Cars Alternative Drives Manual Disable of The High-Voltage On-Board Electrical System and New High-Voltage Tests Fly Participant Document
Cars Alternative Drives Manual Disable of The High-Voltage On-Board Electrical System and New High-Voltage Tests Fly Participant Document
Cars Alternative Drives Manual Disable of The High-Voltage On-Board Electrical System and New High-Voltage Tests Fly Participant Document
T1192F
15.03.2017
This document is intended for training purposes only. The exercises performed in the course cannot simply be implemented
in practice without regard to various considerations. Country-specific laws, regulations and specifications must always be
observed.
The training documents are not subject to the ongoing update service. When working at the vehicle, always use the most up-
to-date workshop aids (e.g. EPC net, WIS net, DAS, special tools) provided by the manufacturer for the vehicle in question.
Printed in Germany
This document, including all its parts, is protected under the laws of copyright. Any commercial processing or use requires
the previous written consent of Daimler AG. This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including databases and online services.
Note: The term “employee” always refers to both male and female employees.
Table of conten
nts
1 Orienttation .................................................................................................................... 1
1.1 Welcome ................................................................................................................................... 1
1.2 Training agreement .................................................................................................................. 3
1 Orien
ntation
1..1 Welco
ome
Welcom
me to training
g course "Dissable power manually at the
t high-volttage on-board electrical
system and new higgh voltage tessts"
S 500 e P_08__30_206450_FA
GLE
E 500 e 4MATIIC TT_00_00_03924
45_FA
1..2 Train
ning agreeement
• Aggreed times are
a adhered tto
• Leet each otherr finish speakking
• Inttroduce expe
eriences on tthe topic
• Evveryone helpss to tidy up
• Haandle vehicle
es and tools ccarefully
• Mo
obile phone switched
s to m
mute or off
• Teeam work durring practica l work
• Addherence to the safety rules when working on n the high-vooltage on-bo
oard electriccal
syystem! If in doubt,
d pleasse ask your trainer!
• Th
he country-s
specific regu
ulations and
d rules must be observe
ved.
• On
nly the spec
cified speciaal tools and workshop equipment
e m
may be used.
• Th
he required protective eequipment must
m be worn.
2 Safety rules
2.1 Qualificcation con
ncept
The corresp ponding quallifications aree required ass a precondition for the m anual disable
e of the
high-voltagge on-board electrical
e systtem, the insu ance test andd the voltage proof test.
ulation resista
GTT_000284_enn
Training
course
Activities Work- High- High vooltage Highh volt- H
High volt- High voltage e
related voltage qualifica
ation age qualifi- agge qualifi- training, diss-
safety in- awarenesss withoutt cation with caation with able power
struction in productt prodduct p roduct manually
the com- training
g training trraining***
pany
P_08_
_00_002004_FA
Five safety
y rules whe
en dealing w
with high vo
oltage
For safely working
w on electrical
e sysstems, basic safety rules have been ddefined. Thesse generally
known and d applied five
e safety ruless are:
1. Remov ve voltage froom high-voltaage system
2. Prevennt from beingg switched on n again
3. Establish absence of voltage att the high-volltage system
4. Groundd and short-cirrcuit system ( not relevant in
n motor vehicles)
5. Shield or cordon off adjacent live parts (not releevant in vehicles)
Appliication of th
he safety ru
ules in motor vehicles
In thee automotive industry thee first three safety
s rules are
a applied!
The 7 high-voltage
h e safety meaasures in th
he vehicle
• COLOR
O CODING AND
A WARNING
G NOTICES
− Via triggering
V g of the pyrootechnical separators whiich are actuaated by the supple-
s
m
mental restraaint system ccontrol unit in
i the event of crash recoognition
− P
Power from all
a power souurces and sto
orage units is interruptedd by the conttactors
− Deactivation of alternatoor operation (both
D ( the electric machinne and the DC
C/DC con-
v
verter)
− D
Discharge off the intermeediate circuit capacitors below
b a hazaardous voltag
ge range
− A distinction is made bettween two sttages:
1. If only the seat belt tennsioners werre deployed, the high-volttage shutoff is reversi-
ble. When the ignition is switched offf and on again, the high-vvoltage on-bo
b oard electri-
c system iss started up aagain if no in
cal nsulation fault is present..
2 If the airbaags were als o deployed, the high-volttage shutoff is irreversible.
2.
