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Participant Document

T0001F
As at 02.05.2016
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

© 2016 Copyright Daimler AG

Publisher: Mercedes-Benz Global Training

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/or processing in electronic systems, including databases and online
services.

Note: The term “employee” always refers to both male and female employees.

1511 2994 - 3. Edition 02.05.2016 72

 Table of contents

Table of contents
1 Orientation ............................................................................................................ 1
1.1 Welcome ........................................................................................................................ 1
1.2 Training agreement ......................................................................................................... 2

2 Qualification concept ............................................................................................ 3

2.1 Training stages ............................................................................................................... 3

3 General design of different high-voltage vehicles .................................................. 7

3.1 General design of different high-voltage vehicles ............................................................ 7
3.2 Possible vehicle functions ............................................................................................... 12

4 High voltage .......................................................................................................... 13

4.1 Introductory exercise ...................................................................................................... 13
4.2 High voltage .................................................................................................................... 15
4.3 Definition of high voltage in the automotive field ............................................................ 16
4.4 Capacitor ....................................................................................................................... 19

5 Hazards of Electricity ............................................................................................ 21

5.1 Effects of electricity ........................................................................................................ 21
5.2 Current passing through the body ................................................................................... 22
5.3 Electric arcing ................................................................................................................ 25
5.4 Secondary effects ........................................................................................................... 26

6 First aid ................................................................................................................. 27

6.1 Legal background .......................................................................................................... 27
6.2 Rescue chain .................................................................................................................. 28
6.3 Action following an accident caused by electricity .......................................................... 29

7 High-voltage safety measures ............................................................................... 30

7.1 High-voltage safety measures ......................................................................................... 30
7.2 Prerequisites for working on high-voltage vehicles ......................................................... 33
7.3 Safety precautions in TN/IT networks ........................................................................... 34
7.4 High-voltage interlock .................................................................................................... 36

8 High-Voltage Components .................................................................................... 38

8.1 General ........................................................................................................................... 38
8.2 Battery types ................................................................................................................... 39
8.3 Lithium-ion battery ......................................................................................................... 41
8.4 Battery contactors .......................................................................................................... 43
8.5 Handling high-voltage batteries ..................................................................................... 45
8.6 High-voltage charger ...................................................................................................... 47

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Table of contents

9 Information unit on electric machines .................................................................. 52

9.1 Direct-current machine ................................................................................................... 52
9.2 Alternating-current machine .......................................................................................... 56

10 Power electronics ................................................................................................. 58

10.1 Power electronics .......................................................................................................... 58

11 DC/DC converter ................................................................................................. 61

11.1 DC/DC converter ........................................................................................................... 61

12 High-voltage power disconnect ............................................................................. 62

12.1 High-voltage power disconnect on the vehicle, general ................................................. 62

13 Basic legal principles ............................................................................................ 63

13.1 Regulations and guidelines ............................................................................................. 63
13.2 Legal consequences ....................................................................................................... 65

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 Orientation 1
Welcome 1.1

1 Orientation
1.1 Welcome
Welcome to the High-Voltage Training for Motor Vehicles.

The successful completion of this high-voltage qualification for motor vehicles is a

mandatory prerequisite for participating in a high-voltage product training course. Af‐
ter you have completed both qualifications, you are permitted to disconnect power
from a series production vehicle with a high-voltage label.

Installation locations of high-voltage components TT_00_00_041549_FA

Learning objectives of the training course

The participant can …
• carry out tasks on the high-voltage system in a safe and aware manner.
• explain the concept of high-voltage and general technical information related to
the high-voltage components.
• explain technical responsibility.
• explain the three steps for disconnecting power.
• understand the legal background as well as BGV [regulations of the statutory in‐
dustrial accident insurance institutions in Germany] A3, VDE 0105 100 and
DGUV 200-005.
• explain the safety measures on the vehicle.
• perform first aid.
Key questions for the introduction round
• Who am I (name)?
• Which operation do I work for?
• What are my tasks at work?

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1 Orientation
1.2 Training agreement

• When did I finish my vocational training?

• What are my expectations of the training?

