CarTrain "Diagnosis and Maintenance of a High Voltage Battery"

Unceasing advances in the development of hybrid and all-electric vehicle technology continue to pose new challenges for the automotive sector. The high-voltage (HV) battery has long been considered to be a “black box”. But now, more and more manufacturers are also venturing into repairing HV batteries.

This involves lots of challenges and requires a special understanding of “overall systems” in order for proper work to be possible. Our training system focuses on the digitally networked CAN-bus battery management system in a traction battery and on the corresponding components.

List of Articles

CarTrain "Diagnosis and Maintenance of a High Voltage Battery"

Unceasing advances in the development of hybrid and all-electric vehicle technology continue to pose new challenges for the automotive sector. The high-voltage (HV) battery has long been considered to be a “black box”. But now, more and more manufacturers are also venturing into repairing HV batteries.

This involves lots of challenges and requires a special understanding of “overall systems” in order for proper work to be possible. Our training system focuses on the digitally networked CAN-bus battery management system in a traction battery and on the corresponding components.

Particularly important here were the activities involved in the measuring and operational testing of HV components carrying a voltage. Practical and live exercises involving the measurement and diagnosis of battery cells are carried out. The HV battery is designed such that it can be taken apart to replace individual cells and sensors. This is how the trainee develops skills and practices diagnosing and maintaining the HV battery.

Scope of supply:

• CarTrain CO3221-6S “Diagnostics and maintenance of a high-voltage battery”
• Interactive course on CD-ROM with Labsoft browser, course software and additional virtual instruments
• Integrated diagnostic software

Digital measuring instruments:

• Digitally networked measurement capacity
• 4-channel oscilloscope
• Voltmeter
• Ammeter
• Double voltage meter
• Power meter

Training contents:

• Understand customer complaints, carry out operational testing and determine diagnostics approach
• Read out fault memory
• Evaluate work safety
• Check effectiveness of electrical safety measures on the high-voltage system
• Replace high-voltage components
• Become familiar with location of components in the motor vehicle
• Determine faults and their causes with the aid of circuit diagrams and function plans
• Draft an inspection protocol and document results
• Understand measures taken to avoid hazards caused by voltage isolation faults
• Learn about data communication between control units
• Recognise repair needs and carry out repair options
• Determine diagnostics and repair options based on a customer's job order
• Determine system operating states with the aid of the diagnostics systems, compare these to information in databases and evaluate results
• Measuring and testing systems
  • Determine the desired data
  • Select measurement procedure and measuring instruments
  • Document the measurement results
• Determine the measurement results, compare these to the desired data and evaluate
• Measure, check and evaluate signals at components and systems
• Measure, test and evaluate electrical connections
• Test high-voltage systems with diagnostics equipment, in particular perform measurements on isolation, equipotential bonding and voltage drops
• Analyze and evaluate messages in data bus systems
• Learn how battery cells are designed and function in the HV battery
• Learn how temperature sensors are designed and function in the HV battery
• Design and function of HV charging systems
• Advantages and disadvantages of individual HV charging systems
• Options to practically measure power consumption for different driving profiles
• Measuring voltage characteristics in HV batteries for different charging and discharging cycles
• How sensors and actuators interact
• IPO principle
• Open-loop control processes in the motor vehicle
• Closed-loop control processes in the motor vehicle
• Differences between open- and closed-loop processes

Components of the training-panel system:

• Mains power switch
• Emergency-stop safety switch
• Ignition switch
• Control unit BMS 1
• Control unit BMS 2
• Central control unit for BMS1 and BMS2
• Pre-charging and main relay with self-diagnostic function
• 16 battery modules, interchangeable, digitally encoded, including fault simulation circuits
• Active battery cooling
• 8 battery-temperature sensors, interchangeable
• Pilot line with diagnostics function
• Hall-effect current sensor for non-contact measurement of the charging and discharging processes
• Real battery cell balancing
• Selectable driving profile
  • Incline
  • Level
  • Coasting
  • Gradients with recuperation
  • Electrical braking with recuperation
• Visualised display of selected driving profile
• Low-voltage service disconnect
• High-voltage service disconnect
• HV protection for emergency services
• Combination instruments with
  • Power meter – power display
  • Speed indicator
  • Battery charge indicator
  • HV-ready and EPC warning light
  • Charging station control light
  • Warning light for power limitation
• Rotating drive gear
• Bidirectional power flow indicator between drive gear and HV battery
• Type 1 charging plug for AC charging
• CCS-type 2 rapid charging plug for DC and AC charging
• Charge buttons for controlling charge initiation
• Power flow visualisation from the charging plug to the HV battery
• 2-mm and 4-mm safety measurement sockets
• Removable complete battery cover
• Contact protection guards for battery cell terminals
• Digitally networked CAN-bus battery management system with measurement interface
• Test sockets for temperature sensors
• Test sockets for CAN-bus
• Test sockets for HV
• Test socket battery module 1
• Test socket battery module 2
• Test socket 12V
• Terminals for measuring equipotential bonding
• Terminal designations according to DIN 72552
• 46 fault simulation options
• USB connection socket

