Student Assingments for EV-601-TS_053322 EV-601-TS_053322-95_V2024-3 © ConsuLab Educatech Inc, 2024. Tous droits réservés. Interactive Demonstrative Electric Vehicle EV-601-TS_053322-95 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 Basics of EV’s 4 Electric Vehicle Safety Features 7 High Voltage Safety Hazards 8 What is Arc Flash Safety 9 High Voltage PPE 12 High Voltage Components 14 Common Electric Vehicle Terms 18 Student Assignments Student Learning Module 1 Component Identification 23 Electric Vehicle Components 24 Component Locations 30 SA-1 Component #1 32 SA-2 Component #2 33 SA-3 Component #3 34 SA-4 Component #4 35 SA-5 Component #5 36 SA-6 Component #6 37 SA-7 Component #7 38 SA-8 Component #8 39 SA-9 Component #9 40 SA-10 Component #10 41 SA-11 Component #11 42 SA-12 Component #12 43 SA-13 Component #13 44 SA-14 Component #14 45 SA-15 Component #15 46 SA-16 Component #16 47 SA-17 Component #17 48 SA-18 Component #18 49 SA-19 Component #19 50 SA-20 Component #20 51 SA-21 Component #21 52 SA-22 Component #22 53 SA-23 Component #23 54 SA-24 Component #24 55 SA-25 Component #25 56 Power Flow of an Electric System 57 SA-26 Quiz on Power Flow 61 SA-26 Quiz on Power Flow — Answer Sheet 62 EV-601-TS_053322-95 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. 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EV-601-TS_053322-95 Table of contents Student Learning Module 2 High Voltage Battery Construction 63 High Voltage Battery Construction 64 High Voltage Safety Disconnects 67 High Voltage Battery Safety 68 SA-27 High Voltage Battery Specifications 71 SA-28 High Voltage Battery Modules 72 SA-29 High Voltage Battery Configuration 73 Student Learning Module 3 EV Charging Systems and Drive Modes 74 Electric Vehicle Theory of Operation 75 EV Charging Systems 76 SA-30 Opening the Charge Port 78 SA-31 Charging with Battery Temperature Hot 81 SA-32 Onboard Charger and How it Works 82 Drive modes of the EV-601 83 SA-33 Touchscreen Drive Mode A 84 SA-34 Touchscreen Drive Mode B 86 SA-35 Watching the Power Drive to the Rear Drive Unit 88 Student Learning Module 4 First Responder Training 89 First responder Training for EV’s with the EV-601-TS 90 First Responder Loop 95 SA-36 First Responder Loop Function 96 Quiz on First Responder for EV-601 97 Quiz on First Responder for EV-601 — Answer Sheet 101 Student Learning Module 5 Autopilot (ADAS) 102 Autopilot and Full Self-Driving Capability 103 STUDENT ASSIGNMENTS FOR MODULE 5 109 Student Learning Module 6 Isolation Testing – Loss of Isolation (LOI) 110 Isolation Testing – Loss of Isolation (LOI) 111 SA-37 A/C Compressor Testing – Component Side for Loss of Isolation (LOI) 116 SA-38 PTC Heater Testing – Component Side for Loss of Isolation (LOI) 117 SA-39 High Voltage Safety Fundamentals 118 SA-40 Identifying High Voltage Components and Circuits 122 High Voltage Safety Certification Testing Beta 124 consulab.com info@consulab.com 4 EV-601-TS_053322-95 Introduction consulab.com info@consulab.com 4 Basics of EV’s Over the past few years, electric vehicles have gained increased credibil- ity as a viable substitute for traditional gasoline-powered cars. While we often perceive electric cars as a recent technological advancement, their origins trace back to the late 19th century when the first electric vehicle was introduced around 1890. As early as the 1900s, electric cars were already being offered to the public for those with the financial means, sharing the market with steam and gasoline-driven vehicles. An electric vehicle (EV) is a type of vehicle that is powered by electricity rather than internal combustion engine that run on gasoline or diesel. EVs use one or more electric motors to drive the vehicle’s wheels and are typically fueled by elec- tricity stored in rechargeable batteries or, in some cases, by on-board generators powered by gasoline or other fuels (plug-in hybrid electric vehicles or PHEVs). Understanding the Different Types of EVs What is a ZEV? ZEV stands for Zero Emission Vehicle. A ZEV is defined as a motor vehicle that is propelled by electricity or hydrogen from an external source, and emits no greenhouse gases at least some of the time while the motor vehicle is being operated. A ZEV is a vehicle that has the potential to operate without producing tailpipe emissions. They can still have a conventional internal combustion engine but must also be able to operate without using it. These would include any type of electric vehicle that derives its electrical power from an external source, such as a plug-in charger. What is an EV? EV stand for electric vehicle and usually refers to any vehicle that is powered, in part or in full, by a battery that can be directly plugged into the electrical grid for charging. There are primarily three types of battery-powered vehicles on the road today: 1. Hybrid Electric Vehicle (HEV): These are an older form of electric vehicle and use an electric motor and an internal combustion engine (ICE) for propulsion. They are not considered a true EV. The vehicle’s internal combustion engine also charges the battery, as opposed to plugging the vehicle into a charger or electrical socket. Since this type of a vehicle does not obtain electrical power from an external source, it is not considered a Zero Emission Vehicle under the Emissions Vehicle Act. Theory ** add safety theory here** Basics of EV’s Over the past few years, electric vehicles have gained increased credibility as a viable substitute for traditional gasoline-powered cars. While we often perceive electric cars as a recent technological advancement, their origins trace back to the late 19th century when the first electric vehicle was introduced around 1890. As early as the 1900s, electric cars were already being offered to the public for those with the financial means, sharing the market with steam and gasoline-driven vehicles. An electric vehicle (EV) is a type of vehicle that is powered by electricity rather than internal combustion engine that run on gasoline or diesel. EVs use one or more electric motors to drive the vehicle's wheels and are typically fueled by electricity stored in rechargeable batteries or, in some cases, by on-board generators powered by gasoline or other fuels (plug-in hybrid electric vehicles or PHEVs). What is an EV? 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! Understanding the Different Types of EVs What is a ZEV? ZEV stands for Zero Emission Vehicle. A ZEV is defined as a motor vehicle that is propelled by electricity or hydrogen from an external source, and emits no greenhouse gases at least some of the time while the motor vehicle is being operated. A ZEV is a vehicle that has the potential to operate without producing tailpipe emissions. They can still have a conventional internal combustion engine but must also be able to operate without using it. These would include any type of electric vehicle that derives its electrical power from an external source, such as a plug-in charger. What is an EV? EV stand for electric vehicle and usually refers to any vehicle that is powered, in part or in full, by a battery that can be directly plugged into the electrical grid for charging. There are primarily three types of battery-powered vehicles on the road today: Hybrid Electric Vehicle (HEV) – these are an older form of electric vehicle and use an electric motor and an internal combustion engine (ICE) for propulsion. They are not considered a true EV. The vehicle’s internal combustion engine also charges the battery, as opposed to plugging the vehicle into a charger or electrical socket. Since this type of a vehicle does not obtain electrical power from an external source, it is not considered a Zero Emission Vehicle under the Emissions Vehicle Act. consulab.com info@consulab.com 5 EV-601-TS_053322-95 Introduction 2. Battery Electric Vehicle (BEV): These vehicles are fully electric and run entirely on elec- tricity stored in rechargeable batteries. BEVs do not have an internal combustion engine and produce zero tailpipe emissions. They need to be plugged into an electrical outlet or a charging station to recharge their batteries. Common examples of BEVs include the Tesla Model 3 and the Nissan Leaf. 3. Plug-in Hybrid Electric Vehicle (PHEV): These vehicles combine an electric motor and a gasoline or diesel engine. They can be plugged in to charge their batteries and operate in all-electric mode for a limited range before switching to the internal combustion engine for longer journeys. This dual power source can provide increased range and flexibility. The Chevrolet Volt is an example of a PHEV. They use only electric motors for propulsion charged only from an external power source. To help preserve the charge in the high voltage battery a 12-Volt battery is used to provide the power necessary to run auxiliary features such as lights, wipers and audio. While PHEVs utilize an internal combustion engine and a high voltage battery to power the vehicle, a BEV is powered by electricity alone. BEVs don’t need an ICE. BEVs use a much larger and more efficient battery that stores and supplies its power. An electrical motor then uses this power to propel the vehicle. Basic Differences between an EV and a Conventional Vehicle Weight Distribution For EVs, the wheels can be driven directly at each wheel, or the wheel can even be the motor. The advantage of small- er mass at more locations, where maximum force is required, allows for greater freedom of design, lower centre of gravity and better overall handling. Acceleration Electric cars are capable of accelerating quicker than gas-powered cars, but are not necessarily faster… Since an elec- tric car’s motor eliminates the need for a traditional transmission in many modern designs, the power goes straight to the wheels for instant acceleration, making EVs quicker on the start. In gas-powered vehicles up to 15% of power can be lost due to inefficiencies as it travels through the powertrain. Use of Space Because there is only a single centre of mass, EVs can make more use of cabin space than conventional vehicles. Noise pollution Electric cars are quieter than their ICE counterparts are. The only noises EVs usually generate is caused by wind resis- tance or tire noises, and that is only at moderate to higher speeds. However, this lack of noise can mean that they pose a danger to other road users, especially pedestrians who are vision impaired. the internal combustion engine for longer journeys. This dual power source can provide increased range and flexibility. The Chevrolet Volt is an example of a PHEV. Electric vehicles offer several advantages, including: Reduced greenhouse gas emissions: EVs emit minimal to no tailpipe pollutants, aiding in air quality improvement and climate change mitigation, especially when charged with clean energy. Lower operating costs: Electricity costs less than gasoline, and EVs require less maintenance due to their simpler design. Quiet and smooth operation: Electric motors offer quieter and smoother driving experiences compared to internal combustion engines. Instant torque: Electric motors provide immediate power, leading to rapid acceleration and responsive performance. Challenges include limited range per charge, longer refueling times, and the need for widespread charging infrastructure. As technology advances and infrastructure improves, electric vehicles are increasingly popular and eco-friendly transportation choices. In the 1990s, Toyota's introduction of the initial Prius Hybrid brought electric vehicles out of a thought into widespread recognition. Following this, Tesla unveiled its inaugural all- electric vehicle in 2008, while the Nissan Leaf and Chevrolet Volt made their debuts in 2010. 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. Plug-in Hybrid Electrical Vehicle (PHEV) – these vehicles are newer versions of hybrids that can also be charged by an external electrical outlet. Essentially, a PHEV the same as a regular hybrid, but with a larger battery pack that can be plugged into the electrical grid for charging. PHEVs offer extended all-electric range over regular hybrids. There are four primary powertrain and drivetrain components: • An internal combustion engine fueled by gasoline • One or more electric motors • A high voltage battery • A transmission that sends power to the wheels Most PHEVs start out in all-electric mode and the gasoline engine only runs when most of the charge from the battery is depleted. An on-board computer continuously monitors the state of charge of the battery. A PHEV is designed so that the primary power is electrical but when the battery can no longer provide enough power the internal combustion engine takes over. For some PHEVs, the electric motor can even compliment the internal combustion engine to the power the vehicle such as when driving up a steep hill. PHEVs vary in their all-electric mode. Some models may only drive for 15-20kms while others may drive up to 60kms. Some PHEVs motors may also charge the battery once it is depleted – these are called range extenders. Battery Electric Vehicle (BEV) – These vehicles are also termed pure electric vehicles, or PEVs, as they do not produce any tailpipe emissions. They have the lowest environmental impact of the three. They use only electric motors for propulsion…charged only from an external power source. To help preserve the charge in the high voltage battery a 12-Volt battery is used to provide the power necessary to run auxiliary features such as lights, wipers and audio. consulab.com info@consulab.com 6 EV-601-TS_053322-95 Introduction Guide to the Various Types of Hybrids and EVs, and Terminology As you can see in the following chart, there are numerous variations, but there are commonalities between them, as you will learn when we explore the components and how they work. Vehicle Type Description Electric Vehicle/Car (EV), Electrically Chargeable Vehicle/Car Generic terms for a vehicle powered in part or in full by a battery that can be plugged into the grid for charging. Pure-EV, Pure-Electric Car, Vehicle, All Electric, Battery Electric Vehicle (BEV), Fully Electric A vehicle powered only by a battery charged from an external source of electricity. Currently, typical pure-electric cars have a range of 100-200 miles (160-320 kilometres). Some upscale models now boast a range of more than 600 kilometres. Plug-In Hybrid Electric Vehicle (PHEV), Plug-In Hybrid Vehicle (PHV) A vehicle with a plug-in battery and an internal combustion engine (ICE). Typical PHEVs will have a pure-electric range of 10 to 30 miles (16-48 kilo- metres). After the pure-electric range is used up, the vehicle reverts to the benefits of full hybrid capability. Extended-Range Electric Vehicle (E-REV), Range Extended Electric Vehicle (RE-EV) A vehicle powered by a battery with an ICE-powered generator onboard. E-REVs are like pure-EVs, but range is extended by the onboard generator. With an E-REV the vehicle is still always electrically driven and is known as a series hybrid. Hybrid Electric Vehicles (HEV), Full/ Normal/ Parallel/Standard hybrid A hybrid vehicle is powered by a battery and/or an ICE. The power source is selected automatically by the vehicle, depending on speed, engine load and battery charge. This battery cannot be plugged in, so charge is main- tained by regenerative braking, supplemented by ICE-generated power. Mild Hybrid A mild hybrid vehicle cannot be plugged in or driven solely on battery pow- er. However, it does harvest power during regenerative braking and uses this during acceleration. Some mild hybrids now use 48V technology. Micro Hybrid A micro hybrid normally employs a stop-start system and regenerative braking which charges the 12V battery. Stop-start Hybrid A stop-start system shuts off the engine when the vehicle is stationary. An enhanced starter motor is used to support the increased number of engine starts. Alternatively, Fueled Vehicle (AFV) Any vehicle which is not solely powered by traditional fuels (i.e. gasoline or diesel) is referred to as alternative fuel vehicle. Internal Combustion Engine (ICE) Gasoline or diesel engine, as well as those adapted to operate on alterna- tive fuels. Electric quadricycles This is a four-wheeled vehicle that is categorized in a similar way to a mo- ped or three-wheeled motorcycle. Electric motorcycles Battery only, so full-electric drive. consulab.com info@consulab.com 7 EV-601-TS_053322-95 Introduction Electric Vehicle Safety Features EVs are designed with a number of built in safety features that you should be aware of: • The high voltage systems are isolated from the vehicle’s chassis so the vehicle can be touched even after a severe crash without coming into contact with high voltage electricity. HEVs, PHEVs and BEVs have a number of built-in safety systems: • High voltage system shutdown: this is activated in the event of a crash. It is initiated when the vehicle’s occupant protection systems deploy. If airbags have been deployed, expect that the HV shutdown has automatically been deployed. • EV systems include fuses and fault protection: these disable the HV systems if circuits are compromised. They occur in the case of a fault, short or other damage to the system. • Voltage leakage on high voltage systems is being constantly monitored. • High voltage is isolated from the chassis. • Interlock and switch protection is monitored for unplugged or damaged connections. • Always Double check to ensure that the vehicle is off during the disabling step. • Always avoid contact with damaged high voltage components and wiring. • Always ensure that a person never meets, never touches, disconnects, or works on any of these HV components without the proper training, equipment and/or certifications. • Li-ion batteries have a large risk of fire, and an emergency response plan should be in place whenever stored, dis- mantled or transported. • Most Ni-MH batteries are relatively small and can be moved with the help of a co-worker and pushed around on a cart. However, Li-ion batteries are too large to be manually lifted and require lifting devices such as a powertrain lift or a forklift. EVs introduce other hazards into the workplace in addition to those normally associated with recycling, repair, and roadside recoveries. These include: HEVs, PHEVs and BEVs have a number of built-in safety systems: • High voltage system shutdown: this is activated in the event of a crash. It is initiated when the vehicle’s occupant protection systems deploy. If airbags have been deployed, expect that the HV shutdown has automatically been deployed. • EV systems include fuses and fault protection: these disable the HV systems if circuits are compromised. They occur in the case of a fault, short or other damage to the system. • Voltage leakage on high voltage systems is being constantly monitored. • High voltage is isolated from the chassis • Interlock and switch protection is monitored for unplugged or damaged connections. • Always Double check to ensure that the vehicle is off during the disabling step. • Always avoid contact with damaged high voltage components and wiring. • Always ensure that a person never meets, never touches, disconnects, or works on any of these HV components without the proper training, equipment and/or certifications. • Li-ion batteries have a large risk of fire, and an emergency response plan should be in place whenever stored, dismantled or transported. • Most Ni-MH batteries are relatively small and can be moved with the help of a co- worker and pushed around on a cart. However, Li-ion batteries are too large to be manually lifted and require lifting devices such as a powertrain lift or a forklift. EVs introduce other hazards into the workplace. consulab.com info@consulab.com 8 EV-601-TS_053322-95 Introduction High Voltage Safety Hazards Electricity wants to get from wherever it is to earth (or ground), and if it can, it will use the human body as a conduit. So, 70-90 volts is all that is required to cause a fatal accident. While we have concentrated upon fatal electric shock, staff can experience non-fatal electric shock, which could cause other, long-term issues, including: • Memory loss • Balance issues • Fatigue • Loss of consciousness • Sleep problems • Other neurological issues, So, we must be concerned about more than just a fatal incident. There could be other issues as well. Hazadards Of High Voltage Electricity wants to get from wherever it is to earth (or ground), and if it can, it will use the human body as a conduit. So, 70-90 volts is all that is required to cause a fatal accident. While we have concentrated upon fatal electric shock, staff can experience non-fatal electric shock, which could cause other, long-term issues, including: • Memory loss • Balance issues • Fatigue • Loss of consciousness • Sleep problems • Other neurological issues, So, we must be concerned about more than just a fatal incident. There could be other issues as well. Hazadards Of High Voltage Electricity wants to get from wherever it is to earth (or ground), and if it can, it will use the human body as a conduit. So, 70-90 volts is all that is required to cause a fatal accident. While we have concentrated upon fatal electric shock, staff can experience non-fatal electric shock, which could cause other, long-term issues, including: • Memory loss • Balance issues • Fatigue • Loss of consciousness • Sleep problems • Other neurological issues, So, we must be concerned about more than just a fatal incident. There could be other issues as well. Arc flash is where the electrical power jumps between two points and ignites the air around it, which has the potential to create sparks, fire or cause significant burns to people nearby. consulab.com info@consulab.com 9 EV-601-TS_053322-95 Introduction What is Arc Flash Safety Arc flash safety in the automotive industry is paramount to ensuring the well-being of workers and the integrity of elec- trical systems. In the automotive sector, where electrical systems are integral to modern vehicles, the risk of arc flash in- cidents demands specific safety measures. Personal Protective Equipment (PPE) is a cornerstone of arc flash safety, with workers wearing flame-resistant clothing, face shields, gloves, and other gear designed to withstand the thermal energy released during an incident. Clear warning labels on electrical equipment are essential to inform automotive technicians about potential arc flash hazards, including details about arc flash boundaries, incident energy levels, and required PPE. Arc flash refers to a sudden and explosive release of electrical energy that occurs when a fault or short circuit in an electrical system creates an electric arc. This arc generates intense heat, light, sound, and a pressure wave that can lead to serious injuries, extensive damage to equipment, and even fatalities. Arc flash incidents are particularly hazardous because of the high temperatures involved, often reaching levels hotter than the surface of the sun. The conditions that trigger arc flash events include a breakdown in the insulation of electrical components, equipment failure, or accidental contact with energized parts. The severity of an arc flash incident is influenced by factors such as the available fault current, the duration of the fault, and the distance between the worker and the equipment. To mitigate the risks associated with arc flash, safety measures are implemented, including the use of personal protec- tive equipment (PPE), warning labels on equipment, employee training on safe work practices, and engineering controls in the design of electrical systems. Risk assessments and analyses are also conducted to determine the potential haz- ards and establish protective measures, such as establishing arc flash boundaries and incident energy levels. The goal is to create a safer work environment and reduce the likelihood and impact of arc flash incidents. Arc flash is where the electrical power jumps between two points and ignites the air around it, which has the potential to create sparks, fire or cause significant burns to people nearby. Arc flash is where the electrical power jumps between two points and ignites the air around it, which has the potential to create sparks, fire or cause significant burns to people nearby. consulab.com info@consulab.com 10 EV-601-TS_053322-95 Introduction PPE related to arc flash risk and how its measured Arc flash incidents are measured in terms of incident energy, which is the amount of thermal energy impressed on a sur- face at a specific distance from the electrical arc. Incident energy is typically measured in calories per square centime- ter (cal/cm²) and is a critical parameter used to assess the potential harm that can result from an arc flash. What is Arc Flash Safety Arc flash safety in the automotive industry is paramount to ensuring the well-being of workers and the integrity of electrical systems. In the automotive sector, where electrical systems are integral to modern vehicles, the risk of arc flash incidents demands specific safety measures. Personal Protective Equipment (PPE) is a cornerstone of arc flash safety, with workers wearing flame-resistant clothing, face shields, gloves, and other gear designed to withstand the thermal energy released during an incident. Clear warning labels on electrical equipment are essential to inform automotive technicians about potential arc flash hazards, including details about arc flash boundaries, incident energy levels, and required PPE. Arc flash refers to a sudden and explosive release of electrical energy that occurs when a fault or short circuit in an electrical system creates an electric arc. This arc generates intense heat, light, sound, and a pressure wave that can lead to serious injuries, extensive damage to equipment, and even fatalities. Arc flash incidents are particularly hazardous because of the high temperatures involved, often reaching levels hotter than the surface of the sun. The conditions that trigger arc flash events include a breakdown in the insulation of electrical components, equipment failure, or accidental contact with energized parts. The severity of an arc flash incident is influenced by factors such as the available fault current, the duration of the fault, and the distance between the worker and the equipment. To mitigate the risks associated with arc flash, safety measures are implemented, including the use of personal protective equipment (PPE), warning labels on equipment, employee training on safe work practices, and engineering controls in the design of electrical systems. Risk assessments and analyses are also conducted to determine the potential hazards and establish protective measures, such as establishing arc flash boundaries and incident energy levels. The goal is to create a safer work environment and reduce the likelihood and impact of arc flash incidents. The incident energy is influenced by several factors, including: • Fault Current: The amount of current flowing during an electrical fault. • Fault Duration: The time it takes for protective devices to clear the fault. • Working Distance: The distance from the arc source to the worker’s face and chest, which determines the exposure level. The calculation of incident energy involves complex engineering calculations, often performed using specialized software or tables provided by standards such as NFPA 70E (Standard for Electrical Safety in the Workplace) and IEEE 1584 (Guide for Performing Arc-Flash Hazard Calculations). These calculations take into account the system’s voltage, available fault current, and other parameters to estimate the potential thermal energy release during an arc flash event. The incident energy is used to establish the arc flash boundary, which is the minimum safe distance from the arc source where the incident energy is below a certain threshold (commonly 1.2 cal/cm²). Workers within this boundary are re- quired to wear appropriate Personal Protective Equipment (PPE) to mitigate the potential impact of an arc flash. PPE related to arc flash risk and how its measured Arc flash incidents are measured in terms of incident energy, which is the amount of thermal energy impressed on a surface at a specific distance from the electrical arc. Incident energy is typically measured in calories per square centimeter (cal/cm²) and is a critical parameter used to assess the potential harm that can result from an arc flash. The incident energy is influenced by several factors, including: Fault Current: The amount of current flowing during an electrical fault. Fault Duration: The time it takes for protective devices to clear the fault. Working Distance: The distance from the arc source to the worker's face and chest, which determines the exposure level. The calculation of incident energy involves complex engineering calculations, often performed using specialized software or tables provided by standards such as NFPA 70E (Standard for Electrical Safety in the Workplace) and IEEE 1584 (Guide for Performing Arc-Flash Hazard Calculations). These calculations take into account the system's voltage, available fault current, and other parameters to estimate the potential thermal energy release during an arc flash event. The incident energy is used to establish the arc flash boundary, which is the minimum safe distance from the arc source where the incident energy is below a certain threshold (commonly 1.2 cal/cm²). Workers within this boundary are required to wear appropriate Personal Protective Equipment (PPE) to mitigate the potential impact of an arc flash. It's important to note that measuring incident energy directly during an arc flash event is challenging due to the dynamic and rapidly changing nature of the event. Instead, PPE related to arc flash risk and how its measured Arc flash incidents are measured in terms of incident energy, which is the amount of thermal energy impressed on a surface at a specific distance from the electrical arc. Incident energy is typically measured in calories per square centimeter (cal/cm²) and is a critical parameter used to assess the potential harm that can result from an arc flash. The incident energy is influenced by several factors, including: Fault Current: The amount of current flowing during an electrical fault. Fault Duration: The time it takes for protective devices to clear the fault. Working Distance: The distance from the arc source to the worker's face and chest, which determines the exposure level. The calculation of incident energy involves complex engineering calculations, often performed using specialized software or tables provided by standards such as NFPA 70E (Standard for Electrical Safety in the Workplace) and IEEE 1584 (Guide for Performing Arc-Flash Hazard Calculations). These calculations take into account the system's voltage, available fault current, and other parameters to estimate the potential thermal energy release during an arc flash event. The incident energy is used to establish the arc flash boundary, which is the minimum safe distance from the arc source where the incident energy is below a certain threshold (commonly 1.2 cal/cm²). Workers within this boundary are required to wear appropriate Personal Protective Equipment (PPE) to mitigate the potential impact of an arc flash. It's important to note that measuring incident energy directly during an arc flash event is challenging due to the dynamic and rapidly changing nature of the event. Instead, consulab.com info@consulab.com 11 EV-601-TS_053322-95 Introduction It’s important to note that measuring incident energy directly during an arc flash event is challenging due to the dynamic and rapidly changing nature of the event. Instead, 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. consulab.com info@consulab.com 12 EV-601-TS_053322-95 Introduction High Voltage PPE PPE is necessary when working on or a round high voltage systems. ln comparison to most regulations about high volt- age in the workplace, electric vehicle high voltage is seen as lower voltage. For an electrician, they might be working around 100,000 V, as an electric vehicle might be upwards of 800 V. ln comparison to commercial vehicles, electric vehi- cle voltage is seen as very high. Despite the comparison voltage over 50 volts can be deadly. The use of PPE is required. What is PPE? Persona! Protective Equipment is protective clothing, helmets, goggles, or other garments or equipment designed to protect the wearer’s body from injury or infection. The hazards addressed by protective equipment include physical, electrical, heat, chemicals, biohazards, and airborne particulate matter. The purchase and testing, requirements and obligations of PPE are listed in OSHA standard #1910.132: https://www. osha.gov/laws-regs/regulations/standardnumber/1910/1910.132. This document describes what are the employer and employee obligations. Employer Obligations: • Performing a hazard assessment of the workplace to identify and contrain physical and health hazards. • ldentifying and providing appropriate PPE for employees. • Training employees in the use and care of the PPE. • Maintaining PPE, including replacing worn or damaged PPE. • Periodically reviewing, updating and or damaged PPE. Worker Obligations: • Properly wear PPE. • Attend training sessions on PPE. • Care for, clean and maintain PPE. • lnform a supervisor of the need to repair or replace PPE. Different PPE is used depending on the workplace hazards. Some of the PPE used when working with electric vehicles are: • Face protection (face shield). • Protective gloves. • Protective footwear. • Protective clothing. • Hearing Protection. Additionally, the testing of high voltage gloves can be found in gloves ASTM 496-08: Standard Specification for lnService Care of lnsulating Gloves and Sleeves:https://www.astm.org/DATABASE.CART/HISTORICAL/F496-08.htm. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.132 https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.132 https://www.astm.org/DATABASE.CART/HISTORICAL/F496-08.htm consulab.com info@consulab.com 13 EV-601-TS_053322-95 Introduction PPE Ratings: • This PPE has different ratings depending on the risk of potential incident energy release. • Depending on the job that is performed you might be exposed to different amounts of voltages. This energy can cause an arc flash and is measured in cal/cm2. • The rating of the PPE is given an Arc Thermal Protective Value (ATPV), also known as (AR) Arc Rated. • Clothing worn over your PPE should also have these ratings. Clothing worn under should be made of non-melting fabrics like cotton or wool. What are Calories per Centimeter Squared (cal/cm2)? • This is a number identifying the amount of energy that can be delivered to a point at a particular distance from an arc flash. • Once this value is known, the ATPV rating of the clothing required from the potential flash hazard is also known. What is Arc Thermal Performance Value (ATPV)? • An Arc Thermal Performance Value (ATPV) refers to the maximum incident energy (in calories per centimeter squared) that protective equipment can be exposed to and prevent the onset of a second degree burn. • Ratings are based upon the total weight of the fabric. • If the worker is exposed to a potential incident heat energy level of less than 4.0 cal/cm2, the proper ATPV clothing system is 4cal/cm2 or higher. What is (FR) Flame Resistant Stand for? • Flame Resistant refers to the ability of a material to self-extinguish upon the removal of an ignition source once the material has been burned this stops it from continually burning. • FR clothing is not always ATPV rated, but all ATPV rated clothing is FR. What is (AR) Arc Rated Stand for? • Arc Rated is basically the same thing as ATPV, but AR Arc Rating usually does not give the incident energy value (cal/ cm2) just a number. • ALL AR clothing is flame resistant (FR), but not all FR rated clothing has been Arc Rated. Flame resistance stops the fabric from burning, arc value stops it from penetrating through the clothing. What are the PPE categories used and rated by the incident energy they protect a worker from? • PPE Category 1: Minimum Arc Rating 4 cal/cm2 • PPE Category 2: Minimum Arc Rating 8 cal/cm • PPE Category 3: Minimum Arc Rating 25 cal/cm • PPE Category 4: Minimum Arc Rating 40 cal/cm. For each of these categories, a different PPE is required. The arc rating can be higher than the category required, just not lower. If you are working on equipment that re- quires getting different categories, think about just getting the highest needed catego- ry and use it for all situations. Source: e-Hazard consulab.com info@consulab.com 14 EV-601-TS_053322-95 Introduction consulab.com info@consulab.com 14 High Voltage Components It is the responsibility of the employer to ensure the right safety equipment is being used when working around and on BEV, PHEV, and hybrid vehicles Protective Gloves Class 0 HV insulating gloves must be worn when working on HV vehicle components. These are the most important piece of safety equipment, these are what you are going to put your hands into and touch the vehicle with. It is imperative that these gloves are in good condition and are tested and checked EVERY time they are used. Prior to a worker putting on gloves, a leak check must be completed on the gloves. Regulations require regular inspections of PPE. It is recommended that these gloves are tested and certified every six months. Every time, before these gloves are used, they must be visually inspected for damage, cuts or splits, and then air-tested to make certain that they hold air. This is required to confirm there are no pinholes in the gloves. Prior to a worker putting on gloves, a leak check must be completed on the gloves. Regulations require regular inspections of PPE. It is recommended that these gloves are tested and certified every six months. Every time, before these gloves are used, they must be visually inspected for damage, cuts or splits, and then air-tested to make certain that they hold air. This is required to confirm there are no pinholes in the gloves. Protective Glove Type’s First, for insulating gloves there are two “Type’s”: Type 1 glove is not ozone resistant /Type II is ozone-resistant. Don’t rely on the colour of the glove but watch for the colour of the tag. Always use an air test. NEVER fill them with water to complete this test! Once the work has been completed, the gloves should be put back into the bag they came in and stored flat – do not fold them up as this will put strain on the gloves and could cause damage. The onus is on the operator to inspect and test the gloves every time before use. A glove pack will include some cotton under gloves for comfort and hygiene, and some leather over gauntlets. The over gauntlets are there to prevent the electricians’ gloves from getting damaged during use and are strongly recommended. Protective Glove Types First, for insulating gloves there are two “Type’s”: • Type 1 glove is not ozone resistant • Type II glove is ozone-resistant. Warning: Don’t rely on the colour of the glove but watch for the colour of the tag. Warning: Always use an air test. NEVER fill them with water to complete this test. Equipment Used for Working on High-Voltage Components It is the responsibility of the employer to ensure the right safety equipment is being used when working around and on BEV, PHEV, and hybrid vehicles. Electricians Safety Gloves – Class 0 (1000v) minimum Class 0 HV insulating gloves must be worn when working on HV vehicle components. These are the most important piece of safety equipment, these are what you are going to put your hands into and touch the vehicle with. It is imperative that these gloves are in good condition and are tested and checked EVERY time they are used. Lithium – Ion Batteries Lithium metal EV-601-TS_053322-95 Titre de la section consulab.com info@consulab.com 15 Once the work has been completed, the gloves should be put back into the bag they came in and stored flat – do not fold them up as this will put strain on the gloves and could cause damage. The onus is on the operator to inspect and test the gloves every time before use. A glove pack will include some cotton under gloves for comfort and hygiene, and some leather over gauntlets. The over gauntlets are there to prevent the electricians’ gloves from getting damaged during use and are strongly recommended. Protective Face Sheild: • The face shield and hardhat provide a reduced risk of the outcomes of an arc flash. • Arc flashes throw pieces of molten and sol id materials at the person inside the arc flash bound- aries. • Face shields are arc rated and impact rated. • They must be inspected before use. Protective Foot Wear: • Boots are required to be leather and have either an: - (EH) electrical hazard rating. That is located on the tong of the boot. - Or the CSA White Rectangle with the omega symbol. • Both of these refer to an electrical insulating property able to withstand 18,000 Volts and a leakage current not exceeding 1 mA for 60 seconds. • If you are working in areas that have the potential of having electrical energy under your feet dielectric boots might be required. • Look into CSA Standard 2195-14 (R2019) • Boots must be inspected before use and not used if wet. Protective Clothing: • Protective clothing might consist of coveralls, shirts, pants, and hoods. • They must be arc rated for the level of possible risk. • They must be inspected before each use by the employee. • Youtube Video: How To Wear Protective Clothing Hearing Protection: Different types of hearing protectors are available: • Earplugs are inserted in the ear canal. They may be premolded (preformed), moldable, rolldown foam, push-to-fit, or custom molded. Disposable, reusable and custom earplugs are available. • Semi-insert earplugs consist of two earplugs held over the ends of the ear canal by a rigid headband. consulab.com info@consulab.com 16 EV-601-TS_053322-95 Introduction • Earmuffs consist of sound-attenuating material and soft ear cushions that fit around the ear and hard outer cups. They are held together by a headband. Cat III, 1000v Multimeter or Voltage Detector Another essential piece of equipment that is used in the vehicle shut down and test process is the multimeter. This device is used to check for the absence of voltage at a suitable test point. Like the gloves, there are some tests to complete every time this device is used to confirm that it is working correctly When measuring an HV battery on a BEV, PHEV, and hybrid vehicle, a CAT III multimeter and matching CAT III leads must be