• SHUT-OFF OF THE HIGH-VOLTAGE OON-BOARD ELEECTRICAL SYSTEM BY RESCUEE SERVICES, STTORAGE OF IN-
FORMA
ATION IN THE VEHICLE
V FOR REESCUE SERVICES
3 High--voltage connecction /5
N83/ Charger
4 Circuuit 30 9/1
N129 Power electronics contrrol unit
5 Insulaation monitorin
ng S7 High-volttage disconnectt device
F4
4 Fuse for DC/DC con
nverter (replace
eable) CP Control pilot
p
Fuse for high-voltage distributor pla
ate on power
F5
5 L Phases L1-L3
L
electronics control unit
u (replaceablle)
F6
6 Fuse for high-voltage battery (not replaceable)
r N Neutral conductor
c
F3
33 Batteery compartmen
nt prefuse box PE Protectivve earth conducctor
Implem
mentation in
n Mercedes--Benz workshops
Prerequuisites in Mercedes-Be nz worksho
ops for work
king on the hhigh-voltage
e vehicle
(high-v
voltage safetty precautioons):
• Traaining
− High-voltaage and prodduct qualificaation concep
pt with high-vvoltage aware eness trainin
ng
for workshop personnnel for workin ng with electtrical voltagees in the defin
ned high-
voltage raange and wit h the new teechnology in the vehicles
− High-voltaage awareneess training fo
or the workshop personnnel for general types of
work on the
t vehicle (aaccording to the qualifica
ation conceptt)
• Veehicle diagno
osis system (X nostics)
Xentry Diagn
− Check of all relevant ffeatures of th age status annd output of the current
he high-volta
high-voltaage status
− Printout of
o a power diisable event log after determining thee high-voltage status
− Provision of safety nootices throughout the diag
gnostic proceess
• orkshop Information (WIS
Wo S)
− Provision of safety nootices and reppair instructions for workk requiring th
he remov-
al/installaation or replaacement of one
o or more high-voltagee componentts
Worksh
hop operatio
ons on the h
high-voltage
e on-board electrical
e syystem (as pe
er AH54.00--P-
0010-0
01A)
For worrk on the high-voltage on--board electrical system,, the power ssupply must be disabled
and thiss must be de
etermined annd documented.
2.4 High-vo
oltage defiinition
Accordingg to ECE R 100,
1 the folllowing volta
ages are deffined as high
h voltages in
i the volt-
age class:
Direct volltage Alternating voltage
> 60 V DC > 30 V AC
≤ 1500 V DC
D ≤ 1,000 V AC
A
3 The three
t neew special proceesses on the high
h voltag
ge vehiclle
3..1 Disab
ble power manually
y at the hiigh-voltag
ge on-boar
ard electriical system
m
A Test adapte
er
Generaal descriptio
on of how too disable po
ower manua
ally
Manual power disab
bling was intrroduced in addition to the previous ddiagnosis-asssisted power
disable process.
Th
he difference to diagnossis-based po
ower disabling is the innterruption of the high--
vo
oltage on-bo
oard electriccal system with
w high vo oltage possiibly presentt at the sourrce.
Durin
ng the entire
e power dis able processs, no other persons maay be present in or at
the vehicle.
A 2-pole hiigh-impedan
nce voltage ttester must be
b used.
Personal protective
p equipment
e ( PSA)
Basic procedure
p off disabling p
power man
nually at the
e high-voltagge on-board
d electrical
system
m
To
o be perform
med if:
• Absence of voltage off the high-voltage on-board electrical system coulld not be cleaarly
establishe
ed and docum mented during diagnosis-based poweer disabling via
v XENTRY Di- D
agnosticss.
• An insulattion fault is ppresent.
Complete the log and pllace behind thhe windshield Following the
t restart proocedure of the e high-
up to the restart
r proced
dure voltage on--board electriccal system, file with repair
documenta ation
Insula
lation resistancce test of highh-
voltagge battery moodule TT_54_1
10_045083_FA
Insulatiion resistance test for defecct localization TT_08_00_031476_FA
5 Insulation monitorring
General description
d on
o the insullation resisttance test
In general, the insulatio
on resistancee is the ohmiic resistance
e portion amoong electricaal conduc-
tors or tow
wards the earrth potential or the vehicle ground.
In high-volttage systemss, the insulattion resistance of (HV+) or
o (HV-) to veehicle ground
d is meas-
ured in parrticular.
The value should be higher
h than 1 MΩ.
Insulation resistances
r can
c change aas a result off aging proceesses, humiddity, soiling, damage,
d ra-
d chemical or physical inffluences. If the changes lead to insulaation faults, fault cur-
diation and
rents can develop
d that are high enoough to damaage compone ents. This dooes not necessarily trig-
ger an overcurrent prottection equippment.
Gaalvanic sepa
aration
Veehicle-side insulation monnitoring takees place up to
o galvanic seeparation in the
t onboard
ch
harger. For a double isola tion fault, the fuse in the
e high-voltagee battery or in the corre-
sp
ponding high--voltage commponent is triiggered.
Fo
or the in-cable box, the RC
CD is triggerred and for a public chargging station, the RCD and
d
fusse are triggered.