Supply voltage:

• 100-240 V AC 50-60 Hz

Operating voltage:

• 13.5V and 67V DC

Dimensions:

• 1010x320x805 (WxDxH)

Additionally Required

Cable Set for "CarTrain Diagnosis and Maintenance of a High Voltage Battery"

This set of 4-mm connecting leads has been specially assembled for the "CarTrain: Diagnostic and Repair of  High Voltage Batteries" training system. To this end, the individual colours and the lengths of the leads are designed to support the educational aim of the training system, making it easier to wire up the sensors, actuators and power supply. Each of the measurement leads and jumpers features a special, protected design, whereby it is not possible to make contact with any current-carrying components. To make it possible to carry out measurements without difficulty, all the connector plugs include a tap socket. For each of the leads and jumpers included in the set, there is also a spare. In detail, the following components are included in the set:

Connecting leads

• 4x 2mm safety measurement leads (yellow, 30 cm)

Measurement leads

• 4 x 4mm Safety measurement leads (red, 100 cm)
• 4 x 4mm Safety measurement leads (black, 100 cm)
• 1 x 4mm Connector plugs (red)
• 1 x 4mm Connector plugs  (brown)

Personal Protective Equipment (PPE) for Diagnostic Work on High-Voltage Vehicles

This set provides you with the optimum safety equipment for any type of work on hybrid or electric vehicles. The fact that all these products have been developed and manufactured in Germany means that they meet the highest safety standards and comply with all essential German standards.

The set comprises the following items:

• 1000 V electricians' safety helmet, "yellow" (DIN EN 397)
• 1000 V face protection screen (DIN EN 166)
• 1000 V electrical safety gloves, class 0
• Fabric liner gloves
• 1000 V insulating mat, 1000 x 1000 x 4 mm

1000 V Electricians' safety helmet, "yellow"  (DIN EN 397)

Light and modern protective helmet conforming to DIN EN 397, made of HDPE (high-density polyethylene) with air holes, electrically insulating for up to 440 V AC or 1000 V in conjunction with a face screen, extension to protect the neck, with hygienic terry sweat band, rain channel and slits in the side for attaching ear and face protection, ratchet head strap, 8-hole interior strap adjustment, for hat sizes 50-66 cm, 310 g. Supplied in signal yellow.

1000 V Face protection screen (DIN EN 166)

Compliant with DIN EN 166 for combination with Electricians' safety helmet, full protection against flame arcs, short-circuit arc flashovers, liquid splashes and other damage for the whole face including ears, colourless, transparent, lifting protective screen.

1000 V electrical safety gloves, class 0

Compliant with DIN EN 60903, with test stamp for work in voltage ranges up to 1000 V, made of natural latex, anatomically shaped, optimum flexibility.

Fabric liner gloves

Glove liners for absorbing skin moisture and for better ventilation when wearing electrical safety gloves, made of 100% cotton, unbleached and not dyed, elasticated, especially good for protecting sensitive skin.

1000 V insulating mat, 1000 x 1000 x 4 mm

Protective mats for electrical switching rooms, tested in accordance with DIN EN 61111, resistant against weather, ozone, light, acid, oil and fire (UL 94 V-0). Mats 3 mm thick possess a dielectric strength compliant with voltage protection class 0 (1000 V), made of grey polymer (Shore A hardness 65° approx.), rupture strength > 10 N/mm , elongation at breaking point > 600%, high-quality rough surface (ribbed) to prevent slipping, abrasive wear < 300 mm, temperature-resistant from –30 °C to +70 °C. Mats are free of nitrosamines and polycyclic aromatic hydrocarbons in compliance with EU 1272/2013.

Two-Pole Voltage Tester, 12-690V/AC/DC CAT III 690V, CAT IV 600V

This high-quality voltage tester provides the kind of fast test results you need in your daily work and includes large user-friendly buttons, background illumination and intuitive acoustic signalling and indicator display suitable for any working situation. The device has a robust and high-quality design for a long working life. This includes a sturdy, injection-moulded plastic housing, an extra-thick measurement lead including wear indicator, a solid battery casing as well as a tightly fitting safety guard for the measurement probe tips. It also complies with the latest European safety regulations according to EN 61243-3: 2010, which is the current and valid standard for this kind of testing device.