used. Using the wrong testing equipment will cause an electric shock that could injure or kill. First, check the leads to make certain they are the correct leads (cat III, 1000v), and that they are not damaged in any way. Connect the multimeter and test it against a known source – this could be the 12-volt battery on the car. This confirms that the multimeter is operating. When we test the vehicle, we will be looking for zero voltage, if the multimeter is not operating correctly, we could see zero on the display when there are 700 volts going through it, so this test is essential. Warning: When testing the vehicle, we follow the Live-Dead-Live principle. Test the multimeter or voltage detector on a known source to confirm operation, then look for zero voltage on the vehi- cle, then go back to our known source to re-test and confirm that the multimeter is operating correctly. HV Rescue Hook In the event a worker suffers an electric shock, and he/she is still in contact with the source, an HV rescue hook must be used to pull the worker away from the voltage source. Never attempt to pull a worker away without the correct safety equipment. Do not touch a person who may still be connected to an electrical source. The safety hook shown on above is black HD polyethylene, with high temperature stabilizer additive, and 2% U.V. stabilizer for high U.V. protection. It has excellent chemical resistance. Its anticipated life is 10 years, after which the hook should be replaced. The year of manufac- ture is embossed on the hook.It is suitable for outdoor storage, (e.g. outdoor substation) on account of its U.V. stabilization additive. However, the Safety Rescue Hook must not be stored permanently in direct sunlight. It is used for retrieval of victims of electric shock and should be placed in a prominent and easily and immediately accessible position near to the work area. Possible Electrical injuries include loss of consciousness, electrical burns, heart fibrillations, neurological effects, and muscle contractions. Check to see if the victim is conscious. Call the emergency services or get a colleague to call them. Even if the victim is conscious, they High-Voltage Tools When measuring an HV battery on a BEV, PHEV, and hybrid vehicle, a CAT III multimeter and matching CAT III leads must be used. Using the wrong testing equipment will cause an electric shock that could injure or kill. In the event a worker suffers an electric shock, and he/she is still in contact with the source, an HV rescue hook must be used to pull the worker away from the voltage source. Never attempt to pull a worker away without the correct safety equipment. Keeping Safe Having warned you about the dangers of high-voltage batteries, how do we keep you safe? Here is a list of the personal protective equipment and tools that are required by all. Rubber matting or overboots – 1000v minimum As stated before, electricity wants to get from the battery to ground (or earth), and the human body can be used as a conduit for this energy. By insulating the operator at the hands and feet, Do not touch a person who may still be connected to an electrical source The safety hook shown on the left is black HD polyethylene, with high temperature stabilizer additive, and 2% U.V. stabilizer for high U.V. protection. It has excellent chemical resistance. Its anticipated life is 10 years, after which the hook should be replaced. The year of manufacture is embossed on the hook.It is suitable for outdoor storage, (e.g. outdoor substation) on account of its U.V. stabilization additive. However, the Safety Rescue Hook must not be stored permanently in direct sunlight. It is used for retrieval of victims of electric shock and should be placed in a prominent and easily and immediately accessible position near to the work area. Possible Electrical injuries include loss of consciousness, electrical burns, heart fibrillations, neurological effects, and muscle contractions. Check to see if the victim is conscious. Call the emergency services or get a colleague to call them. Even if the victim is conscious, they will still need to be examined. Call first aid immediately. Only a certified first aid attendant can perform CPR. Battery fire Remember, the batteries we are dealing with are multiple cells, so if one cell is damaged the effect can be like a chain reaction. It is called thermal runaway, as the batteries heat up and catch fire one after the other. Causes of Battery Fire • Mechanical Damage • External Thermal Stress • External Short Circuit Do not touch a person who may still be connected to an electrical source The safety hook shown on the left is black HD polyethylene, with high temperature stabilizer additive, and 2% U.V. stabilizer for high U.V. protection. It has excellent chemical resistance. Its anticipated life is 10 years, after which the hook should be replaced. The year of manufacture is embossed on the hook.It is suitable for outdoor storage, (e.g. outdoor substation) on account of its U.V. stabilization additive. However, the Safety Rescue Hook must not be stored permanently in direct sunlight. It is used for retrieval of victims of electric shock and should be placed in a prominent and easily and immediately accessible position near to the work area. Possible Electrical injuries include loss of consciousness, electrical burns, heart fibrillations, neurological effects, and muscle contractions. Check to see if the victim is conscious. Call the emergency services or get a colleague to call them. Even if the victim is conscious, they will still need to be examined. Call first aid immediately. Only a certified first aid attendant can perform CPR. Battery fire Remember, the batteries we are dealing with are multiple cells, so if one cell is damaged the effect can be like a chain reaction. It is called thermal runaway, as the batteries heat up and catch fire one after the other. Causes of Battery Fire • Mechanical Damage • External Thermal Stress • External Short Circuit High-Voltage Tools When measuring an HV battery on a BEV, PHEV, and hybrid vehicle, a CAT III multimeter and matching CAT III leads must be used. Using the wrong testing equipment will cause an electric shock that could injure or kill. In the event a worker suffers an electric shock, and he/she is still in contact with the source, an HV rescue hook must be used to pull the worker away from the voltage source. Never attempt to pull a worker away without the correct safety equipment. Keeping Safe Having warned you about the dangers of high-voltage batteries, how do we keep you safe? Here is a list of the personal protective equipment and tools that are required by all. Rubber matting or overboots – 1000v minimum As stated before, electricity wants to get from the battery to ground (or earth), and the human body can be used as a conduit for this energy. By insulating the operator at the hands and feet, Equipment Used for Working on High-Voltage Components It is the responsibility of the employer to ensure the right safety equipment is being used when working around and on BEV, PHEV, and hybrid vehicles. Electricians Safety Gloves – Class 0 (1000v) minimum Class 0 HV insulating gloves must be worn when working on HV vehicle components. These are the most important piece of safety equipment, these are what you are going to put your hands into and touch the vehicle with. It is imperative that these gloves are in good condition and are tested and checked EVERY time they are used. Lithium – Ion Batteries Lithium metal the energy cannot reach ground, thus protecting the operator from a fatal electric shock. 1000v rubber matting on the floor, or high-voltage overboots provide this protection. Safety Rescue Hook As we just mentioned, one of the most important pieces of safety kit is the safety hook, to be utilized by a colleague to rescue a person suffering an electric shock and still in contact with the source. By safely separating them from the source, use of this device could save someone’s life, while also protecting the person doing the rescue. This hook should be close to where people are working, available for immediate use, and everyone in the business should know what this hook is for and how to use it! Cat III, 1000v Multimeter or Voltage Detector Another essential piece of equipment that is used in the vehicle shut down and test process is the multimeter. This device is used to check for the absence of voltage at a suitable test point. Like the gloves, there are some tests to complete every time this device is used to confirm that it is working correctly. First, check the leads to make certain they are the correct leads (cat III, 1000v), and that they are not damaged in any way. Connect the multimeter and test it against a known source – this could be the 12-volt battery on the car. This confirms that the multimeter is operating. When we test the vehicle, we will be looking for zero voltage, if the multimeter is not operating EV-601-TS_053322-95 Titre de la section consulab.com info@consulab.com 17 will still need to be examined. Call first aid immediately. Only a certified first aid attendant can perform CPR. This hook should be close to where people are working, available for immediate use, and everyone in the business should know what this hook is for and how to use it! As stated before, electricity wants to get from the battery to ground (or earth), and the human body can be used as a conduit for this energy. By insulating the operator at the hands and feet, the energy cannot reach ground, thus protecting the operator from a fatal electric shock. 1000v rubber matting on the floor, or high-voltage overboots provide this protection. the energy cannot reach ground, thus protecting the operator from a fatal electric shock. 1000v rubber matting on the floor, or high-voltage overboots provide this protection. Safety Rescue Hook As we just mentioned, one of the most important pieces of safety kit is the safety hook, to be utilized by a colleague to rescue a person suffering an electric shock and still in contact with the source. By safely separating them from the source, use of this device could save someone’s life, while also protecting the person doing the rescue. This hook should be close to where people are working, available for immediate use, and everyone in the business should know what this hook is for and how to use it! Cat III, 1000v Multimeter or Voltage Detector Another essential piece of equipment that is used in the vehicle shut down and test process is the multimeter. This device is used to check for the absence of voltage at a suitable test point. Like the gloves, there are some tests to complete every time this device is used to confirm that it is working correctly. First, check the leads to make certain they are the correct leads (cat III, 1000v), and that they are not damaged in any way. Connect the multimeter and test it against a known source – this could be the 12-volt battery on the car. This confirms that the multimeter is operating. When we test the vehicle, we will be looking for zero voltage, if the multimeter is not operating consulab.com info@consulab.com 18 EV-601-TS_053322-95 Introduction Common Electric Vehicle Terms Alternating Current (AC): Alternating current periodically changes direction, and the power inverter converts the DC from the battery into AC for the electric motor. Battery Management System (BMS): A critical component ensuring uniform cell charging, preventing overcharging or undercharging, managing thermal condi- tions, and providing real-time data on battery health. Advanced BMS implementations include machine learning algo- rithms for predictive maintenance. Battery Pack: A complex assembly comprising interconnected lithium-ion cells, designed with a Battery Management System (BMS) to monitor individual cell voltages, temperatures, and overall health. It acts as the primary energy storage unit for the electric vehicle, providing the necessary voltage and current for propulsion. Cabin Preconditioning: A feature that allows the heating or cooling of the vehicle’s interior while it is still connected to a power source, helping to optimize cabin temperature without using the vehicle’s battery. Charge Connector Types: Standardized connectors, such as CCS, CHAdeMO, and Type 2, play a pivotal role in facilitating safe and efficient elec- tric vehicle charging. Compatibility with different charging networks is crucial for user convenience. Charging Station: A station equipped with high-power AC/DC converters and standardized connectors (e.g., CCS, CHAdeMO) to facilitate rapid charging. Charging stations often incorporate communication protocols like ISO 15118 for secure communication between the vehicle and the charging infrastructure. Direct Current (DC): Direct current flows unidirectionally and is used in electric vehicles for energy storage, charging, and power delivery from the battery to the power inverter. consulab.com info@consulab.com 19 EV-601-TS_053322-95 Introduction Electric Motor: A three-phase alternating current (AC) synchronous motor with permanent magnet rotor construction. It features precise control algorithms through the Inverter and Pulse Width Modulation (PWM) techniques to regulate motor speed, torque, and efficiency. Electric Vehicle (EV): An electric vehicle incorporates a powertrain consisting of an electric motor, power inverter, and battery pack. EVs may employ different motor types, such as induction or permanent magnet motors, and various charging standards, including CCS or CHAdeMO. E-Pedal: A feature in electric vehicles that allows the driver to control both acceleration and deceleration using a single pedal, simplifying driving and maximizing energy regeneration during braking. Fast Charging: Fast charging utilizes high-power charging infrastructure, often with power levels exceeding 50 kW. This process requires sophisticated thermal management systems to control battery temperature and maintain optimal charging efficiency. Kilowatt-hour (kWh): A unit of electrical energy used to quantify the capacity of the battery pack. The kWh rating influences the vehicle’s range and charging time. Plug-in Hybrid Electric Vehicle (PHEV): A PHEV features both an internal combustion engine and an electric motor. The powertrain complexity involves control systems managing power distribution between the engine and electric motor, often optimizing for efficiency and perfor- mance. Power Inverter: An advanced power electronics device that employs insulated gate bipolar transistors (IGBTs) to convert the direct current (DC) from the battery into the required three-phase alternating current (AC) for the electric motor. It incorporates control algorithms for optimal power delivery. Public Charging Network: A network of charging stations interconnected through backend systems, allowing electric vehicle owners to access and pay for charging services. Communication protocols like Open Charge Point Protocol (OCPP) enable seamless integra- tion. EV-601-TS_053322-95 Titre de la section consulab.com info@consulab.com 20 Range: The range is determined by the energy capacity of the battery pack (expressed in kilowatt-hours, kWh), the vehicle’s effi- ciency, and driving conditions. It involves complex calculations considering factors like aerodynamics, rolling resistance, and auxiliary power consumption. Range Anxiety: A psychological concern addressed through advanced Battery Management Systems, accurate range estimation al- gorithms, and an expanding network of fast-charging infrastructure. Predictive algorithms consider driving habits and external factors for precise range predictions. Regenerative Braking: An energy recovery system utilizing a combination of regenerative and friction braking. During regenerative braking, the power inverter switches the electric motor to a generator, converting kinetic energy into electrical energy. The BMS manages the energy flow back into the battery, enhancing overall efficiency. State of Charge (SOC): SOC is a dynamic metric determined by the BMS, indicating the percentage of the battery’s full capacity available for use. Precise SOC calculations are crucial for accurate range estimations and optimal battery management. Torque: Torque, produced by the electric motor, is a measure of rotational force influencing acceleration. Torque characteristics are critical for achieving optimal vehicle performance and efficiency. Some EV Acronyms: • ICE: Internal Combustion Engine • AH: Amp Hours energy storage of battery • BEV: Battery Electric Vehicle • Hybrid: Battery / ICE powered vehicle • SOH: State of Health (Battery Condition) • KW: Kilowatt (Bigger number more power) KWh: • Battery capacity = Energy that can be stored in a battery measured • Most cars are rated on battery size • A measure of electrical energy equivalent to a power consumption of 1,000 watts for 1 hour consulab.com info@consulab.com 21 EV-601-TS_053322-95 Introduction KW: • Unit of measurement to measure motor power output • 1 kW = 1.359 hp (horsepower) • 1 hp = 0.73549857 kW • Example 140 kW = 190 hp — 230 hp = 176.5 kW AH: • Unit of measurement to measure capacity in energy available • How much can go back into a battery as usable power • Battery internal resistance will affect AH (charging and output) • (Watts is Power = Amps x Volts) consulab.com info@consulab.com 22 EV-601-TS_053322-95 Student Assignments STUDENT ASSIGNMENTS consulab.com info@consulab.com 23 EV-601-TS_053322-95 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 24 EV-601-TS_053322-95 Module 1 — EV Components Electric Vehicle Components Since battery electric vehicles run on electricity, they do not require oil changes and have far fewer moving parts than ICE vehicles. However, they have several components not found in an ICE. It is important to be able to identify EV com- ponents. In many cases the manufacturer’s information will be needed to assist with identifying some of these compo- nents. Slightly different names are used between manufacturers, but the most common components are: • High-voltage cables (orange) • High-voltage Battery • Electric motor(s) • Relays • Charging Ports • Inverter (AC to DC) • DC to DC Converter • Ignition • Driver Display Panel • Electric motor/generator • Electric HVAC • Capacitors • Built in charger • Battery temperature control • Inverter motor cooling system Some components store EXTREMELY HIGH VOLTAGE! Other components simply carry high voltage: • High-voltage (HV) battery pack – stores energy • Connections and terminals – carry energy • High-voltage (HV) cables – carry energy • Capacitors – store energy • Inverter – carries energy It is important to note the components that simply carry energy will not have any energy in them after the HV sys- tem has been fully shut down. But components that store energy do exactly that – they store the energy even after shutting down. EV Components Above: Volvo hybrid - overhead and side views that show the HV battery and power electrics (orange) 12-volt battery (yellow) to highlight the differing locations Above: BMW hybrid, with high voltage battery and power electrics (orange) and two (yes two) 12- volt batteries located in the trunk. Since battery electric vehicles run on electricity, they do not require oil changes and have far fewer moving parts than ICE vehicles. However, they have several components not found in an ICE. It is important to be able to identify EV components. In many cases the manufacturer’s information will be needed to assist with identifying some of these components. Slightly different names are used between manufacturers, but the most common components are: • High-voltage cables (orange) • High-voltage Battery • Electric motor(s) • Relays • Charging Ports • Inverter (AC to DC) • DC to DC Converter • Ignition • Driver Display Panel • Electric motor/generator • Electric HVAC • Capacitors • Built in charger • Battery temperature control • Inverter motor cooling system Some components store EXTREMELY HIGH VOLTAGE! Other components simply carry high voltage. Above: Volvo hybrid — overhead and side views that show the HV battery and power electrics (orange) 12-volt battery (yel- low) to highlight the differing locations. Above: BMW hybrid, with high voltage battery and power electrics (orange) and two (yes two) 12- volt batteries located in the trunk. EV Components Above: Volvo hybrid - overhead and side views that show the HV battery and power electrics (orange) 12-volt battery (yellow) to highlight the differing locations Above: BMW hybrid, with high voltage battery and power electrics (orange) and two (yes two) 12- volt batteries located in the trunk. Since battery electric vehicles run on electricity, they do not require oil changes and have far fewer moving parts than ICE vehicles. However, they have several components not found in an ICE. It is important to be able to identify EV components. In many cases the manufacturer’s information will be needed to assist with identifying some of these components. Slightly different names are used between manufacturers, but the most common components are: • High-voltage cables (orange) • High-voltage Battery • Electric motor(s) • Relays • Charging Ports • Inverter (AC to DC) • DC to DC Converter • Ignition • Driver Display Panel • Electric motor/generator • Electric