1.2 Training agreement

• Adhere to agreed times
• Let each other finish speaking
• Introduce experiences on the topic
• Everyone help to tidy up
• Handle vehicles and tools carefully
• Mobile phone switched off or muted
• Adherence to the safety rules when working on the high-voltage vehicle
• The country-specific regulations and rules must be observed

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 Qualification concept 2
Training stages 2.1

2 Qualification concept
2.1 Training stages
The following figure displays the training stages to become an "Expert for work on an
intrinsically safe high-voltage series production vehicle". The training takes place in
multiple stages. During high-voltage awareness training, you are made aware of the
dangers associated with a high-voltage on-board electrical system. During the high-
voltage qualification, your are provided with information on the dangers of electric
current, first aid measures, as well as basic information on high-voltage components.
The high-voltage awareness training and high-voltage qualification is valid for all model
series and categories.

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4
2
2.1
Training stages
Qualification concept

* Employees with high voltage awareness training may remove/install high-voltage components on a high-voltage vehicle where voltage was removed TT_00_00_038606_FA

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 Qualification concept 2
Training stages 2.1

Notes on the training concept:

• Work outside the high-voltage system may be performed by electrotechnical
laypersons who have completed the high-voltage awareness training.
• Work on the high-voltage system may be carried out by certified motor vehi‐
cle technicians, electricians, and mechatronic engineers (trained after 1973)
with the completion of additional training (high-voltage training and high-
voltage product training).
• Work on the high voltage system may be performed by body technicians and
vehicle construction technicians, or mechatronic engineers specialized in
bodywork repairs (trained after 2002) with the completion of additional
training (high voltage training and high voltage product training).

2.1.1 Activities and qualification

The table below explains which qualification is required for the defined activities.

Tasks in the workshop area

Qualification Work-related HV awareness HV qualification HV qualification HV training,
safety instruc‐ without product with product manual disa‐
tion training training bling
Activities
"Simple" activi‐ X X X X X
ties outside the
HV system,e.g.
operation, check‐
ing workshop
equipment, start‐
ing assistance
- General repairs -- X X X X
on the HV vehicle
- Working on the
disabled HV sys‐
tem
No activity: -- -- X X X
Intermediate
stage - prerequi‐
site for product
training
Diagnosis-based -- -- -- X (x*)
disabling of vehi‐
cle
- Manual disa‐ -- -- -- -- x**
bling
- insulation resist‐
ance testing
- voltage proof
test

* Diagnosis-based disabling allowed, if product training for specific vehicle has been
completed, attempt to perform diagnosis-based disabling must always take place be‐
fore manual disabling.
** Manual disabling for high-voltage series production vehicles (no metropolitan con‐
cepts) allowed (in accordance with WIS specification).

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2 Qualification concept
2.1 Training stages

Simple tasks
The employees must be instructed in the dealership within the scope of a work-related
safety instruction for carrying out "simple" tasks. This training includes the special
considerations, dangers, safety precautions and rules of conduct in connection with
the high-voltage-on board electrical system.
Simple tasks are:
• Operation (driving, fueling/loading, cleaning)
• Tires (checking condition, changing)
• Checking/refilling coolant, washer fluid, oil
• Changing wiper blades/adjusting spray nozzle
• Charging 12 V battery, checking/changing 12 V fuses
• Jump starting
• Reading out diagnosis (actual value/quick test)
• Retrofitting accessories (without WIS description)
• Vehicle reception, including checking of pending service measures
• Explanation of vehicle-specific functions (in the event of sales/vehicle delivery)
The basis is WIS document AH54.00-P-0010-01A.

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 General design of different high-voltage vehicles 3
General design of different high-voltage vehicles 3.1

3 General design of different high-voltage vehicles

3.1 General design of different high-voltage vehicles

Exercise 1 What is a hybrid vehicle?

Exercise 2 The trainer will divide you into three groups. Each group will work on a solution to one
of the following exercises. The solution will then be discussed in the larger group.
Group 1

Use the cards/vehicle components on the pin board to sketch a vehicle with a serial
hybrid drive. Next, allocate the functions (e.g., electric driving) made possible by the
system to the vehicle.