Two pla
anned types
s of insulatiion resistance tests:
CONST
TANT AS REQ
QUIRED FOR DEFECT LOCALIZATION
1. Insu
ulation monittoring unit in the battery 2. Insulation resistaance test: EX
XTERNAL
manag gement systeem control un nit (BMS): IN--
TERNA AL
As partt of continuou
us monitoring, the insulation
n Measurring the insulaation resistancce with an insuu-
resistance is checkeed automatica lly in the BMSS. lation re
esistance meaasuring instrument
Carrying out
o the test on the HV DC on-board electrical system
Veehicle power disabled
d and system
s secureed against beiing switched
baack on
Prrocedure as per
p the WIS do
ocument for thhe respective vehicle
m
model designattion
HV
V connector disconnected
d from high-volttage battery
Seet insulation resistance
r measuring instruument to 500 V
Caarry out insu
ulation resistance measurrement at the
e test
ad
dapter and at the HV connector with sspecified value >1 MΩ
Innsulation resisstance measurrement at testt adapter
• Red female test connecto or (HV+) to brorown female te
est connect-
or (vehicle ground)
g
• Black femalle test connec ctor (HV-) to bbrown female test
t con-
nector (vehicle ground)
Innsulation resisstance measurrement at highh-voltage conn
nector
• Bush of HV connector (HV+) to groundd connection of o vehicle
• Bush of HV connector (HV-) to ground connection of vehicle
Paay attention to o DISCHARGING with the mmeasuring insttrument!
Procedure for defect loccaliza- D isconnect thee electrical con
nnectors of thhe individual HV
H compo-
tion neents one by one
AN
ND
Reepeat the meaasurement until the fault is localized.
2. Insulation
n resistance measurement
m d value >1 MΩ
with specified Ω
• L1 to PE
E
• N to PE
TT_08_00_031529_FA
Chargee socket • L2 to PE
E
Additio
onal with (3-p
phase) • L3 to PE
E
CHARG
GING CABLE without
w RCD Measuremeent as in 1. and 2.
General description
d on
o the voltaage proof tesst after the transmissio
t on repair
Transmission mod. dess. 724.2 is flaange-mounteed to the elec
ctric machinee.
6 External pla
ate carrier B1 15 Electric m
machine, rotor
Main transmission NAT-2FFE+ (mod. des.
7 16 Displacem
ment device
722.9)
8 Park pawl 17 Primary puump
After th
he completionn of the repaair, a voltage
e proof test and an insuulation test must be carr-
ried outt on the removed hybrid transmission.
TT_08_
_00_031759_FA
3.3..2 Voltag
ge proof tesster and sp
pecial tools
Voltagee proof testerr with extern al operating unit
TT_08_00
0_031473_FA
W000 589
5 00 21 00
0 break-out-bbox kit
TT_00_00_031 753_FA
TT_00_00_0317
754_FA
Preparatio
on
Setting up the test work
kstation Safety prec
cautions for seecuring area
• Secure ed • Test obbject on insulaated mat
• Non-stationary • Blocking off with barrricade tape
• Marking g using countrry-specific waarning and
informaation signs
Safety precautions Safety prec
cautions:
• Hybrid transmission unit is removeed!
• To be carried out afteer the comple
etion of re-
pair!
• Use only designated test adapters s and test
cables!
• Do not damage HV ccontacts!
• During the tests, all ppersons must remain out-
side the
e blocked off aarea!
Print out event
e log 1 form
Sample of
o operating insttructions TT_00_00
0_031756_FA
A n test equipmeent
Connector on
B Low voltage connector
c
C High voltage connector
Resolver resisstance, excitaation wind-
Pin 1-2
ing
Pin 3-4 Resolver resisstance, cos
Pin 5-6 Resolver resisstance, sin
Pin 7-8 Temperature sensor
Pin 9-
10
Interlock circuit
1. Test of interlock
i circu
uit in transmisssion Beforee the test, che
eck multimeteer and test cab
ble: Con-
using multtimeter: LV connector tacts short circuited
d, specified vaalue <1 Ω
Additional items to be teested: Test cable
c W724 5889 04 63 00 cconnected to removed
r
• The tem mperature sen nsor transm
mission LV plu
ug connectionn
• The ressolver resistan nce: Excitationn Use th
he multimeterr to carry out oohmic measurrements
windingg
Comppare measurem
ment values w
with the given specified
• The ressolver resistan nce with sin aand valuess
cos
2. Test of interlock
i using
g the test equuip- LV co
onnector NOT
T connected tto transmission
ment: HV connector
c Conneect HV connec
ctor to transm
mission
Conneect HV conne
ector/LV connnector test cable to test
equipm
ment
Switchh on test equipment and moonitor displayy. The inter-
lock circuit
c is check
ked.