HVAC • Capacitors • Built in charger • Battery temperature control • Inverter motor cooling system Some components store EXTREMELY HIGH VOLTAGE! Other components simply carry high voltage. EV Components Above: Volvo hybrid - overhead and side views that show the HV battery and power electrics (orange) 12-volt battery (yellow) to highlight the differing locations Above: BMW hybrid, with high voltage battery and power electrics (orange) and two (yes two) 12- volt batteries located in the trunk. Since battery electric vehicles run on electricity, they do not require oil changes and have far fewer moving parts than ICE vehicles. However, they have several components not found in an ICE. It is important to be able to identify EV components. In many cases the manufacturer’s information will be needed to assist with identifying some of these components. Slightly different names are used between manufacturers, but the most common components are: • High-voltage cables (orange) • High-voltage Battery • Electric motor(s) • Relays • Charging Ports • Inverter (AC to DC) • DC to DC Converter • Ignition • Driver Display Panel • Electric motor/generator • Electric HVAC • Capacitors • Built in charger • Battery temperature control • Inverter motor cooling system Some components store EXTREMELY HIGH VOLTAGE! Other components simply carry high voltage. consulab.com info@consulab.com 25 EV-601-TS_053322-95 Module 1 — EV Components Capacitors These are another type of energy storage utilized by EVs. When making these vehicles safe we allow time for these capacitors to naturally discharge (normally 10 minutes) before we start working on the high voltage system. Orange Cables In an EV, high voltage cables are coloured orange. High voltage cables require greater insulation to prevent voltage leakage, but also because the risk of harm if touched is very high. Stickers with various symbols are used as a warning together with the bright orange color. The centre of a typical power cable contains the conductor. This has a very low resistance and rated for continuous operation. Surrounding the conductor is a layer of insulation that prevents leakage of high electrical energy. The next layer of the cable is the shielding. This is braided to protect other electronic systems from electromagnetic interference (EMI) created by the high energy passing through the cables. The final layer is the sheath that protects the cable from extreme temperatures, dust and fluids. If the orange high-voltage cables become damaged, they cannot be repaired. They must be replaced. These cables are designed by the manufacturer for their specific length. Any changes to the length will change the internal resistance and could affect the vehicle operation. Some of these cables run underneath the vehicle, they can be damaged in an accident, so there may be a sales opportunity in the future for these cables, as long as they are handled correctly while being removed for re-use. Note – if fitting a cable to an electric vehicle, always ensure that the connections like the ones shown in the photo on the right are tightened to the correct torque using an insulated torque wrench. Over-tightening can result in damage to a terminal that may not be visible, but will create resistance that will create heat! High Voltage Battery The most common battery technology in electric vehicles today is lithium-ion. The complete battery pack consist of several cell modules (the actual battery consists of several hundred to several thousand individual cells), a cooling system, insulation, junction box, battery management and a suitable case or shell. These features combine so that the pack can withstand impacts and a wide range of temperatures. • High-voltage (HV) battery pack – stores energy • Connections and terminals – carry energy • High-voltage (HV) cables – carry energy • Capacitors – store energy • Inverter – carries energy It is important to note the components that simply carry energy will not have any energy in them after the HV system has been fully shut down. But components that store energy do exactly that – they store the energy even after shutting down. Capacitors These are another type of energy storage utilized by EVs. When making these vehicles safe we allow time for these capacitors to naturally discharge (normally 10 minutes) before we start working on the high voltage system. Orange cables In an EV, high voltage cables are coloured orange. High voltage cables require greater insulation to prevent voltage leakage, but also because the risk of harm if touched is very high. Stickers with various symbols are used as a warning together with the bright orange color. The centre of a typical power cable contains the conductor. This has a very low resistance and rated for continuous operation. Surrounding the conductor is a layer of insulation that prevents leakage of high electrical energy. The next layer of the cable is the shielding. This is braided to protect other electronic systems from electromagnetic interference (EMI) created by the high energy passing through the cables. The final layer is the sheath that protects the cable from extreme temperatures, dust and fluids. • High-voltage (HV) battery pack – stores energy • Connections and terminals – carry energy • High-voltage (HV) cables – carry energy • Capacitors – store energy • Inverter – carries energy It is important to note the components that simply carry energy will not have any energy in them after the HV system has been fully shut down. But components that store energy do exactly that – they store the energy even after shutting down. Capacitors These are another type of energy storage utilized by EVs. When making these vehicles safe we allow time for these capacitors to naturally discharge (normally 10 minutes) before we start working on the high voltage system. Orange cables In an EV, high voltage cables are coloured orange. High voltage cables require greater insulation to prevent voltage leakage, but also because the risk of harm if touched is very high. Stickers with various symbols are used as a warning together with the bright orange color. The centre of a typical power cable contains the conductor. This has a very low resistance and rated for continuous operation. Surrounding the conductor is a layer of insulation that prevents leakage of high electrical energy. The next layer of the cable is the shielding. This is braided to protect other electronic systems from electromagnetic interference (EMI) created by the high energy passing through the cables. The final layer is the sheath that protects the cable from extreme temperatures, dust and fluids. • High-voltage (HV) battery pack – stores energy • Connections and terminals – carry energy • High-voltage (HV) cables – carry energy • Capacitors – store energy • Inverter – carries energy It is important to note the components that simply carry energy will not have any energy in them after the HV system has been fully shut down. But components that store energy do exactly that – they store the energy even after shutting down. Capacitors These are another type of energy storage utilized by EVs. When making these vehicles safe we allow time for these capacitors to naturally discharge (normally 10 minutes) before we start working on the high voltage system. Orange cables In an EV, high voltage cables are coloured orange. High voltage cables require greater insulation to prevent voltage leakage, but also because the risk of harm if touched is very high. Stickers with various symbols are used as a warning together with the bright orange color. The centre of a typical power cable contains the conductor. This has a very low resistance and rated for continuous operation. Surrounding the conductor is a layer of insulation that prevents leakage of high electrical energy. The next layer of the cable is the shielding. This is braided to protect other electronic systems from electromagnetic interference (EMI) created by the high energy passing through the cables. The final layer is the sheath that protects the cable from extreme temperatures, dust and fluids. If the orange high-voltage cables become damaged, they cannot be repaired. They must be replaced. These cables are designed by the manufacturer for their specific length. Any changes to the length will change the internal resistance and could affect the vehicle operation. Some of these cables run underneath the vehicle, they can be damaged in an accident, so there may be a sales opportunity in the future for these cables, as long as they are handled correctly while being removed for re-use. Note – if fitting a cable to an electric vehicle, always ensure that the connections like the ones shown in the photo on the right are tightened to the correct torque using an insulated torque wrench. Over-tightening can result in damage to a terminal that may not be visible, but will create resistance that will create heat! The high-voltage battery The most common battery technology in electric vehicles today is lithium-ion. The complete battery pack consist of several cell modules (the actual battery consists of several hundred to several thousand individual cells), a cooling system, insulation, junction box, battery management and a suitable case or shell. These features combine so that the pack can withstand impacts and a wide range of temperatures. A Chevy Bolt battery assembly 12-volt battery Yes, most EVs have a 12-volt battery, needed for lights, wipers, in-car entertainment systems and more, including some safety systems. If the 12-volt battery goes dead, you will not be able to start the vehicle. You can jump-start an electric vehicle by connecting a jump pack to the 12-volt battery and following manufacturer’s instructions to start the vehicle. If the 12-volt battery is in the trunk, you will find jump points under the hood. If the orange high-voltage cables become damaged, they cannot be repaired. They must be replaced. These cables are designed by the manufacturer for their specific length. Any changes to the length will change the internal resistance and could affect the vehicle operation. Some of these cables run underneath the vehicle, they can be damaged in an accident, so there may be a sales opportunity in the future for these cables, as long as they are handled correctly while being removed for re-use. Note – if fitting a cable to an electric vehicle, always ensure that the connections like the ones shown in the photo on the right are tightened to the correct torque using an insulated torque wrench. Over-tightening can result in damage to a terminal that may not be visible, but will create resistance that will create heat! The high-voltage battery The most common battery technology in electric vehicles today is lithium-ion. The complete battery pack consist of several cell modules (the actual battery consists of several hundred to several thousand individual cells), a cooling system, insulation, junction box, battery management and a suitable case or shell. These features combine so that the pack can withstand impacts and a wide range of temperatures. A Chevy Bolt battery assembly 12-volt battery Yes, most EVs have a 12-volt battery, needed for lights, wipers, in-car entertainment systems and more, including some safety systems. If the 12-volt battery goes dead, you will not be able to start the vehicle. You can jump-start an electric vehicle by connecting a jump pack to the 12-volt battery and following manufacturer’s instructions to start the vehicle. If the 12-volt battery is in the trunk, you will find jump points under the hood. If the orange high-voltage cables become damaged, they cannot be repaired. They must be replaced. These cables are designed by the manufacturer for their specific length. Any changes to the length will change the internal resistance and could affect the vehicle operation. Some of these cables run underneath the vehicle, they can be damaged in an accident, so there may be a sales opportunity in the future for these cables, as long as they are handled correctly while being removed for re-use. Note – if fitting a cable to an electric vehicle, always ensure that the connections like the ones shown in the photo on the right are tightened to the correct torque using an insulated torque wrench. Over-tightening can result in damage to a terminal that may not be visible, but will create resistance that will create heat! The high-voltage battery The most common battery technology in electric vehicles today is lithium-ion. The complete battery pack consist of several cell modules (the actual battery consists of several hundred to several thousand individual cells), a cooling system, insulation, junction box, battery management and a suitable case or shell. These features combine so that the pack can withstand impacts and a wide range of temperatures. A Chevy Bolt battery assembly 12-volt battery Yes, most EVs have a 12-volt battery, needed for lights, wipers, in-car entertainment systems and more, including some safety systems. If the 12-volt battery goes dead, you will not be able to start the vehicle. You can jump-start an electric vehicle by connecting a jump pack to the 12-volt battery and following manufacturer’s instructions to start the vehicle. If the 12-volt battery is in the trunk, you will find jump points under the hood. Chevy Bolt battery assembly consulab.com info@consulab.com 26 EV-601-TS_053322-95 Module 1 — EV Components 12-volt Battery Yes, most EVs have a 12-volt battery, needed for lights, wipers, in-car entertainment systems and more, including some safety systems. If the 12-volt battery goes dead, you will not be able to start the vehicle. You can jump-start an electric vehicle by connecting a jump pack to the 12-volt battery and following manufacturer’s instructions to start the vehicle. If the 12-volt battery is in the trunk, you will find jump points under the hood. Note – the jump points under the hood are designed to allow the trunk to be opened not to start the vehicle. Warning: NEVER use one of these vehicles to jump start another vehicle as the power spike may damage the sensitive electrics in the vehicle. Battery Management Controller This device monitors and controls the battery and determines the state of charge of the cells and other functions. It regulates the temperature and protects the cells against overcharging and deep discharge. Electronically activated switches are included that disconnect the battery system when idle and in critical situations such as an accident or fire. The device is usually part of the battery pack, but not always, so check the manufac- turer’s data. Inverter The inverter takes high voltage DC from the battery and converts it to higher voltage (three phase) AC to power the electric motor, and when the vehicle is slowing down (regen) it takes the AC power produced by the motor and changes it to DC to charge the battery The inverter also produces AC power to drive the air conditioning pump. The air condi- tioning is a high voltage system and needs to be treated as such when working on it. The air conditioning may be used to provide climate control for the battery as well the cabin, but this is all managed by the electronic control units and everything is run form the single pump and condenser. DC to DC Converter This may be part of the inverter unit or a separate package. It is used to step down the high voltage to supply the 12-volt system because a normal alternator is not used in some configurations. On some systems, it can work in both directions. Some manufacturers split these components into two different devices, while others (Toyota for example) combine them into a single component. If the orange high-voltage cables become damaged, they cannot be repaired. They must be replaced. These cables are designed by the manufacturer for their specific length. Any changes to the length will change the internal resistance and could affect the vehicle operation. Some of these cables run underneath the vehicle, they can be damaged in an accident, so there may be a sales opportunity in the future for these cables, as long as they are handled correctly while being removed for re-use. Note – if fitting a cable to an electric vehicle, always ensure that the connections like the ones shown in the photo on the right are tightened to the correct torque using an insulated torque wrench. Over-tightening can result in damage to a terminal that may not be visible, but will create resistance that will create heat! The high-voltage battery The most common battery technology in electric vehicles today is lithium-ion. The complete battery pack consist of several cell modules (the actual battery consists of several hundred to several thousand individual cells), a cooling system, insulation, junction box, battery management and a suitable case or shell. These features combine so that the pack can withstand impacts and a wide range of temperatures. A Chevy Bolt battery assembly 12-volt battery Yes, most EVs have a 12-volt battery, needed for lights, wipers, in-car entertainment systems and more, including some safety systems. If the 12-volt battery goes dead, you will not be able to start the vehicle. You can jump-start an electric vehicle by connecting a jump pack to the 12-volt battery and following manufacturer’s instructions to start the vehicle. If the 12-volt battery is in the trunk, you will find jump points under the hood. Note – the jump points under the hood are designed to allow the trunk to be opened not to start the vehicle. NEVER use one of these vehicles to jump start another vehicle as the power spike may damage the sensitive electrics in the vehicle. Battery Management Controller This device monitors and controls the battery and determines the state of charge of the cells and other functions. It regulates the temperature and protects the cells against overcharging and deep discharge. Electronically activated switches are included that disconnect the battery system when idle and in critical situations such as an accident or fire. The device is usually part of the battery pack, but not always, so check the manufacturer’s data. . The inverter The inverter takes high voltage DC from the battery and converts it to higher voltage (three phase) AC to power the electric motor, and when the vehicle is slowing down (regen) it takes the AC power produced by the motor and changes it to DC to charge the battery The inverter also produces AC power to drive the air conditioning pump. The air conditioning is a high voltage system and needs to be treated as such when working on it. The air conditioning may be used to provide climate control for the battery as well Note – the jump points under the hood are designed to allow the trunk to be opened not to start the vehicle. NEVER use one of these vehicles to jump start another vehicle as the power spike may damage the sensitive electrics in the vehicle. Battery Management Controller This device monitors and controls the battery and determines the state of charge of the cells and other functions. It regulates the temperature and protects the cells against overcharging and deep discharge. Electronically activated switches are included that disconnect the battery system when idle and in critical situations such as an accident or fire. The device is usually part of the battery pack, but not always, so check the manufacturer’s data. . The inverter The inverter takes high voltage DC from the battery and converts it to higher voltage (three phase) AC to power the electric motor, and when the vehicle is slowing down (regen) it takes the AC power produced by the motor and changes it to DC to charge the battery The inverter also produces AC power to drive the air conditioning pump. The air conditioning is a high voltage system and needs to be treated as such when working on it. The air conditioning may be used to provide climate control for the battery as well the cabin, but this is all managed by the electronic control units and everything is run form the single pump and condenser. DC to DC converter This may be part of the inverter unit or a separate package. It is used to step down the high voltage to supply the 12-volt system because a normal alternator is not used in some configurations. On some systems, it can work in both directions. Some manufacturers split these components into two different devices, while others (Toyota for example) combine them into a single component. Inverter cooling system Due to the amount of heat generated by the inverter it has some form of cooling system. It can be air-cooled or water-cooled. The image shows the cooling system from a Toyota Prius inverter. What this means is there could be two or three separate cooling systems to service. The Prius has cooling for the engine and another system for the inverter. The Chevrolet Volt has three cooling systems – engine, inverter and battery. If the inverter is water cooled, the coolant used in these systems is a non- conductive coolant. Electric motors These are 3-phase AC motors and each motor has its own inverter. They contain powerful magnets, so if you ever expose the motors, keep other electrical devices such as phones and pacemakers (and your fingers) away. consulab.com info@consulab.com 27 EV-601-TS_053322-95 Module 1 — EV Components consulab.com