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3 General design of different high-voltage vehicles
3.1 General design of different high-voltage vehicles

Exercise 3 Group 2

Use the cards/vehicle components on the pin board to sketch a vehicle with a parallel
hybrid drive. Next, allocate the functions (e.g., electr. driving) made possible by the
system to the vehicle.

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 General design of different high-voltage vehicles 3
General design of different high-voltage vehicles 3.1

Exercise 4 Group 3

Use the cards/vehicle components on the pin board to sketch a vehicle with an elec-
tric drive. Next, allocate the functions (e.g., electr. driving) made possible by the sys‐
tem to the vehicle.

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3 General design of different high-voltage vehicles
3.1 General design of different high-voltage vehicles

Exercise 5 Other hybrid concepts

A range extender additionally has an internal combustion engine tasked only with
charging the battery. A range extender is not a hybrid vehicle.

In addition to the above concepts, the power-split hybrid drive is a further variant. This
combines the parallel and serial drive concept.

Range extender TT_00_00_024990_FA

1 Internal combustion engine 5 Power electronics

2 Generator (sun gear) 6 High-voltage battery
3 Planet carrier 7 Fuel tank
4 Electric motor (annulus gear)

In the PLUG-IN-HYBRID, the high-voltage battery can also be recharged via a high-volt‐
age charger integrated in the vehicle.

Plug-in-Hybrid TT_00_00_024992_FA

1 Internal combustion engine 4 High-voltage charger

2 Generator/engine 5 High-voltage battery
3 Power electronics 6 Fuel tank

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 General design of different high-voltage vehicles 3
General design of different high-voltage vehicles 3.1

Complete the legend for the vehicle with range extender.

Range extender TT_00_00_024991_FA

1 4

2 5
3 6

Hybrid systems can also be classified based on the complexity of hybridization:

• Micro hybrid
– Start/Stop function
• Mild hybrid:
– Start/Stop function
– Boosting
– Regenerative braking
• Full hybrid
– Start/Stop function
– Boosting
– Regenerative braking
– Electric driving

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3 General design of different high-voltage vehicles
3.2 Possible vehicle functions

3.2 Possible vehicle functions

Diagram Functions
Engine stop and engine start
• Automatic shutoff of combustion engine at
standstill or if speed drops below a minimum
value
• Automatic starting of the combustion engine
when the accelerator pedal is operated, the
brake pedal is released or the high-voltage bat‐
tery's charge level drops below a minimum val‐
ue. Either via a conventional starter or via the
electric motor
Regenerative braking
• The electric machine operates as an alternator
and charges the high-voltage battery. The vehi‐
cle is decelerated by the alternator.

TT_08_30_008983_FA

Boosting
• Support for combustion engine when driving
off or accelerating
• Improvement in torque at low combustion en‐
gine speeds
TT_08_30_008984_FA

Electric driving
• Drive exclusively by the electric motor
• Internal combustion engine shutoff

TT_08_30_008985_FA

Load-free rolling
• Propulsion via the electric machine, only to
compensate for the deceleration via air and
rolling resistance

TT_08_30_008985_FA

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 High voltage 4
Introductory exercise 4.1

4 High voltage
4.1 Introductory exercise

TT_08_00_009561_SW
TT_54_00_024996_FA

G1 180 V
G2 180 V
R1 5Ω
R2 7.5 Ω
R3 15 Ω

TT_54_00_024997_FA

Exercise 6 Calculate Rtot , Itot and Ptot, when S2 and S3 are closed.

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4 High voltage
4.1 Introductory exercise

Exercise 7 Calculate Rtot , Itot and Ptot, when S1 and S3 are closed.

TT_08_00_009561_SW

G1 180 V R2 7.5 Ω
G2 180 V R3 15 Ω
R1 5Ω

Rtot:

TT_08_00_009572_SW

Itot:

TT_08_00_009573_SW

Ptot:

TT_08_00_009574_SW

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 High voltage 4
High voltage 4.2

4.2 High voltage

The smart fortwo electric drive (model series 451) has a 35 kW electric motor as the
source of power.

