticky side to sticky side. This will be used to cover the Service Plug connector (If applicable). Done 20. Prepare the Personal Protection Equipment (PPE) required: - Safety glasses: Done - Lineman’s gloves: Done What class of glove should you wear? 0 Date Inspected stamped? Do they need inspection? Yes No 21. What is the inspection period on new gloves unopened? 12 months 22. What is the inspection period on gloves after this date? 12 months 23. What must be done to test the Linesman’s gloves before use? Air leakage test 24. Cover the Service Plug connector with the insulating tape you previously prepared. Done 25. Wait at least 10 minutes for the high voltage to dissipate. Done 26. If you have removed your personal protection equipment, please put it on now. Done Potential Equalization Inspection 27. After 10 minutes have elapsed, you may begin performing the potential equalization inspection. Personal Protection Equipment (PPE) must be worn. Done 28. Carefully disconnect all the high voltage harness connectors at the lithium-ion battery. Done 29. Inspect the test leads and meter provided at this workstation for damage or wear. Done 30. Verify the leads and meters are rated for up to 500 volts. Done 31. Are there any problems with the multi-meter or leads. Yes No. See your instructor if there are any concerns with your multi-meter or test leads. 32. Measure and record the voltage readings at high voltage harness connectors: - Lithium-ion Battery Harness: volts - PTC Heater Harness: volts - Other: (specify) volts See your instructor if the voltage reading on the insulation resistance tester is over 5.0 V. Service Tip: The potential equalization inspection does not require a special ized meter. Any voltmeter or digital multi-meter capable of measuring up to 500V is acceptable for this inspection. Do not reconnect the high-voltage harnesses to the lithium-ion battery. consulab.com info@consulab.com 134 EV-601-TS_053322-96 Certification Test 33. Next attach the negative probe of the meter to body or chassis ground and touch the positive probe to the case of each high voltage component listed below. Record the voltage reading for the following components: • Lithium-ion Battery: 360-400 volts • Traction motor: volts • TDC/DC converter or PDM: volts • A/C compressor: volts • Inverterr: volts • Other: (specify) volts Service Tip: Each high voltage component is bonded or grounded to the chas sis. After shutting off the high voltage system and waiting 10 minutes, all capacitors in the system should have discharged to ground. The equalization of this voltage potential should read approximately 0.0 volt. Insulation Resistance Test 34. The insulation resistance test is a method of determining if the insulation in a high voltage circuit is breaking down or decaying. The following steps will familiarize you with the inspection procedure. This inspection will be practiced on a good circuit. The readings you will see are at or above factory specification. Personal Protection Equipment (PPE) must be worn. Done WARNING: Insulation resistance inspection does require a specialized meter. The insulation resistance tester out- puts 500V to test the circuit insulation. This is sufficient voltage to cause injury. DO NOT TOUCH THE METAL TEST PROBES DURING THE INSULATION RESISTANCE TEST. 35. If necessary, attach the test leads to the insulation resistance tester. Put leads into appropriate test points. Done 36. Turn the rotary switch on the meter to 500V. Done Refer to manufactures test voltage specifications for each component or cable tested. 37. Why is the Tester turned to 500 volts+ doing this test? 38. Attach the COM test lead to the housing or ground chassis of a high voltage components. Done 39. Connect the positive test probe to one terminal of the high voltage harness connector at the lithium-ion battery. Done consulab.com info@consulab.com 135 EV-601-TS_053322-96 Certification Test 40. Press and hold the TEST button until the meter reading stabilizes. Write down the reading from the meter display in the space below for both sides: POSITIVE NEGATIVE A. Traction: volts volts B. DC/DC converter or PDM: volts volts C. A/C compressor: volts volts D. Inverter: volts volts E. Other: (specify) volts volts Service Tip: If the insulation in a high voltage circuit were to break down or the circuit became shorted or leak current to the component case, the reading on the meter would display resistance values lower than the specification listed in the service manual. 