info@consulab.com 27 Inverter Cooling System Due to the amount of heat generated by the inverter it has some form of cooling system. It can be air- cooled or water-cooled. The image shows the cooling system from a Toyota Prius inverter. What this means is there could be two or three separate cooling systems to service. The Prius has cooling for the engine and another system for the inverter. The Chevrolet Volt has three cooling systems – engine, inverter and battery. If the inverter is water cooled, the coolant used in these systems is a non-con- ductive coolant. Electric Motors These are 3-phase AC motors and each motor has its own inverter. They con- tain powerful magnets, so if you ever expose the motors, keep other electrical devices such as phones and pacemakers (and your fingers) away. These motors are very reliable and rarely fail, so do not expect significant sales demand for replacement components; but there will be demand from businesses convert- ing vehicles into electric power. If the motor is ‘Induction” it wont have perma- nent magnets inside where the permanent motor has neodymium magnets in the rotor section. Tesla Model 3 rear motor uses an Internal Permanent Magnet synchronous Induction Motor (IMPsyncIP Motor). Electric HVAC System HVAC (Heating, Ventilation and Air Conditioning): in many electric vehicles, the whole cabin heating system is powered by the high voltage system. When very cold, the cabin can be pre-conditioned while the vehicle is charging, meaning that Most EVs allow the operation of heating or cooling when the vehicle is plugged in and charging. This means that the driver can step into a vehicle that has already been de-frosted with the heated seats. Each electric motor has its own inverter. These motors are very reliable and rarely fail, so do not expect significant sales demand for replacement components; but there will be demand from businesses converting vehicles into electric power. If the motor is ‘Induction” it wont have permanent magnets inside where the permanent motor has neodymium magnets in the rotor section. Tesla Model 3 rear motor uses an Internal Permanent Magnet synchronous Induction Motor (IMPsyncIP Motor) Electric HVAC system HVAC (heating, ventilation and air conditioning): in many electric vehicles, the whole cabin heating system is powered by the high voltage system. When very cold, the cabin can be pre- conditioned while the vehicle is charging, meaning that Most EVs allow the operation of heating or cooling when the vehicle is plugged in and charging. This means that the driver can step into a vehicle that has already been de-frosted with the heated seats. The most important aspect is that this allows the vehicle cabin to be ‘pre-conditioned’ (heated or cooled), therefore saving battery capacity and increasing range. The most important aspect is that allows the vehicle cabin to be ‘pre-conditioned’ (heated or cooled), therefore saving battery capacity and increasing range. the cabin, but this is all managed by the electronic control units and everything is run form the single pump and condenser. DC to DC converter This may be part of the inverter unit or a separate package. It is used to step down the high voltage to supply the 12-volt system because a normal alternator is not used in some configurations. On some systems, it can work in both directions. Some manufacturers split these components into two different devices, while others (Toyota for example) combine them into a single component. Inverter cooling system Due to the amount of heat generated by the inverter it has some form of cooling system. It can be air-cooled or water-cooled. The image shows the cooling system from a Toyota Prius inverter. What this means is there could be two or three separate cooling systems to service. The Prius has cooling for the engine and another system for the inverter. The Chevrolet Volt has three cooling systems – engine, inverter and battery. If the inverter is water cooled, the coolant used in these systems is a non- conductive coolant. Electric motors These are 3-phase AC motors and each motor has its own inverter. They contain powerful magnets, so if you ever expose the motors, keep other electrical devices such as phones and pacemakers (and your fingers) away. the cabin, but this is all managed by the electronic control units and everything is run form the single pump and condenser. DC to DC converter This may be part of the inverter unit or a separate package. It is used to step down the high voltage to supply the 12-volt system because a normal alternator is not used in some configurations. On some systems, it can work in both directions. Some manufacturers split these components into two different devices, while others (Toyota for example) combine them into a single component. Inverter cooling system Due to the amount of heat generated by the inverter it has some form of cooling system. It can be air-cooled or water-cooled. The image shows the cooling system from a Toyota Prius inverter. What this means is there could be two or three separate cooling systems to service. The Prius has cooling for the engine and another system for the inverter. The Chevrolet Volt has three cooling systems – engine, inverter and battery. If the inverter is water cooled, the coolant used in these systems is a non- conductive coolant. Electric motors These are 3-phase AC motors and each motor has its own inverter. They contain powerful magnets, so if you ever expose the motors, keep other electrical devices such as phones and pacemakers (and your fingers) away. the cabin, but this is all managed by the electronic control units and everything is run form the single pump and condenser. DC to DC converter This may be part of the inverter unit or a separate package. It is used to step down the high voltage to supply the 12-volt system because a normal alternator is not used in some configurations. On some systems, it can work in both directions. Some manufacturers split these components into two different devices, while others (Toyota for example) combine them into a single component. Inverter cooling system Due to the amount of heat generated by the inverter it has some form of cooling system. It can be air-cooled or water-cooled. The image shows the cooling system from a Toyota Prius inverter. What this means is there could be two or three separate cooling systems to service. The Prius has cooling for the engine and another system for the inverter. The Chevrolet Volt has three cooling systems – engine, inverter and battery. If the inverter is water cooled, the coolant used in these systems is a non- conductive coolant. Electric motors These are 3-phase AC motors and each motor has its own inverter. They contain powerful magnets, so if you ever expose the motors, keep other electrical devices such as phones and pacemakers (and your fingers) away. Each electric motor has its own inverter. These motors are very reliable and rarely fail, so do not expect significant sales demand for replacement components; but there will be demand from businesses converting vehicles into electric power. If the motor is ‘Induction” it wont have permanent magnets inside where the permanent motor has neodymium magnets in the rotor section. Tesla Model 3 rear motor uses an Internal Permanent Magnet synchronous Induction Motor (IMPsyncIP Motor) Electric HVAC system HVAC (heating, ventilation and air conditioning): in many electric vehicles, the whole cabin heating system is powered by the high voltage system. When very cold, the cabin can be pre- conditioned while the vehicle is charging, meaning that Most EVs allow the operation of heating or cooling when the vehicle is plugged in and charging. This means that the driver can step into a vehicle that has already been de-frosted with the heated seats. The most important aspect is that this allows the vehicle cabin to be ‘pre-conditioned’ (heated or cooled), therefore saving battery capacity and increasing range. Each electric motor has its own inverter. consulab.com info@consulab.com 28 EV-601-TS_053322-95 Module 1 — EV Components The two most common HVAC systems allow: • Cooling with an electrically driven air conditioner compressor • Heating with a high-voltage positive temperature coefficient (PTC) heater These cooling and heating functions using the high-voltage components are usually activated with a timer or a remote app. Many hybrid car systems combine the heating circuit by running it in parallel to the coolant circuit. It consists of a heat exchanger, a heater unit, and a feed pump. Cabin cooling systems operate in much the same way as on a conventional vehicle except that the AC compressor is electrically driven. This can be by the high voltage or a lower voltage system such as 42-volt (but not normally from 12- volt). The system uses a POE based refrigerant oil. When necessary, the battery control unit can request cooling of the battery when it is being charged, so for this reason the battery cooling circuit, and in some cases the motor cooling circuit, are combined with the engine cooling system on a hybrid. The electric pump makes the coolant flow. Charger Unit This device is used on pure-EVs and PHEVs and is usually located near where the exter- nal power source is connected. It converts and controls the household voltage (typi- cally 120V AC in North America) to a suitable level for charging the battery cells (now usually about 400V DC). There are three levels of charging: • Level 1 and Level 2 are done both in car with the supply of ACV voltage that is converted to DC voltage. • Level 3 of Direct Current Fast Charging (DCFC) is done by direct power to the battery. As example, the Tesla Model 3 pure electric vehicle can be charged using: • Mobile Connector: Included with the vehicle. Allows the vehicle to be plugged into a 240 volt outlet or a 120 volt outlet. In 240V outlets, the maximum charge rate is 32A, or about 7.7 kW of charge power. • Wall Connector (WC): Wall Connector is the preferred method of charging when at home, providing high-power reliable charging. A Wall Connector is permanently installed on a 240 volt circuit. Model 3 accepts up to 48A when equipped with the Long Range Battery. This is about 11 kW of charge power. • Public Charging: J1772 adapters can be used to charge vehicles on public charging stations adhering to the SAE J1772 specification. • Supercharger: Tesla Superchargers are used to quickly recharge the HV battery on long trips. The vehicle charges up to 170 miles (long range battery) in 30 minutes. consulab.com info@consulab.com 29 EV-601-TS_053322-95 Module 1 — EV Components HVDC Relay The HVDC Relay, applied to an electric vehicle, is installed between the vehicle battery and the in- verter 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. Note: These vehicles can carry and store extremely high voltage – the battery and capacitors store high voltage everything else carries. Warning: 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. Display Panel and Driver Interface To keep the driver informed there are a number of methods used. Most common now is a touch screen interface where information can be presented as well as allowing the driver to change settings such as the charge rate on this PHEV. Ser- vicing and diagnosing EVs takes some time and experience to learn the different functions that the driver control center uses. It should be noted almost all EVs you can set time to charge, level of amps, and previous trips. 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 30 EV-601-TS_053322-95 Module 1 — Component Locations Component Locations Now that you’ve been introduced to the components of an EV, let’s look at where they are located. 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. High Voltage Battery The HV Battery 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 System 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. High Voltage Cables (orange) From the battery to the power systems normally run underneath the vehicle (in exactly the same manner as fuel lines) so be careful if lifting one of these vehicles with fork lift to make certain that the cables are not damaged. Inverter The inverter changes the electrical power from DC to AC. Location varies from one vehicle to another. Consult manufacturer’s data. Tesla Model 3 HV Battery Tesla Model 3 HV Battery Drain & Refill Tesla Model 3 Rear Drive Inverter consulab.com info@consulab.com 31 EV-601-TS_053322-95 Module 1 — Component Locations Electric Motor The electric motor sits between the engine and transmission on a hybrid vehicle. Locating the electric motors in the wheels creates more space for the HV battery, cargo or passenger cabin. 12-volt Battery The EVs still have a 12v system. It is needed for lights, wipers, in-car entertainment, and much more, including some safety systems. As mentioned previously, if the 12-volt battery goes dead, the vehicle will not start. You can jump-start an electric vehicle by connecting a jump pack to the battery and following manufacturer’s instructions to start the vehicle. The 12-volt battery also supplies power to the HV system relay so it can close and make the vehicle ready to drive. The “Ready” light on the driver dispay is usually a green car icon, and indicates that the vehicle is ready to drive. High voltage (orange) cables – from the battery to the power systems normally run underneath the vehicle (in exactly the same manner as fuel lines) so be careful if lifting one of these vehicles with fork lift to make certain that the cables are not damaged Inverter – changes the electrical power from DC to AC. Location varies from one vehicle to another. Consult manufacturer’s data. The electric motor sits between the engine and transmission on a hybrid vehicle. Above: Locating the electric motors in the wheels creates more space for the HV battery, cargo, or passenger cabin. Above: Volvo hybrid - overhead and side views that show the HV battery and power electrics (orange) 12-volt battery (yellow) to highlight the differing locations Tesla Model 3 12V / LV Battery consulab.com info@consulab.com 32 EV-601-TS_053322-95 Module 1 — SA-1 SA-1 Component #1 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 33 EV-601-TS_053322-95 Module 1 — SA-2 SA-2 Component #2 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 34 EV-601-TS_053322-95 Module 1 — SA-3 SA-3 Component #3 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 35 EV-601-TS_053322-95 Module 1 — SA-4 SA-4 Component #4 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 36 EV-601-TS_053322-95 Module 1 — SA-5 SA-5 Component #5 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 37 EV-601-TS_053322-95 Module 1 — SA-6 SA-6 Component #6 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 38 EV-601-TS_053322-95 Module 1 — SA-7 SA-7 Component #7 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 39 EV-601-TS_053322-95 Module 1 — SA-8 SA-8 Component #8 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 40 EV-601-TS_053322-95 Module 1 — SA-9 SA-9 Component #9 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 41 EV-601-TS_053322-95 Module 1 — SA-10 SA-10 Component #10 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 42 EV-601-TS_053322-95 Module 1 — SA-11 SA-11 Component #11 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 __________ You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 43 EV-601-TS_053322-95 Module 1 — SA-12 SA-12 Component #12 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 44 EV-601-TS_053322-95 Module 1 — SA-13 SA-13 Component #13 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 45 EV-601-TS_053322-95 Module 1 — SA-14 SA-14 Component #14 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 46 EV-601-TS_053322-95 Module 1 — SA-15 SA-15 Component #15 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 47 EV-601-TS_053322-95 Module 1 — SA-16 SA-16 Component #16 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 48 EV-601-TS_053322-95 Module 1 — SA-17 SA-17 Component #17 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 49 EV-601-TS_053322-95 Module 1 — SA-18 SA-18 Component #18 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 50 EV-601-TS_053322-95 Module 1 — SA-19 SA-19 Component #19 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________________ You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 51 EV-601-TS_053322-95 Module 1 — SA-20 SA-20 Component #20 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 52 EV-601-TS_053322-95 Module 1 — SA-21 SA-21 Component #21 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_____________________________________ You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 53 EV-601-TS_053322-95 Module 1 — SA-22 SA-22 Component #22 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 54 EV-601-TS_053322-95 Module 1 — SA-23 SA-23 Component #23 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 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 55 EV-601-TS_053322-95 Module 1 — SA-24 SA-24 Component #24 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 56 EV-601-TS_053322-95 Module 1 — SA-25 SA-25 Component #25 You should put your answers directly on this document. 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: 2. What is the component function? 3. High Voltage or Low Voltage? 4. Other names for component: 5. Component location: 6. Does the component store or carry HV (if applicable)? 7. Are their any identifiers that indicate what the component does? 8. Would this component cause the vehicle not to turn on (ready mode)? 9. Would this component prevent the vehicle from driving? 10. Is this component cooled by or heated by coolant? 11. Does the component have a “high voltage” warning sign or icon on it? Yes / No Explain: 12. Is the component HV DC or AC powered (2 or 3 leads on the cable)? Yes / No Explain: 13. Removing this component would it require disconnecting/disabling the HV system? Yes / No Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 57 EV-601-TS_053322-95 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 operation 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 58 EV-601-TS_053322-95 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. 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 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 59 EV-601-TS_053322-95 Module 1 — Power Flow 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. List in order of operaCon of each of the circles in the diagram consulab.com info@consulab.com 60 EV-601-TS_053322-95 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 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 operation) Note: Monitoring and Regulation happens throughout the voltage ramp-up process, the pre-charge circuit con- tinuously 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 incorpo- rate 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. 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 consulab.com info@consulab.com 61 EV-601-TS_053322-95 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 62 EV-601-TS_053322-95 Module 1 — SA-26 SA-26 Quiz on Power Flow — Answer Sheet 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 Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 63 EV-601-TS_053322-95 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 64 EV-601-TS_053322-95 Module 2 — High Voltage Battery Construction consulab.com info@consulab.com 64 High Voltage Battery Construction 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. 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 pos- itive and negative terminals initiates the flow of ions between the electrodes through a liquid electro- lyte 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. 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 65 EV-601-TS_053322-95 Module 2 — High Voltage Battery Construction HV Battery Types There are two types of High Voltage (HV) Batteries found in production vehicles: 1. Lithium Ion Battery (Li-ion) Made up of carbon and highly reactive lithium, these batteries store high amounts of energy. It is primarily used in BEV and PHEV vehicles because of the increased capacity. The complete battery pack is composed of several cell modules (the actual battery con- sists of several hundred to several thousand cells, a cooling system, insulation, junction box, battery management and a suitable case or shell.) The battery is usually installed in the underbody of the car. On a battery electric vehicle (BEV, also know as pure-electric vehicle, or PEV) it can weight in excess of 300kg (660lbs) and in the region of 120kg (265lbs) for a PHEV. Voltages vary and can be up to 800V; how- ever, typically this is around 400V. 2. Nickel Metal Hydride Battery (NiMH) This is the battery most hybrid (and mostly older) vehicles on the market use. The battery uses hydrogen to store ener- gy, plus nickel and another metal, such as titanium, to secure the hydrogen ions. 