TT_08_00_024998_SW

Exercise 8 What current would flow if the smart fortwo electric drive would have a 12 V battery
instead of a high-voltage battery?

Exercise 9 What do you have to do to keep the line cross-section as small as possible? Use the
diagram to find the answer!

TT_08_00_008909_SW

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4 High voltage
4.3 Definition of high voltage in the automotive field

4.3 Definition of high voltage in the automotive field

The ECE R 100 standard defines high voltages as follows:
• DC > 60 volts ≤ 1,500 volts
• AC > 30 volts ≤ 1,000 volts

Exercise 10 Draw in the specified voltages in the diagrams below!

DC = 60 volts

TT_08_00_024999_SW

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 High voltage 4
Definition of high voltage in the automotive field 4.3

Exercise 11 Draw in the specified voltages in the diagrams below!

AC = 30 volts

TT_08_00_025000_SW

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4 High voltage
4.3 Definition of high voltage in the automotive field

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 High voltage 4
Capacitor 4.4

4.4 Capacitor
Each capacitor consists of two metallic surfaces. An insulating material, the dielectric,
is situated between them. The capacitor stores an electric charge (energy) between
the two surfaces.

4.4.1 Charging process of the capacitor

TT_08_00_009782_FA

When the capacitor is switched on, the current jumps from zero to the maximum val‐
ue. From this point on, the current is steadily reduced according to an electrical func‐
tion. The voltage source attracts the electrons from the upper capacitor surface and
presses them towards the lower capacitor surface. This process charges the capaci‐
tor. While the current steadily decreases to zero, the voltage increases from zero to
the maximum value. The higher the voltage, the higher the resistance of the capacitor.
Once capacitor voltage UC has reached charging voltage Utot, current ceases to flow
and the capacitor resistance becomes infinite. The capacitor functions as a lock for
the direct current.

4.4.2 Discharging the capacitor

TT_08_00_009783_FA

The capacitor acts as a voltage source with a low internal resistance. From the time of
discharge, the voltage decreases from its maximum value to zero. The current
changes its direction of flow (polarity) and decreases from its maximum value to zero.
In other words, it flows opposite to the charging current.
Voltage UC behaves in the same way as the current. It sinks from the maximum value
down to zero. The polarity remains unchanged. From the point when the current
ceases to flow, the capacitor is discharged (five time constants).

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4 High voltage
4.4 Capacitor

4.4.3 The capacitor as energy storage unit

There are capacitors within a high-voltage system, among other things in the power
electronics, the high-voltage charger and the DC/DC converter. Residual energy may
remain in these capacitors due to malfunctions.

This leads to an abort of the routine during a diagnosis-based power disconnect.

A voltage value > 60 volts is displayed.

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 Hazards of Electricity 5
Effects of electricity 5.1

5 Hazards of Electricity
5.1 Effects of electricity
The following effects of electricity can lead to human injuries:
• The effect of an electric shock (current passes through body)
• Electric arcing
• Secondary effects

TT_08_00_008870_SW

1 Pain 3 Circulation problems

2 Muscle cramps 4 Fibrillation of the heart

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5 Hazards of Electricity
5.2 Current passing through the body

5.2 Current passing through the body

The effect of an electric shock on a person depends on:
• Type of current
• Amperage
• Length of exposure
• Path of current through body
• Frequency

5.2.1 Body's resistance and currents through a human body

Path of current Body's resistance

Hand – hand; hand – foot 1,000 Ω
Hand – feet 750 Ω
Hands – feet 500 Ω
Hand – chest 450 Ω
Hands – chest 230 Ω
Hands – buttocks 300 Ω

MI_54_0A_008376_FA

I=V/R
I = 12 V / 1000 Ω = 0.012 A = 12 mA
I = 120 V / 1000 Ω = 0.12 A = 120 mA

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 Hazards of Electricity 5
Current passing through the body 5.2

5.2.2 Hazardous Body Currents According to VDE 0100 Part 410

The strength ranges show the danger of electric shocks depending on the length of
exposure to the shock. Therefore, there is a risk of death starting at an amperage of
approx. 30 mA.