Furthermore, the voltage tester also includes a host of varied and simply understood signalling with four separate voltage indicators:  Clear representation of the status and measurement values via LEDs, measurement value indication on the well-lit digital display, continuity testing with acoustic signal or a vibration generator which provides a tactile feedback signal (vibrations generator in T110, T130, and T150). Depending on the situation you can select the most effective method available. The battery display keeps you informed in good time prior to the voltage level dropping below the permitted value. But the testing device can also detect the existence of voltage (>50 V AC, >120 V DC) even without batteries – an important safety feature. However, you should still always use the voltage tester with fully operational batteries. In rare cases, however, it could happen that the batteries fail and then this function is extremely useful to determine the presence of a voltage.

Technical data

• Voltage measurement range:  12 - 690 V/AC/DC 
• Frequency range: DC/40 - 400 Hz
• Protection class: IP64
• Measurement category: CAT III 690 V, CAT IV 600 V 
• Power supply: 2 micro cells (1.5 V IEC LR03 AAA)
• Calibration according to: ISO / DAkkS

Insulation and Electrical Resistance Meter (Automotive)

This meter for testing insulation and measuring resistance allows for standard-conformant testing of electrical systems, such as testing of insulation resistance for high-voltage systems in hybrid or electric vehicles. The meter has the following attributes to make it the best instrument for use with high voltages such as those present in the aforementioned vehicles. Safe and comfortable measurement of insulation resistance is made possible in particular by the switchable measuring probes.

Technical features

• Measurement of insulation resistance with test voltages of 50 V, 100 V, 250 V, 500 V and 1000 V (VDE 0413-2)
• Determination of polarisation index (PI) and dielectric absorption ratio (DAR)
• Selectable limits for ISO measurements, green LED for successful tests, red LED for test/external voltages
• Resistance measurement using 200 mA test current for testing protective earth connections (VDE 0413-4) complete with zero calibration for measurement leads.
• Switchable test probes for initiation of test procedures
• Internal memory for 100 measurement values per measurement function
• True RMS voltage measurement with low-pass filter
• Includes pouch, switchable test probes

Additionally Recommended

Safety Zone for CarTrain (Hybrid and Electric Vehicles)

This set gives you the option of setting up a complete safety zone for working with high-voltage hybrid and electric vehicles or their high-voltage batteries. Four securely free-standing poles with cordon straps allow you to set up a safety zone which meets the highest safety demands. Such a safety zone needs to be set up to secure high-voltage vehicles or their HV components and to protect trainees in laboratories or repair shops. For any work on a high-voltage battery it is essential for the area to be cordoned off. Setting up a safety zone is therefore an essential aspect of any training.

The cordon straps require no maintenance, are resistant to tearing and do not sag. This guarantees the highest level of safety and durability. The three magnetic roof pylons can be simply attached to the roof of a vehicle without any tools. Everything in the set is a certified and tested safety product.

Charging Station for PEV and PHEV

This charging station is extremely well suited to teaching trainees how HV battery charging works in a motor vehicle. The charging station can be used in conjunction with the CarTrain “Electromobility” or “Hybrid and all-electric vehicles” course as well as with the CarTrain course "Diagnostics and maintenance of a HV battery". The station may also be used without any restrictions on a real plug-in hybrid or electric vehicle. The charging station is equipped with a type-2 charge connector with a corresponding charge controller, which monitors the communication with the vehicle in terms of charge parameters according to IEC 61851. The charging station pole uses Mode 3 with a maximum charging current of 10 amperes.

Technical features

• Charge socket type 2 for Mode 3 – charging mode
• Safety cover for the charging socket
• Actuator as part of the charging socket for locking or releasing the connector plug inside the socket
• Contactor for disconnection of the charge terminal from the power grid
• Max. charge current 10 A
• Inputs and outputs: 4-mm safety sockets
• Internal auxiliary voltage 24V DC / 1A
• Voltage supply: 230V AC/50-60Hz

Type 2 - Charging Cable for HV Vehicles/CarTrain

Mobile AC charging cable with Vehicle Connector and Infrastructure plug for charging electric vehicles (EV) with alternating current (AC), via type 2 Vehicle Inlets, compatible with type 2 Infrastructure Socket Outlets at charging stations for E-Mobility (EVSE). It is also possible to use this charging cable in combination with our CarTrains for hybrid and electric vehicle.

Standard Group Lock Box for Lockout/Tagout (with 1 Padlock)

This lockable secure box gives you the option to keep keys and other items essential to security safe from unauthorised access. By using multiple padlocks (not included), it is even possible to arrange for multiple person protection. The box itself conforms to the highest standards of quality and can easily be moved thanks to its lightweight construction.

This box is ideal for preventing access to hybrid and electric vehicles in which the high-voltage system has been deactivated. Storing the key and the service/maintenance plug in here means that it is impossible for anyone to reactivate the HV system without authorisation.  