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 Battery Types There are two types of High Voltage (HV) Batteries found in production vehicles: Lithium Ion Battery (Li-ion) Made up of carbon and highly reactive lithium, these batteries store high amounts of energy. It is primarily used in BEV and PHEV vehicles because of the increased capacity. The complete battery pack is composed of several cell modules (the actual battery consists of several hundred to several thousand cells, a cooling system, insulation, junction box, battery management and a suitable case or shell.) The battery is usually installed in the underbody of the car. On a battery-electric vehicle (BEV, also know as pure-electric vehicle, or PEV) it can weight in excess of 300kg (660lbs) and in the region of 120kg (265lbs) for a PHEV. Voltages vary and can be up to 800V; however, typically this is around 400V. Battery Types There are two types of High Voltage (HV) Batteries found in production vehicles: Lithium Ion Battery (Li-ion) Made up of carbon and highly reactive lithium, these batteries store high amounts of energy. It is primarily used in BEV and PHEV vehicles because of the increased capacity. The complete battery pack is composed of several cell modules (the actual battery consists of several hundred to several thousand cells, a cooling system, insulation, junction box, battery management and a suitable case or shell.) The battery is usually installed in the underbody of the car. On a battery-electric vehicle (BEV, also know as pure-electric vehicle, or PEV) it can weight in excess of 300kg (660lbs) and in the region of 120kg (265lbs) for a PHEV. Voltages vary and can be up to 800V; however, typically this is around 400V. consulab.com info@consulab.com 66 EV-601-TS_053322-95 Module 2 — High Voltage Battery Construction 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. In addition to the HV battery, most EVs also come equipped with a regular 12-volt battery. To help preserve the charge in the HV battery, a 12-volt battery provides the power necessary to run auxiliary features such as lights, wipers and au- dio. It is important to keep an eye on the power of the 12-volt battery, as use of accessories while not driving the vehicle could cause the 12-volt battery to go flat. Note: The 12-volt battery supplies power to close the relay in the HV system and make the vehicle ready to drive. Note: The “Ready” light in the driver display is usually a green car icon and indicates that the vehicle is ready to drive. The composition of an electric vehicle (EV) battery might vary slightly depending on the types of electric vehicles, but generally, EV batteries are composed of cells, modules and a pack. See HV battery composition on Vimeo. consulab.com info@consulab.com 67 EV-601-TS_053322-95 Module 2 — High Voltage Safety Disconnects High Voltage Safety Disconnects Before starting any high voltage work its important to disable the vehicles high voltage system. Some of these switches cut direct current from the system and some break the power withing the internal battery dropping its voltages. Either way this is a very important part of High Voltage servicing and maintenance in some cases. The big question is when do I need to disable the high voltage disconnect? Answer is simple any time your working on a system or component that carries, stores or activates high voltage the system must be disabled. • Cuts direct power from HV battery to vehicle controllers. • Not all vehicles do this or have one (TESLA). • Can be used for resets and powering down a vehicle. • When working on or around HV systems. Disable Procedure Generic: Step 1 Turn off ignition and remove key from vehicle (lock box even better). Step 2 Create a identifier that High Voltage work is being preformed. Step 3 Remove the negative terminal of the battery and tape up or secure it. Step 4 Make sure any loose tools or nuts and bolts are stored. Step 5 Test your meter on a good known source 12 volt. Step 6 Remove any metal objects from your body (watches, rings). Step 7 Unlock the service plug using gloves and proper PPE. Step 8 Wait at least 10min for power to dissipate capacitors. Step 9 Using meter test terminals or component for voltage before proceeding Test – dead – Test method. High Voltage Safety Disconnects Before starting any high voltage work its important to disable the vehicles high voltage system. Some of these switches cut direct current from the system and some break the power withing the internal battery dropping its voltages. Either way this is a very important part of High Voltage servicing and maintenance in some cases. The big question is when do I need to disable the high voltage disconnect? Answer is simple any time your working on a system or component that carries, stores or activates high voltage the system must be disabled. • Cuts direct power from HV battery to vehicle controllers • Not all vehicles do this or have one (TESLA) • Can be used for resets and powering down a vehicle • When working on or around HV systems Disable procedure generic Step 1. Turn off ignition and remove key from vehicle (lock box even better) Step 2. Create a identifier that High Voltage work is being preformed Step 3. Remove the negative terminal of the battery and tape up or secure it Step 4. Make sure any loose tools or nuts and bolts are stored Step 5. Test your meter on a good known source 12 volt Step 6. Remove any metal objects from your body (watches, rings) Step 7. Unlock the service plug using gloves and proper PPE Step 8. Wait at least 10min for power to dissipate capacitors Step 9. Using meter test terminals or component for voltage before proceeding Test – dead – Test method consulab.com info@consulab.com 68 EV-601-TS_053322-95 Module 2 — High Voltage Battery Safety consulab.com info@consulab.com 68 High Voltage Battery Safety HV batteries have a safety label affixed to the case indicating the construction type of the battery. Nickel Metal Hydride Battery (NiMH) This is the battery most hybrid (and mostly older) vehicles on the market use. The battery uses hydrogen to store energy, plus nickel and another metal, such as titanium, to secure the hydrogen ions. In addition to the HV battery, most EVs also come equipped with a regular 12-volt battery. To help preserve the charge in the HV battery, a 12-volt battery provides the power necessary to run auxiliary features such as lights, wipers and audio. It is important to keep an eye on the power of the 12-volt battery, as use of accessories while not driving the vehicle could cause the 12-volt battery to go flat. The 12-volt battery supplies power to close the relay in the HV system and make the vehicle ready to drive. The “Ready” light in the driver display is usually a green car icon and indicates that the vehicle is ready to drive. The composition of an electric vehicle (EV) battery might vary slightly depending on the types of electric vehicles, but generally, EV batteries are composed of cells, modules and a pack. HV battery composition on Vimeo HV Battery Safety HV batteries have a safety label affixed to the case indicating the construction type of the battery. Li-ion batteries have greater risks than the NiMH batteries and therefore additional safety measures need to be followed when handling and storing them. You should consider the following when handling and storing HV batteries: • A relatively small fire source, such as a spark, is sufficient to start a lithium battery fire. • Batteries of the same type, but from different manufacturers, exhibit varying flammability characteristics. • Fully charged batteries can ignite more violently. • A Li-ion battery that has been excessively discharged is no longer usable, is more unstable and has a greater fire risk. Do not attempt to manually charge a battery that has been removed with external equipment. Only charge the battery through the vehicle’s charge port, and only if the vehicle is able to safely perform this. Warning: Do not work on an EV or PHEV while it is plugged in and charging. Batteries are in protective cases and even if the case is damaged, they will not leak a significant amount of electrolyte. Nickle-metal-hydride (NiMH) and lithium-ion (Li-ion) are dry cell batteries and will only produce a few drops per cell if crushed. Some models may leak battery coolant, and this should not be confused with electrolyte. In the unlikely event the electrolyte does leak, but if does it can be easily neutralized with a dilute boric acid solution or vinegar. When working on or near electric vehicles and high voltage batteries be aware of the following: • Most EVs have at least two batteries – the high voltage battery that supplies power to the electric motor and drive system, and a standard 12-volt battery that runs the vehicle’s low voltage systems. Li-ion batteries have greater risks than the NiMH batteries and therefore additional safety measures need to be followed when handling and storing them. You should consider the following when handling and storing HV batteries: • A relatively small fire source, such as a spark, is sufficient to start a lithium battery fire • Batteries of the same type, but from different manufacturers, exhibit varying flammability characteristics • Fully charged batteries can ignite more violently • A Li-ion battery that has been excessively discharged is no longer usable, is more unstable and has a greater fire risk Do not attempt to manually charge a battery that has been removed with external equipment. Only charge the battery through the vehicle’s charge port, and only if the vehicle is able to safely perform this. Do not work on an EV or PHEV while it is plugged in and charging. Batteries are in protective cases and even if the case is damaged, they will not leak a significant amount of electrolyte. Nickle-metal-hydride (NiMH) and lithium-ion (Li-ion) are dry cell batteries and will only produce a few drops per cell if crushed. Some models may leak battery coolant, and this should not be confused with electrolyte. In the unlikely event the electrolyte does leak, but if does it can be easily neutralized with a dilute boric acid solution or vinegar. When working on or near electric vehicles and high voltage batteries be aware of the following: Most EVs have at least two batteries – the high voltage battery that supplies power to the electric motor and drive system, and a standard 12-volt battery that runs the vehicle’s low voltage systems. consulab.com info@consulab.com 69 EV-601-TS_053322-95 Module 2 — High Voltage Battery Safety • High voltage (HV) systems typically produce 100-400 volts DC (but can produce up to 800 volts), enough to cause serious injury from direct contact with damaged high voltage components. • HV batteries are protected by the vehicle’s structure or enclosed in a metal case. • In hybrids (HEV), high voltage batteries are usually in the rear of the vehicle, typically in the trunk for passenger vehicles, or under the second-row seat for trucks and SUVs. Since BEVs require a larger battery capacity, in pas- senger vehicles they are typically found under the passenger compartment. • HV batteries are protected by the vehicle’s structure or enclosed in a metal case. • In Hybrids and BEVs the HV system is controlled by vehicle’s 12 volt or low volt system. In some EVs the high volt- age contactors (relays) close the moment the door is opened or when the key fob commands it (which can be from several meters away) and you should never assume the system is not energized. Note: Consult OEM Service Information to determine whether the system is powered up. • Otherwise, when the ignition is turned on, energizing the 12-volt system, it closes a relay in the HV battery, allowing the HV current to flow. When the 12-volt system is interrupted by turning off the ignition the relay opens and the HV system is shut down. In newer vehicles, shutting off the ignition also shuts down the 12-volt source to supplemental restraint systems, disabling the air bags. • After shutting down the HV system there may be residual power in the system capacitors until the energy dissi- pates. The same is true for airbags and other Supplemental Restraint System SRS components, which have their own capacitors independent of those in the HV system. • After the HV system has been shut off the airbags can still deploy, even after their capacitors drain down. For specif- ic details on how long it can take these systems to drain down refer to the OEM Emergency Response Guide (ERG). • Reconnecting the 12-volt power will reenergize the supplemental restraint systems. Warning: It is important to remember that even after the system has been shut down and the capacitors are drained the HV battery retains its charge. • In some cases the OEMs recommend disconnecting the vehicle’s HV electrical system by removing the High Voltage Service Disconnect. This is also referred to as a manual disconnect or service plug. • This disconnect (interlock) is most often located on the battery itself. Only a qualified technician should remove an interlock switch. • Remote operation keys that only need to be close to the vehicle for the ve- hicle to be powered up should be kept away from vehicles. This is to prevent the vehicle from accidentally moving. People who move these vehicles around the workplace should be aware that others may not hear it approaching them. Similarly, people who work around EVs should be aware that they may move without warning. Pressure washing has the potential to damage high voltage electrical components and cables. • The disconnect (interlock) is located on the battery itself. In some cases the OEMs recommend disconnecting the vehicle’s HV electrical system by removing the High Voltage Service Disconnect. This is also referred to as a manual disconnect or service plug. This disconnect (interlock) is most often located on the battery itself. Only a qualified technician should remove an interlock switch. Remote operation keys that only need to be close to the vehicle for the vehicle to be powered up should be kept away from vehicles. This is to prevent the vehicle from accidentally moving. People who move these vehicles around the workplace should be aware that others may not hear it approaching them. Similarly, people who work around EVs should be aware that they may move without warning. Pressure washing has the potential to damage high voltage electrical components and cables. The disconnect (interlock) is located on the battery itself. Electric Vehicle Safety Features In some cases the OEMs recommend disconnecting the vehicle’s HV electrical system by removing the High Voltage Service Disconnect. This is also referred to as a manual disconnect or service plug. This disconnect (interlock) is most often located on the battery itself. Only a qualified technician should remove an interlock switch. Remote operation keys that only need to be close to the vehicle for the vehicle to be powered up should be kept away from vehicles. This is to prevent the vehicle from accidentally moving. People who move these vehicles around the workplace should be aware that others may not hear it approaching them. Similarly, people who work around EVs should be aware that they may move without warning. Pressure washing has the potential to damage high voltage electrical components and cables. The disconnect (interlock) is located on the battery itself. Electric Vehicle Safety Features consulab.com info@consulab.com 70 EV-601-TS_053322-95 Module 2 — High Voltage Battery Safety Harmful substances released by a battery fire: • Hydrogen Fluoride • Phosphoric Acid • Oxyhydrogen • Toxic Metals • Nickel • Cobalt • Manganese • Lithium • Aluminium It is not just high voltage batteries that are hazardous. Many vehicles have multiple batteries in them, and they all need to be removed and recycled. In the image shown aside there is a 15.5-volt Li-ion battery from a vehicle, at the top there is an intact battery, below it is a similar unit that was in the vehicle when it went through the crusher. This could be the source of a major salvage yard fire. It may go bang when the vehicle is crushed, and it may just smoulder and start a fire a few hours later. By then the vehicle is underneath a pile of scrap vehicles! In the event of a fire, call 911 immediately. It can take approximately 2,500 gallons (10,000 litres) of water, applied directly to the battery, to fully extinguish and cool down a battery fire. Use full PPE and self-contained breathing appara- tus. Control the temperature of the battery for at least 1 hour after has cooled down. There is a risk that the battery will re-ignite. Class D fires involve combustible metals, such as magnesium, titanium, and sodium. Extinguishers with a D rating are designed to extinguish fires involving combustible metals. When encountering a fire with a lithium-metal battery, only use a Class D fire extinguisher. Lithium-ion batteries are different than a lithium metal battery. So using a dry chemical such as one found in a type D extinguisher wont work. Lithium -ion batteries don’t contain lithium metal and only the lithium salt or electrolyte is used. So, a Type B is a better extinguisher to use on a lithium- ion fire. This is important when working with High Voltage Lithium batteries is to know the type it is. Most batteries will be la- belled with the type of composition of the electrolyte in the module. Lithium-ion or Lithium Metal. If not sure, then having a ABC and type D extinguisher available will be important. Equipment Used for Working on High-Voltage Components It is the responsibility of the employer to ensure the right safety equipment is being used when working around and on BEV, PHEV, and hybrid vehicles. Electricians Safety Gloves – Class 0 (1000v) minimum Class 0 HV insulating gloves must be worn when working on HV vehicle components. These are the most important piece of safety equipment, these are what you are going to put your hands into and touch the vehicle with. It is imperative that these gloves are in good condition and are tested and checked EVERY time they are used. Lithium – Ion Batteries Lithium metal • Internal Short Circuit • Incorrect Handling • Overcharging • Deep Discharging • Water intrusion (flood and immersion) Vehicle fires do not necessarily occur more often in electric, or hybrid vehicles as compared to conventionally powered vehicles. But the effect of a high voltage battery catching fire can be significant. Fire services are advising that one electric vehicle fire could require 10,000 litres (2,500 gallons) of water. The reason is that once the fire has been put out, the battery needs to be cooled down for at least one hour. How quickly can this amount of water be brought to your site, and where will the water run off to? Harmful substances released by a battery fire • Hydrogen Fluoride • Phosphoric Acid • Oxyhydrogen • Toxic Metals • Nickel • Cobalt • Manganese • Lithium • Aluminium It is not just high voltage batteries that are hazardous. Many vehicles have multiple batteries in them, and they all need to be removed and recycled. In the image shown here there is a 15.5-volt Li-ion battery from a vehicle, at the top there is an intact battery, below it is a similar unit that was in the vehicle when it went through the crusher. This could be the source of a major salvage • Internal Short Circuit • Incorrect Handling • Overcharging • Deep Discharging • Water intrusion (flood and immersion) Vehicle fires do not necessarily occur more often in electric, or hybrid vehicles as compared to conventionally powered vehicles. But the effect of a high voltage battery catching fire can be significant. Fire services are advising that one electric vehicle fire could require 10,000 litres (2,500 gallons) of water. The reason is that once the fire has been put out, the battery needs to be cooled down for at least one hour. How quickly can this amount of water be brought to your site, and where will the water run off to? Harmful substances released by a battery fire • Hydrogen Fluoride • Phosphoric Acid • Oxyhydrogen • Toxic Metals • Nickel • Cobalt • Manganese • Lithium • Aluminium It is not just high voltage batteries that are hazardous. Many vehicles have multiple batteries in them, and they all need to be removed and recycled. In the image shown here there is a 15.5-volt Li-ion battery from a vehicle, at the top there is an intact battery, below it is a similar unit that was in the vehicle when it went through the crusher. This could be the source of a major salvage yard fire. It may go bang when the vehicle is crushed, and it may just smoulder and start a fire a few hours later. By then the vehicle is underneath a pile of scrap vehicles! In the event of a fire, call 911 immediately. It can take approximately 2,500 gallons (10,000 litres) of water, applied directly to the battery, to fully extinguish and cool down a battery fire. Use full PPE and self-contained breathing apparatus. Control the temperature of the battery for at least 1 hour after has cooled down. There is a risk that the battery will re-ignite. Class D fires involve combustible metals, such as magnesium, titanium, and sodium. Extinguishers with a D rating are designed to extinguish fires involving combustible metals. When encountering a fire with a lithium-metal battery, only use a Class D fire extinguisher. Lithium-ion batteries are different than a lithium metal battery. So using a dry chemical such as one found in a type D extinguisher wont work. Lithium - ion batteries don’t contain lithium metal and only the lithium salt or electrolyte is used. So, a Type B is a better extinguisher to use on a lithium- ion fire. This is