41. The specification from the service manual for this measurement is 30 MΩ for. Are the values you wrote in steps 33 and 40 correct or NG?. Yes No. Equipotential Inspection (Ground Integrity Check) 42. An equipotential inspection is a check of the bonding integrity (grounding) of high voltage components. This is per- formed whenever high voltage components are removed and/or replaced. This inspection can be performed with a standard ohm meter. The meter must have the capability to be zeroed for a correct reading. Set the meter to OHMS (Ω). Done 43. Touch the test probes together and zero the meter reading. Done 44. Attach the COM test lead to chassis ground. Done 45. Touch the positive test probe to the housing of the lithium-ion battery. You may need to press the TEST button on the meter or probe handle. Done 46. Once the meter value stabilizes record the reading: ohms 47. Next touch the positive probe to the case of each high voltage component listed below. Record the resistance reading for each one. - Traction motor: ohms - Controller: ohms - A/C compressor: ohms - Inverter: ohms consulab.com info@consulab.com 136 EV-601-TS_053322-96 Certification Test Service Tip: Each high voltage component is bonded or grounded to the chassis. After shutting off the high voltage system and waiting 10 min utes, all capacitors in the system should have discharged to ground. The equalization of this voltage potential should read approximately 0.0 volt on the meter. 48. The standard listed in the service manual for this inspection is a meter reading of less than 0.05 ohms. Did your inspection of each component meet this specification?. Yes No. See your instructor if any measurement you made was out of specification. Note: Excessive resistance in the ground or bond connection of a high voltage component could prevent the discharge of any stored voltage. There is a danger of electric shock. 49. Replace any components you removed to perform the steps of this worksheet. Done 50. Disconnect the test probes from the vehicle and turn the meter OFF. Done 51. Carefully reconnect the high voltage harnesses for the lithium-ion battery and PTC heater. Done 52. Restore the vehicle and install the service plug if applicable. Done 53. Remove the insulating tape from the negative cable end for the 12V battery and reconnect it to the battery. Done consulab.com info@consulab.com 137 EV-601-TS_053322-96 Notes Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. Tous droits réservés. Introduction to High Voltage EVs Instructors’ Notes Required Equipment and PPE Working on High Voltage Vehicles Maintenance and Safety Educational Outcomes Student Assignments ANSWERS Student Learning Module 1 Component Identification Trainer Layout and Familiarization iDev Component locator Tesla Model 3 Components SA-1 Component #1 — Answers SA-2 Component #2 — Answers SA-3 Component #3 — Answers SA-4 Component #4 — Answers SA-5 Component #5 — Answers SA-6 Component #6 — Answers SA-7 Component #7 — Answers SA-8 Component #8 — Answers SA-9 Component #9 — Answers SA-10 Component #10 — Answers SA-11 Component #11 — Answers SA-12 Component #12 — Answers SA-13 Component #13 — Answers SA-14 Component #14 — Answers SA-15 Component #15 — Answers SA-16 Component #16 — Answers SA-17 Component #17 — Answers SA-18 Component #18 — Answers SA-19 Component #19 — Answers SA-20 Component #20 — Answers SA-21 Component #21 — Answers SA-22 Component #22 — Answers SA-23 Component #23 — Answers SA-24 Component #24 — Answers SA-25 Component #25 — Answers Power Flow of an Electric System SA-26 Quiz on Power Flow SA-26 Quiz on Power Flow — Answer Sheet SA-26 Quiz on Power Flow — Answers Student Learning Module 2 High Voltage Battery Construction High Voltage Battery Construction SA-27 High Voltage Battery Specifications — Answers SA-28 High Voltage Battery Modules — Answers SA-29 High Voltage Battery Configuration — Answers Student Learning Module 3 EV Charging Systems and Operation Drive Modes EV Charging Systems SA-30 Opening the Charge Port — Answers SA-31 Charging with Battery Temperature Hot — Answers SA-32 Onboard Charger and How it Works — Answers Drive mode of the EV-601 SA-33 Touchscreen Drive Mode A — Answers SA-34 Touchscreen Drive Mode B — Answers SA-35 Watching the Power Drive to the Rear Drive Unit — Answers Student Learning Module 4 First Responder Training First responder Training for EV’s with the EV-601-TS First Responder Loop SA-36 First responder loop Function — Answers Quiz on First Responder for EV-601 Quiz on First Responder for EV-601 Answer Sheet Quiz on First Responder for EV-601 — Answers Student Learning Module 5 Autopilot (ADAS) Student Learning Module 6 Isolation Testing – Loss of Isolation (LOI) Isolation Testing – Loss of Isolation (LOI) SA-37 A/C Compressor Testing – Component Side for Loss of Isolation (LOI) - Answers SA-38 PTC Heater Testing – Component Side for Loss of Isolation (LOI) - Answers SA-39 High Voltage Safety Fundamentals — Answers SA-40 Identifying High Voltage Components and Circuits Answers High Voltage Safety Certification Testing Beta High Voltage Safety Certification — Answers