AVL Ditest HV Safety 2000

When carrying out measurements on vehicles using high-voltage systems, special requirements are set with regard to safety for measurement and testing. This is why we provide a high-voltage measuring system "HV Safety 2000" with a USB interface. It has been specifically developed for automotive requirements. It allows for high-voltage safety requirements to be maintained in repair workshops and for measurement procedures to be documented.

The following functions are included:

• Diagnostic and measurement procedures with built-in guidance
• Initialisation and self-testing
• Measurement confirming absence of power with thorough documentation
• Measurement of insulation resistance as per SAE J1766
• Voltmeter for up to 1000 V
• Equipotential bonding conforms to UNECE R100
• Measurement of resistance
• Diode testing
• Measurement of capacitance
• Calibrated for reproducible accuracy
• Power provided via USB port

Additionally required:

PC with up-to-date Windows operating system and two available USB-2 ports

Warning: The equipment is authorised exclusively for measurements on vehicles in conjunction with selected training systems, such as CarTrain CO3221-6K and CO3221-6D. Measurements on circuits connected directly to the mains are not permitted.

Accessories

SybaPro Mobile InsTrain/CarTrain Experiment Trolley, 1070x1350x700mm

The mobile aluminium-profile experiment trolley is specially designed to accommodate components of the InsTrain and CarTrain system. All the Ins-Train and CarTrain system components can be safely mounted in structured fashion for lessons from the front of a class or for students' own practicals. For students, this provides a modern, educationally designed workplace with a worktop and connections for multimedia.

• The mobile experiment stand is delivered in kit form and needs to be assembled by the customer
• Aluminium profile with integrated grooves for attaching a wide variety of components (e.g. PC and monitor-holders)
• 4 steerable double casters, 2 with brakes
• Worktop 1000 x 30 x 700 mm (WxHxD)
• Table top made of highly compressed multilayered chipboard conforming to DIN EN 438-1, light grey, with double-sided 0.8 mm slightly textured laminate coating (Resopal) in compliance with DIN 16926
• Table top bordered with solid, impact-resistant edging made of 3-mm thick plastic, colour RAL 7047
• Coating and adhesives must be PVC-free
• Power strip with 5-outlet sockets and power switch, lead and earthed plug
• Height of table top 830 mm
• Dimensions without CarTrain/InsTrain-System: 1070 x 1350 x 700 (WxHxD)
• Dimensions with CarTrain/InsTrain-System: 1070 x 1650 x 700 (WxHxD)

Monitor Holder for Flat Screen Monitor of Weight up to 15kg / 33lbs

Pivoting monitor holder for attachment to aluminium profiles of furniture in the SybaPro range. Allows a monitor to be placed in the optimum position so that work and experiments are less tiring.

• Pivoting arm with two-part joint
• Quick-lock for adjustment to any height on extruded aluminium profile
• VESA fastening 7.5 x 7.5cm
• Includes VESA 75 (7.5x7.5) - VESA 100 (10x10) adapter
• 2 Cable clips
• Adequate carrying capacity 15 kg / 33 lbs
• TFT monitor can be turned parallel to the table edge
• Separation can be adjusted to anywhere between 105 and 480 mm

Additionally included:

Cable management set for installing cables along the profiles of the aluminium lab system furniture in the SybaPro range, consisting of:

• 3 Cross cable blocks for front and rear grooves of aluminium profile
• 3 Cross cable blocks for side grooves of aluminium profile
• 12 Cable ties 
• 4 Aluminium cover profiles for covering and enabling wires to be run along the grooves of an aluminium profile

Protection Cover for CarTrain/InsTrain Experiment Trolleys

Dust cover for CarTrain/InsTrain experiment trolleys

• For protecting equipment from dust and damp
• For keeping equipment out of sight
• Colour: matt dark grey with printed LN logo in orange)
• Material: nylon fabric with polyurethane coating
• High resistant to tearing, impregnated to be washable and waterproof

Under-Table Cabinet, Suspended, 4 Drawers, Central Locking

• 1 Utensil drawer
• 1 Drawer, 2 HU
• 2 Drawers, 4 HU
• Usable width: 330mm, usable depth: 480 mm
• Central locking
• Metal drawers with surrounding row of slots
• Body made of 19 mm-thick, highly-compressed, multi-layered fine chipboard with grade E1 plastic coating on both sides
• Dimensions: 430 x 580 x 590 mm (WxDxH)

PC Holder for SybaPro Experiment Trolleys, Height/Width Adjustable

Shelf for desktop PC made of 2 mm sheet steel punched with holes, suitable for all furniture in the SybaPro aluminium profile range

• Adjustable assembly height
• for slim PCs, adjustable width (60 - 160 mm)
• with fastening and rubber stopper
• Can be mounted to left or right
• Includes all equipment necessary for assembly (4 bolts and 4 tenon blocks)
• Acid-resistant epoxy-resin powder coating, 80 µm thick approx., colour RAL7047