important when working with High Voltage Lithium batteries is to know the type it is. Most batteries will be labelled with the type of composition of the electrolyte in the module. Lithium-ion or Lithium Metal. If not sure, then having a ABC and type D extinguisher available will be important. yard fire. It may go bang when the vehicle is crushed, and it may just smoulder and start a fire a few hours later. By then the vehicle is underneath a pile of scrap vehicles! In the event of a fire, call 911 immediately. It can take approximately 2,500 gallons (10,000 litres) of water, applied directly to the battery, to fully extinguish and cool down a battery fire. Use full PPE and self-contained breathing apparatus. Control the temperature of the battery for at least 1 hour after has cooled down. There is a risk that the battery will re-ignite. Class D fires involve combustible metals, such as magnesium, titanium, and sodium. Extinguishers with a D rating are designed to extinguish fires involving combustible metals. When encountering a fire with a lithium-metal battery, only use a Class D fire extinguisher. Lithium-ion batteries are different than a lithium metal battery. So using a dry chemical such as one found in a type D extinguisher wont work. Lithium - ion batteries don’t contain lithium metal and only the lithium salt or electrolyte is used. So, a Type B is a better extinguisher to use on a lithium- ion fire. This is important when working with High Voltage Lithium batteries is to know the type it is. Most batteries will be labelled with the type of composition of the electrolyte in the module. Lithium-ion or Lithium Metal. If not sure, then having a ABC and type D extinguisher available will be important. yard fire. It may go bang when the vehicle is crushed, and it may just smoulder and start a fire a few hours later. By then the vehicle is underneath a pile of scrap vehicles! In the event of a fire, call 911 immediately. It can take approximately 2,500 gallons (10,000 litres) of water, applied directly to the battery, to fully extinguish and cool down a battery fire. Use full PPE and self-contained breathing apparatus. Control the temperature of the battery for at least 1 hour after has cooled down. There is a risk that the battery will re-ignite. Class D fires involve combustible metals, such as magnesium, titanium, and sodium. Extinguishers with a D rating are designed to extinguish fires involving combustible metals. When encountering a fire with a lithium-metal battery, only use a Class D fire extinguisher. Lithium-ion batteries are different than a lithium metal battery. So using a dry chemical such as one found in a type D extinguisher wont work. Lithium - ion batteries don’t contain lithium metal and only the lithium salt or electrolyte is used. So, a Type B is a better extinguisher to use on a lithium- ion fire. This is important when working with High Voltage Lithium batteries is to know the type it is. Most batteries will be labelled with the type of composition of the electrolyte in the module. Lithium-ion or Lithium Metal. If not sure, then having a ABC and type D extinguisher available will be important. consulab.com info@consulab.com 71 EV-601-TS_053322-95 Module 2 — SA-27 SA-27 High Voltage Battery Specifications You should put your answers directly on this document. 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? volts 2. Is this AC or DC volts? 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? volts 5. Accelerating vehicle using the touch screen to 100 km/h (62 mph), what is the voltage at? 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? volts 7. What is the voltage at stop? volts 8. What did you observe that was different during deceleration to vehicle stopped? 9. Why did this happen? 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? ______ Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 72 EV-601-TS_053322-95 Module 2 — SA-28 SA-28 High Voltage Battery Modules You should put your answers directly on this document. 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? 2. What is the average voltage in each module? volts 3. Can you calculate how many cells are in each module if each battery cell is 4.00 volts? 4. Would you say this is capacity or potential of energy? 5. If I wanted to increase capacity, what would you have to do? 6. If I wanted to Increase Potential of energy, you would have to? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 73 EV-601-TS_053322-95 Module 2 — SA-29 SA-29 High Voltage Battery Configuration You should put your answers directly on this document. 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? 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? 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? 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 AC volts or DC volts? volts Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 74 EV-601-TS_053322-95 Student Learning Module 3 consulab.com info@consulab.com 74 Student Learning Module 3 EV Charging Systems and Drive Modes This section comprises assignments which are designed to consulab.com info@consulab.com 75 EV-601-TS_053322-95 Module 3 — EV Theory of Operation Electric Vehicle Theory of Operation An electric vehicle (EV) functions through a series of interconnected components designed to harness and utilize electri- cal energy for propulsion. At the core of this operation is the battery pack, a rechargeable energy storage unit typically using lithium-ion technology, which stores electrical energy in the form of direct current (DC). Charging the EV is facilitated through an external power source, such as electric charging stations, where the battery absorbs electrical energy. This energy, stored in the battery, is in DC form and needs to be converted into alternating current (AC) to power the electric motor. This conversion is achieved by a power inverter, a critical component that transforms the DC from the battery into the AC required for the electric motor’s operation. The electric motor, another central element, is responsible for converting electrical energy into mechanical energy to propel the vehicle. Known for its efficiency and immediate torque delivery, the electric motor contributes to the responsive and smooth acceleration characteristic of electric vehicles. In some cases, electric vehicles incorporate a transmission system, although many feature a single-speed transmis- sion due to the electric motor’s ability to function efficiently across various speeds. Additionally, electric vehicles are equipped with regenerative braking systems. When the driver applies the brakes, the electric motor transitions into a generator, converting kinetic energy back into electrical energy. This regenerative process enhances energy efficiency and extends the vehicle’s range. Coordinating these components is a sophisticated control system that manages the flow of electrical energy between the battery, inverter, and electric motor. This controller regulates power output based on driver input, ensuring optimal performance and efficiency. In summary, the operation of an electric vehicle involves storing energy in a battery, converting it to AC through a power inverter, and utilizing an electric motor for propulsion. Advanced technologies like regenerative braking and precise control systems contribute to the efficiency and sustainability of electric vehicles. consulab.com info@consulab.com 76 EV-601-TS_053322-95 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 facilitat- ed 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 com- mutes 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 char- gers”. 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 require- ments. 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 stan- dard. 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 longev- ity. 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 77 EV-601-TS_053322-95 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. Additionally, 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 78 EV-601-TS_053322-95 Module 3 — SA-30 SA-30 Opening the Charge Port You should put your answers directly on this document. 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 consulab.com info@consulab.com 79 EV-601-TS_053322-95 Module 3 — SA-30 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. 4. 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 screen to show charging selected the different types of charging on an 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 3 types of High Voltage battery charging? A. B. C. 7. Locate what components turn on and off during each level of charging ? A. B. C. D. E. consulab.com info@consulab.com 80 EV-601-TS_053322-95 Module 3 — SA-30 8. What is the difference between the different types of charging? A. B. C. D. 9. What is the voltage when Level 1 is plugged in and the cabin A/C cabin is set to cool? volts 10. Why is a difference when charging on level 1 with the A/C on? 11. What happens when you switch to Level 2 or DCFC charging? 12. Why is the charging not effected by these two? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 81 EV-601-TS_053322-95 Module 3 — SA-31 SA-31 Charging with Battery Temperature Hot You should put your answers directly on this document. 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. B. C. D. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 82 EV-601-TS_053322-95 Module 3 — SA-32 SA-32 Onboard Charger and How it Works You should put your answers directly on this document. 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. 1. What happens during level 1 and 2 charging for AC power flow?: A. B. C. D. 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 Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 83 EV-601-TS_053322-95 Module 3 — Drive Modes Drive modes 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 84 EV-601-TS_053322-95 Module 3 — SA-33 SA-33 Touchscreen Drive Mode A You should put your answers directly on this document. 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? 2. What is the battery voltage when the vehicle is at 0% charge? volts 3. What is the battery voltage when the vehicle is at 50% charge? volts 4. What is the battery voltage when the vehicle is at 100% charge? volts 5. In order to put the vehicle into drive what must be displayed on the dashboard? 6. Why is this mode (Icon) important in order to operate the drive function of the vehicle? 7. What checks are done to ensure the high voltage system is safe? 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______________ consulab.com info@consulab.com 85 EV-601-TS_053322-95 Module 3 — SA-33 9. What components are now ON? A. B. C. 10. What colour is the ready mode light? 11. What would prevent the “ready mode” from turning ON? 12. Now select the 0% charge what components are ON? A. B. C. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 86 EV-601-TS_053322-95 Module 3 — SA-34 SA-34 Touchscreen Drive Mode B You should put your answers directly on this document. 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? Hint: you can use Steady State to lock in the screen. Tip when locked at speed pressing the accelerator will re- veal the loaded voltage during acceleration. 4. Using the accelerator what is the battery voltage reading at 60 km/h (37 mph) ? volts 5. Using the accelerator what is the battery voltage reading at 100 km/h (62 mph) ? volts 6. Using the accelerator what is the battery voltage reading at 210 km/h (130 mph) ? volts 7. Now when releasing accelerator what happens to the voltage on deceleration? 8. What is this called? 9. Why does this happen? consulab.com info@consulab.com 87 EV-601-TS_053322-95 Module 3 — SA-34 10. What would prevent this from happening? A. B. C. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 88 EV-601-TS_053322-95 Module 3 — SA-35 SA-35 Watching the Power Drive to the Rear Drive Unit You should put your answers directly on this document. 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? 2. What happens when we accelerate the vehicle to 100 km/h (62 mph) ? 3. What happens when we let off the accelerator with the lights? 4. What is this called? 5. What effect would this have on a vehicle slowing down? 6. What is this effect used for? 7. How does the vehicle increase this effect while slowing down? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 89 EV-601-TS_053322-95 Module 4 — First Responder Training 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 90 EV-601-TS_053322-95 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 traditional vehi- cles 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 91 EV-601-TS_053322-95 Module 4 — First Responder Training 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, 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 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 elec- tric 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 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 92 EV-601-TS_053322-95 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 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 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 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. Most important part of the emergency response guides is general understanding and review of the important informa- tion. 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 consulab.com info@consulab.com 93 EV-601-TS_053322-95 Module 4 — First Responder Training 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 responder 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 consulab.com info@consulab.com 94 EV-601-TS_053322-95 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 95 EV-601-TS_053322-95 Module 4 — First Responder Loop First Responder Loop The first responders’ loop in an electric vehicle (EV) serves a crucial safety function by providing a dedicated means for emergency personnel to quickly and safely disable the high-voltage electrical system in the event of an accident or emergency situation. This loop is an integral part of the EV’s safety features and is designed to facilitate rapid response times during rescue operations. Technically, the first responders’ loop typically consists of a manual disconnect switch or a looped cable that is easily accessible from outside the vehicle, often located in an easily identifiable and standardized location. This switch or cable is directly connected to the high-voltage battery system, allowing emergency personnel to manually disconnect the power supply, isolating the high-voltage components to prevent electrical hazards. In the event of a collision or any situation requiring emergency intervention, first responders can use the loop to de-en- ergize the EV’s electrical system swiftly, ensuring the safety of both the occupants and the rescue personnel. This dedicated safety feature reflects the automotive industry’s commitment to addressing the unique challenges associated with high-voltage systems in electric vehicles and aims to provide a standardized and effective solution for emergency scenarios. The first responders’ loop enhances the overall safety profile of electric vehicles and supports the efficient handling of incidents involving these advanced automotive technologies. SA-36 First responders Loop function The first responders' loop in an electric vehicle (EV) serves a crucial safety function by providing a dedicated means for emergency personnel to quickly and safely disable the high- voltage electrical system in the event of an accident or emergency situation. This loop is an integral part of the EV's safety features and is designed to facilitate rapid response times during rescue operations. Technically, the first responders' loop typically consists of a manual disconnect switch or a looped cable that is easily accessible from outside the vehicle, often located in an easily identifiable and standardized location. This switch or cable is directly connected to the high-voltage battery system, allowing emergency personnel to manually disconnect the power supply, isolating the high-voltage components to prevent electrical hazards. In the event of a collision or any situation requiring emergency intervention, first responders can use the loop to de-energize the EV's electrical system swiftly, ensuring the safety of both the occupants and the rescue personnel. This dedicated safety feature reflects the automotive industry's commitment to addressing the unique challenges associated with high-voltage systems in electric vehicles and aims to provide a standardized and effective solution for emergency scenarios. The first responders' loop enhances the overall safety profile of electric vehicles and supports the efficient handling of incidents involving these advanced automotive technologies. FIRST RESPONDER LOOP SAFETY LABEL consulab.com info@consulab.com 96 EV-601-TS_053322-95 Module 4 — SA-36 SA-36 First Responder Loop Function You should put your answers directly on this document. Objective: To demonstrate the function of the first responder loops during an event that the high voltage system needs to be powered down. 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 responder on the EV-601? A. B. 3. What systems are affected by the unplugging of the first responder disconnect? 4. Why are some systems still active even with the loop unplugged? 5. What happens if the first responder loops are reconnected? 6. What must be done in order to restore the vehicle? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 97 EV-601-TS_053322-95 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 98 EV-601-TS_053322-95 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 99 EV-601-TS_053322-95 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 100 EV-601-TS_053322-95 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 101 EV-601-TS_053322-95 Module 4 — Quiz Answer Sheet Quiz on First Responder for EV-601 — Answer Sheet 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 Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 102 EV-601-TS_053322-95 Student Learning Module 5 Student Learning Module 5 Autopilot (ADAS) consulab.com info@consulab.com 103 EV-601-TS_053322-95 Module 5 — Autopilot (ADAS) Autopilot and Full Self-Driving Capability Autopilot is an advanced driver assistance system that enhances safety and convenience behind the wheel. When used properly, Autopilot reduces your overall workload as a driver. Each new Tesla vehicle is equipped with eight external cameras and powerful vision processing to provide an additional layer of safety. All vehicles built for the North Ameri- can market now use our camera-based Tesla Vision to deliver Autopilot features, rather than radar. Autopilot comes standard on every new Tesla. For owners who took delivery of their vehicle without Autopilot, there are multiple packages available for purchase, depending on when your vehicle was built: Autopilot, Enhanced Autopilot and Full Self-Driving Capability. Autopilot, Enhanced Autopilot and Full Self-Driving Capability are intended for use with a fully attentive driver, who has their hands on the wheel and is prepared to take over at any moment. While these features are designed to become more capable over time, the currently enabled features do not make the vehicle autonomous. Autopilot is a suite of driver assistance features that comes standard with the purchase of a new vehicle or can be purchased after delivery, and brings new functionality to your Tesla that makes driving safer and less stressful. Available packages include: Autopilot Autopilot includes the following functionality and features: • Traffic-Aware Cruise Control: Matches the speed of your vehicle to that of the surrounding traffic. • Autosteer: Assists in steering within a clearly marked lane, and uses traffic-aware cruise control. Enhanced Autopilot In addition to the functionality and features of Autopilot, Enhanced Autopilot also includes: • Navigate on Autopilot: Actively guides your vehicle from a highway’s on-ramp to off-ramp, including suggesting lane changes, navigating interchanges, automatically engaging the turn signal and taking the correct exit. • Auto Lane Change: Assists in moving to an adjacent lane on the highway when Autosteer is engaged. • Autopark: Helps automatically parallel or perpendicular park your vehicle, with a single touch. • Summon: Moves your vehicle in and out of a tight space using the mobile app or key. • Smart Summon: Your vehicle will navigate more complex environments and parking spaces, maneuvering around objects as necessary to come find you in a parking lot. consulab.com info@consulab.com 104 EV-601-TS_053322-95 Module 5 — Autopilot (ADAS) Full Self-Driving Capability Your vehicle will be able to drive itself almost anywhere with minimal driver intervention and will continuously improve. In addition to the functionality and features of Autopilot and Enhanced Autopilot, Full Self-Driving Capability also in- cludes: • Autosteer on City Streets. • Traffic and Stop Sign Control: Identifies stop signs and traffic lights and automatically slows your vehicle to a stop on approach, with your active supervision. The currently enabled Autopilot, Enhanced Autopilot and Full Self-Driving features require active driver supervision