SPECIIFIED VALUE: "Interlock oppen"
or message in test equipment "Teest not passed"
Switch
h off test equipment and keeep key in safe place.
Conne
ect LV conne
ector to transsmission
TT_08_00_03148
83_FA
Th
he test procedure is concludded when all test
t results aree
shown on the diisplay. These vvalues must be
b entered in
thee test log.
4 Practiccal block
k2
4.1 Instructtions - Prractical bllock 2
The trainerr introduces you
y to the 3 workstations:
• Manual power disabling of thee high-voltagee on-board electrical
e systtem on the GLE
G 500 e
4MATTIC
• insulaation resistan
nce test on t he S 500 e
• Voltagge proof testt on hybrid trransmission P2-20 (mode
el designatioon 724.2)
You familiaarize yourselff with the woorkstations.
• The trrainer showss you the speecial tools, workshop equ
uipment, worrk instruction
ns and test
logs needed
n for th
he tests.
• Note your findingss and any quuestions for the subseque
ent exchangee of informattion.
• The trrainer demon
nstrates the vvoltage proo
of test on hyb
brid transmisssion P2-20.
Exercise 2 Station 1:
Manual power disab
bling on the G LE 500 e 4MATIC
Exercise
E 3 Station 2:
Insulation resistance
r te
est on the S 500 e
Exercise 4 Station 3:
Voltagee proof test on
o P2-20 hybbrid transmission (mod. des. 724.2)
If you have questionns about the insulation reesistance tesst procedure,, please ask your trainer.. If
you havve technical questions
q abbout the insulation resista
ance test, pleease note them down in
your traaining docum
ment. The tecchnical questtions will then be discusssed during the post-
discusssion of practical block 2.
Exercise
E 7 Outline thee procedure for
f the insulaation resistan
nce test up to
t the high-vooltage distrib
butor in a
simplified flow
f chart.
If you have question ns about the voltage proo of test, please ask your trrainer. If you
u have techniical
questions about the e voltage pro of test, pleasse note themm in your trai ning docume ent. The tech
h-
nical quuestions will then be disccussed duringg the post-discussion of ppractical block 2.
5 List of question
ns
5.1 Questionnaire with
w respoonses
At the timee the training
g document iis created, th
he following information
i iis available:
Question
Q form
mulation Answeer Notes
May
M workshop employees caarry out simple Yes, as of 2014 certaain “simple ac ctivities ” AH54.00-P-0010-01A
acctivities such as driving or wheel
w change may alsso be performed on high-voltage ve-
without
w any speecial training?? hicles. TThe only cond
dition is a prevvious
“work-rrelated safety instruction” inn the
worksh op.
Where
W do I get the personal protective Please order your pro otective equip
pment on
eq
quipment (PSAA)? the freee market. The PSA includes an elec-
tric arc protection jacket, a face protection
(optionaally with helm
met) and protecctive
gloves ffor electrician
ns.
How do I know which PSA I have
h to get? Please get yourself a PSA that meets your AH54.00-P-0010-01A
specificc national requ
uirements. You can find and market in
nformation
the speecifications forr Germany in WIS.
W
How do I deal w
with a high voltage vehicle For howw to deal with a high-voltage vehicle SI54.10-P-00
035A
th
hat had an acccident? that hadd an accident, there is a Se
ervice In-
formati on
How do I diagnose the transport safety of a To anal yze the transpport safety, GS
SP pro- OF54.10-P- 3000-01Z
3 for
hiigh-voltage baattery? vides thhe "Analysis sheet for transport safe- model series 212, 221,
ty" in W
WIS. 222, 451
How do I deal w
with a high-voltage battery Due to the changing legislation on the sub- AH54.10-P-0006-01MEV
th
hat was found to be unsafe for transport?? ject of hhazardous maaterials transp port of Li-
ion battteries, the pro
ocesses used by Daim-
ler are cchanging as well.
w Please ob bserve the
processses prescribed d at the respective
point inn time, both in
n the workshop area as
well as in the logisticcs area. For cu
urrent in-
formati on, please seee WIS or the After-Sales
A
Portal ((Logistics->Reeturn shipment of HV
batteriees->Batteries unsafe for transport). In
the meaantime, alwayys contact the MPC that
is respoonsible for youu and leave thhe battery
in the vvehicle if possible
Which
W activitiess must be perrformed after The ins ulation resistaance and the electric
e For model series 213:
reemoving or insstalling the co
over of an elecc- resistannce of the inteerlock must be
e meas- AR08.10-P-00
004MRD
trric machine onn hybrid transmission 725.0 0? ured.
OF27.19-P-30
000-01A
AR08.10-P-00
004-01MRD