and do not make the vehicle autonomous. Full autonomy will be dependent on achieving reliability far in excess of human drivers as demonstrated by billions of miles of experience, as well as regulatory approval, which may take longer in some jurisdictions. As Tesla’s Autopilot, Enhanced Autopilot and Full Self-Driving capabilities evolve, your vehicle will be continuously upgraded through over-the-air software updates. Using Autopilot, Enhanced Autopilot and Full Self-Driving Capability Before using Autopilot, read your Owner’s Manual for instructions and more safety information. While using Autopilot, it is your responsibility to stay alert, keep your hands on the steering wheel at all times and maintain control of your vehicle. Many of our Autopilot features, like Autosteer, Navigate on Autopilot and Summon, are disabled by default. To enable them, you must go to the Autopilot Controls menu within the Settings tab and turn them on. Before enabling Autopilot, the driver first needs to agree to keep your hands on the steering wheel at all times and to always maintain control and responsibility for your vehicle. Subsequently, every time the driver engages Autopilot, they are shown a visual reminder to keep your hands on the wheel. Traffic-Aware Cruise Control To engage Traffic-Aware Cruise Control in Model S and Model X, pull down once on the cruise control stalk on the left of the steering column. In Model 3 and Model Y, pull down once on the gear selector stalk on the right of the steering column. Autosteer To engage Autosteer in Model S and Model X, pull towards you twice on the cruise control stalk on the left of the steer- ing column. In Model 3 and Model Y, pull down twice on the gear selector stalk on the right of the steering column. A grey steering wheel icon will appear on your display, next to the speedometer, when the system is available to engage. A blue steering wheel icon will appear on your display, next to the speedometer, when Autosteer is engaged. When Autosteer is in use, it measures the amount of torque that you apply to the steering wheel and, if insufficient torque is applied, an escalating series of audible and visual alerts again reminds you to place your hands on the wheel. This helps ensure you are attentive and trains good driving habits. If you repeatedly ignore these warnings, then you will be locked out from using Autopilot for the duration of that trip. consulab.com info@consulab.com 105 EV-601-TS_053322-95 Module 5 — Autopilot (ADAS) Navigate on Autopilot Navigate on Autopilot is designed to get you to your destination more efficiently by actively guiding your vehicle from on-ramp to off-ramp, including suggesting and making lane changes, navigating highway interchanges, and taking exits. It’s designed to make finding and following the most efficient path to your destination even easier on the highway when Autopilot is in use. To engage this feature, you must first enable Autosteer by going to Controls > Autopilot > Autosteer - then enable the Navigate on Autopilot feature. Camera calibration will be required and the latest version of Navigation maps must be downloaded via Wi-Fi. For each route where Navigate on Autopilot is available, you will have the option to activate it by pressing the NAVIGATE ON AUTOPILOT button located in your Navigation Turn List. You can also activate Navigate on Autopilot automatically any time a destination is entered and Autopilot is engaged by adjusting your Navigate on Autopilot settings from Controls > Autopilot > Customize Navigate on Autopilot. On Model 3, Navigate on Autopilot can be engaged on most highways by moving the gear lever twice downwards, in quick succession. Auto Lane Change To initiate an automated lane change, you must first enable Auto Lane Changes through the Autopilot Controls menu within the Settings tab. Then when the vehicle is in Autosteer, a driver must engage the turn signal in the direction that they would like to move. In some markets depending on local regulations, lane change confirmation can be turned off by accessing Controls > Autopilot > Customize Navigate on Autopilot and toggle ‘Lane Change Confirmation’ off. Autopark If your vehicle sees a parking spot, a grey ‘P’ icon will appear on the left or right hand side of your instrument panel, depending on the location of the space. Autopark detects parallel parking locations when driving below 24kph and per- pendicular parking locations when driving below 16kph. To use Autopark at that time, press on the brake and shift the gear selector into Reverse. Keep your foot on the brake. Start Autopark will appear in blue text on your touchscreen – press this to start the feature and release the brake and steering wheel. Autopark will then begin to maneuver the vehicle into the parking space by controlling your vehicle’s speed, gear changes and steering angle, but you should remember to be alert and monitor the backup camera view to check for obstacles. Once Autopark is complete, the vehicle will let you know it is complete and shift into Park. You can override Autopark at any time by taking control of the steering wheel. consulab.com info@consulab.com 106 EV-601-TS_053322-95 Module 5 — Autopilot (ADAS) Summon To use Summon, open the Tesla app. Press Summon and then press the forward or reverse buttons. Model S and Model X owners can use Summon with their key fob by holding the center of the key fob for three seconds until the vehicle’s hazard lights come on, and then pressing either the frunk or trunk button on key fob to Summon forwards and back- wards respectively. Summon also integrates with HomeLink and will open your garage door to pull your vehicle out of the garage. Smart Summon Smart Summon is designed to allow your vehicle to drive to you or a location of your choosing, maneuvering around and stopping for objects as necessary. Like Summon, Smart Summon is only intended for use in private parking lots and driveways. You are still responsible for your vehicle and must monitor it and its surroundings at all times and be within your line of sight because it may not detect all obstacles. Be especially careful around quick moving people, bicycles and vehicles. To use Smart Summon, open your Tesla app, tap Summon and then select the Smart Summon icon. To activate the fea- ture, press and hold the COME TO ME button. Alternatively, tap the target icon, set the target destination of your choice by adjusting the map, and then press and hold the GO TO TARGET button. You can stop your vehicle from driving at any time by releasing the button. Smart Summon works with your Tesla app and your phone’s GPS to operate. You must be within approximately 200 feet of your vehicle to use. Smart Summon requires the latest version of the Tesla mobile app (3.10.0 or later). Please refer to the Owner’s Manual for additional details about this feature. consulab.com info@consulab.com 107 EV-601-TS_053322-95 Module 5 — Autopilot (ADAS) Traffic Light and Stop Sign Control (Beta) Traffic Light and Stop Sign Control (Beta) identifies stop signs and traffic lights and automatically slows your vehicle to a stop upon approach while using Autopilot, with your active supervision. To enable, shift your vehicle into PARK and tap Controls > Autopilot > Traffic Light and Stop Sign Control (Beta), then engage Traffic-Aware Cruise Control or Autosteer. When Traffic Light and Stop Sign Control (Beta) is enabled, the driving visualization displays upcoming traffic lights, stop signs or road markings at intersections where your vehicle may need to stop. As you approach an intersection, even if the traffic light is green, your vehicle will display a red line to indicate where the vehicle will stop and the vehicle will begin to slow. To continue through the stop line, pull the Autopilot stalk or briefly tap the accelerator pedal to confirm that it is safe to proceed. At this time, Traffic Light and Stop Sign Control does not turn the vehicle, whether you are in a turn lane or have your blinker on. Notifications on the touchscreen will provide a stop reason (stop sign or traffic light) and will also provide an estimated distance to when your vehicle will stop. If the Traffic Light notification does not indicate a light color, your vehicle has not confirmed the traffic control state. As with all Autopilot features, you must be in control of your vehicle, pay attention to its surroundings and be ready to take immediate action including braking. This feature is in Beta and may not stop for all traffic controls. While Traffic and Stop Sign Control is enabled on surface streets with Autosteer active, your speed will be confined to the noted limit. Please review the Owner’s Manual for additional information, instructions for use and warnings. consulab.com info@consulab.com 108 EV-601-TS_053322-95 Module 5 — Autopilot (ADAS) Active Safety Features Active safety features come standard on all Tesla vehicles made after September 2014 for elevated protection at all times. These features are made possible by our Autopilot hardware and software system and include: • Automatic Emergency Braking: Detects cars or obstacles that the vehicle may impact and applies the brakes ac- cordingly. • Forward Collision Warning: Warns of impending collisions with slower moving or stationary vehicles. • Side Collision Warning: Warns of potential collisions with obstacles alongside the vehicle. • Obstacle Aware Acceleration: Automatically reduces acceleration when an obstacle is detected in front of your vehicle while driving at low speeds. • Blind Spot Monitoring: Warns when a vehicle or obstacle is detected when changing lanes. • Lane Departure Avoidance: Applies corrective steering to keep your vehicle in the intended lane. • Emergency Lane Departure Avoidance: Steers your vehicle back into the driving lane when it detects that your vehicle is departing its lane and there could be a collision Active safety features are designed to assist drivers, but cannot respond in every situation. It is your responsibility to stay alert, drive safely and be in control of your vehicle at all times. consulab.com info@consulab.com 109 EV-601-TS_053322-95 Module 5 — Student Assignments STUDENT ASSIGNMENTS FOR MODULE 5 COMING SOON consulab.com info@consulab.com 110 EV-601-TS_053322-95 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 111 EV-601-TS_053322-95 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 112 EV-601-TS_053322-95 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 113 EV-601-TS_053322-95 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. • Install the probes to the tester. Done consulab.com info@consulab.com 114 EV-601-TS_053322-95 Module 6 — Isolation Testing • 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. EV-601-TS_053322-95 Titre de la section consulab.com info@consulab.com 115 • 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. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 116 EV-601-TS_053322-95 Module 6 — SA-37 SA-37 A/C Compressor Testing – Component Side for Loss of Isolation (LOI) You should put your answers directly on this document. 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? volts 7. Where is the best place to put the insulation tester ground for testing? 8. Why is this important? 9. How long should you leave the test go for? seconds 10. What is the meter display value? megaohms 11. Is this within specification? Yes No 12. Before removing probe after testing what must you do? A. B. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 117 EV-601-TS_053322-95 Module 6 — SA-38 SA-38 PTC Heater Testing – Component Side for Loss of Iso- lation (LOI) You should put your answers directly on this document. 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? volts 7. Where is the best place to put the insulation tester ground for testing? 8. Why is this important? 9. How long should you leave the test go for? seconds 10. What is the meter display value? megaohms 11. Is this within specification? Yes No 12. Before removing probe after testing what must you do? A. B. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 118 EV-601-TS_053322-95 Module 6 — SA-39 SA-39 High Voltage Safety Fundamentals You should put your answers directly on this document. 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 Orange Red Brown 4. According to the EV Overview, what injuries could result from disassembling, removing or replacing high voltage parts or harnesses? 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 High Voltage Harness Power Delivery Module Traction Motor Traction Motor Inverter Service Plug consulab.com info@consulab.com 119 EV-601-TS_053322-95 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: ABC BC C 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? 8. When will the emergency shut-off system be activated and high voltage systems turned off? Check all that apply: Front/side collisions in which the air bags are deployed Certain rear collisions Certain EV system malfunctions Motor overheating Hard braking 9. The emergency shut-off system activates for what purpose? 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 On his/her person 13. What are you instructed to do to any high voltage connectors or terminals after disconnecting? 14. Why does the service manual direct you to put the service plug in your pocket or lock it in your tool box? 15. What does the service manual state are the risks if high voltage components and vehicle are mishandled? consulab.com info@consulab.com 120 EV-601-TS_053322-95 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 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? 18. What points does the service manual direct you to check before starting maintenance work? Check all that apply: Charge cable (including EVSE) is not connected Charge timer is not set Air conditioner timer is not set Maintenance reminder is set 19. How are hazardous high voltage devices and components identified? 20. Should a person who wears an electronic pacemaker or other medical electronics work on an electric vehicle? Check the correct answer: Yes 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: B. Magnetic recording media: 22. What must be posted to alert others that work is being performed on the high voltage system? 23. What type of personal protection equipment does the service manual indicate to use when working on high voltage systems? 24. What are the service manual instructions regarding a peeling or damaged high voltage label? 25. What should be done to the personal protection equipment daily and before and after every use? consulab.com info@consulab.com 121 EV-601-TS_053322-95 Module 6 — SA-39 26. What is being done in the graphics below? 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? volts 28. What are the dangers of using the tester incorrectly? 29. Before using the insulation tester how can the insolation tester be tested to ensure it is functioning correctly? 30. Should the insulation resistance tester be used on a 12 volt circuit? Check the correct answer: 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. 31. Refer to the Handling of Damaged Vehicles subsection. What is the required voltage rating for the insulated gloves? 32. If the vehicle must be scrapped for any reason, what must be done with the Lithium-ion battery? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 122 EV-601-TS_053322-95 Module 6 — SA-40 SA-40 Identifying High Voltage Components and Circuits You should put your answers directly on this document. 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? 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: Yes No 6. Note the high voltage warning label located on the power delivery module. What warning does it give? 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 No. If so, what does it indicate: consulab.com info@consulab.com 123 EV-601-TS_053322-95 Module 6 — SA-40 9. What would you say is the potential voltage at the terminals of ANY orange connector on this vehicle? volts 10. Replace the service plug access cover. 11. To which high-voltage components do they connect? 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. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 124 EV-601-TS_053322-95 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 125 EV-601-TS_053322-95 Certification Test High Voltage Safety Certification You should put your answers directly on this document. 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 integrity 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? 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: Yes No 5. 5. What point should be checked by ALL technicians before beginning any maintenance or repairs on an EV? consulab.com info@consulab.com 126 EV-601-TS_053322-95 Certification Test 6. Step 1 of the PROCEDURE FOR DISCONNECTING HIGH VOLTAGE is Turn power switch OFF. 7. What must be done with the key? 8. How long should you wait after the service plug is removed or power down is preformed? Check the correct answer: 2 minutes 5 minutes 10 minutes 30 minutes 9. What color are high voltage harnesses? Check the correct answer: Red Yellow Orange 10. What should be done immediately with disconnected high voltage connectors and terminals? 11. What should be done to the PROTECTIVE WEAR daily? 12. Why can an INSULATION RESISTANCE TESTER be dangerous? Check the correct answer: The probe tips are very sharp It applies 500 V or more to the circuit it is testing It contains alkaline electrolyte IIt weighs over 100 lb 13. Can an INSULATION RESISTANCE TEST be used to inspect a 12 V circuit? Check the correct answer: 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. 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 volt- age systems? Check the correct answer: Yes No See your instructor if any abnormal or unusual warning lamps are illuminated. consulab.com info@consulab.com 127 EV-601-TS_053322-95 Certification Test 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. 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? Date Inspected stamped? Do they need inspection? Yes No 21. What is the inspection period on new gloves unopened? 22. What is the inspection period on gloves after this date? 23. What must be done to test the Linesman’s gloves before use? 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 consulab.com info@consulab.com 128 EV-601-TS_053322-95 Certification Test • 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. 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: 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. consulab.com info@consulab.com 129 EV-601-TS_053322-95 Certification Test 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 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 • Traction: volts volts • DC/DC converter or PDM: volts volts • A/C compressor: volts volts • Inverter: volts volts • 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 consulab.com info@consulab.com 130 EV-601-TS_053322-95 Certification Test 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 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 Name : Group : Date : Instructor : Grade : EV-601-TS_053322-95 Titre de la section consulab.com info@consulab.com 131 Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. Tous droits réservés. Basics of EV’s Electric Vehicle Safety Features High Voltage Safety Hazards What is Arc Flash Safety High Voltage PPE High Voltage Components Common Electric Vehicle Terms STUDENT ASSIGNMENTS Student Learning Module 1 Component Identification Electric Vehicle Components Component Locations SA-1 Component #1 SA-2 Component #2 SA-3 Component #3 SA-4 Component #4 SA-5 Component #5 SA-6 Component #6 SA-7 Component #7 SA-8 Component #8 SA-9 Component #9 SA-10 Component #10 SA-11 Component #11 SA-12 Component #12 SA-13 Component #13 SA-14 Component #14 SA-15 Component #15 SA-16 Component #16 SA-17 Component #17 SA-18 Component #18 SA-19 Component #19 SA-20 Component #20 SA-21 Component #21 SA-22 Component #22 SA-23 Component #23 SA-24 Component #24 SA-25 Component #25 Power Flow of an Electric System SA-26 Quiz on Power Flow SA-26 Quiz on Power Flow — Answer Sheet Student Learning Module 2 High Voltage Battery Construction High Voltage Battery Construction High Voltage Safety Disconnects High Voltage Battery Safety SA-27 High Voltage Battery Specifications SA-28 High Voltage Battery Modules SA-29 High Voltage Battery Configuration Student Learning Module 3 EV Charging Systems and Drive Modes Electric Vehicle Theory of Operation EV Charging Systems SA-30 Opening the Charge Port SA-31 Charging with Battery Temperature Hot SA-32 Onboard Charger and How it Works Drive modes of the EV-601 SA-33 Touchscreen Drive Mode A SA-34 Touchscreen Drive Mode B SA-35 Watching the Power Drive to the Rear Drive Unit 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 Quiz on First Responder for EV-601 Quiz on First Responder for EV-601 — Answer Sheet Student Learning Module 5 Autopilot (ADAS) Autopilot and Full Self-Driving Capability STUDENT ASSIGNMENTS FOR MODULE 5 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) SA-38 PTC Heater Testing – Component Side for Loss of Isolation (LOI) SA-39 High Voltage Safety Fundamentals SA-40 Identifying High Voltage Components and Circuits High Voltage Safety Certification Testing Beta