TT_08_00_008875_FA

Strength range 1 Strength range 2

• No effects, inde‐ • 0.5-2 mA: current is perceived
pendent of length • 3-5 mA: sensation of pain begins
of exposure
• 10-20 mA: release threshold
• Perception limit
• No hazardous through-flow usually occurs

Strength range 3 Strength range 4

• Muscle cramps • Fibrillation of the heart
• Breathing difficulties • Cardiac arrest
• Cardiac arrhythmia • Respiratory arrest
• No permanent organ damage is nor‐ • Hazard!
mally to be expected

Always consult a physician in the event of an electric shock.

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5 Hazards of Electricity
5.2 Current passing through the body

Hazards from DC voltage compared with AC voltage

Direct current is always hazardous. However, the physiological effect on humans is
less severe than that of alternating current at the same current intensity. The follow‐
ing effects can occur:
• Muscle cramps
• Muscle contraction
• Nervous shock
• Increased blood pressure
• Fibrillation of the heart (uncoordinated reaction of the heart muscles which can
have a major effect on the function of the heart. I.e. not enough blood or no
blood is pumped through the body)
• Cardiac arrest
• Electric marks (burns) at the entry and exit points of the current
• Fluid loss, coagulation
• Internal burns

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 Hazards of Electricity 5
Electric arcing 5.3

5.3 Electric arcing

An electric arc develops during the separation and connection of electrical conductors
with different potentials, as well as due to insulation faults.
Hazardous for humans caused by electric arcing:
• Thermal radiation (burns)
• UV radiation (flash burn of the eyes)
• Effects of heat (burns, inhalation of harmful metal vapors from evaporating metal
particles)
• Noise exposure (hearing damage)

TT_08.00-009817-FA

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5 Hazards of Electricity
5.4 Secondary effects

5.4 Secondary effects

A secondary effect refers to an accident resulting from an undesired reaction to a pre‐
vious event:
• The brief flow of current triggers muscle spasms. The shock of this could cause
the person to fall over.
• The protective reaction to an electric arc causes the person to fall over.

TT_08.00-009818-FA

26 T0001F <> Participant Document

 First aid 6
Legal background 6.1

6 First aid
6.1 Legal background

Legal texts
• StGB [German Criminal Code] Section 323 c
• ArbSchG [German Occupational Health and Safety Act] Section 10
• BGV [regulations of the statutory industrial accident insurance institutions in Ger‐
many] A1 sections 26, 27
• BGI [information sheet of the statutory industrial accident insurance institutions
in Germany] 503 (First Aid)

Obligation to perform first aid

Probably the most well-known statutory requirement for providing first aid is sec‐
tion 323 c StGB (criminal code) failure to render assistance.
It states: “Whoever does not render assistance during accidents or a common danger
or emergency although it is necessary and can be expected of him/her under the cir‐
cumstances, particularly if it is possible without substantial danger to himself/herself
and without violation of other important duties shall be liable to imprisonment not ex‐
ceeding one year or a fine.”

Do you know who the appointed

first aider is in your company?
Where will you find relevant no‐
tices in your company?

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6 First aid
6.2 Rescue chain

6.2 Rescue chain

Initial actions must be taken immediately following an electrical accident.

If the injured party is responsive, he/she must be thoroughly examined by a

physician.

If the injured party is unconscious, follow the so-called "RESCUE CHAIN".

Section A: Immediate actions Section B: Subsequent actions

TT_08_00_009601_FA

1 Disconnect the electric circuit 4 Medical examination, transport

2 Emergency call 5 Diagnosis, clinic
3 First aid

Measures to disconnect the electric circuit (< 1000 V)

• There is a risk of death from touching live parts
• Disconnect electric circuit immediately by switching off, pulling out plug or re‐
moving fuse
• If these measures cannot be immediately performed:
– Isolate yourself from the source of current and do not touch anything
– Separate casualty from the live parts using a non-conducting object (e.g.
dry wood slat) or pull away by his/her clothes
Initiate first aid
• Call rescue service or emergency physician
• Move injured party into a resting position
• Assess responsiveness, check for breathing and pulse
• Perform first aid depending on the injury
• A medical examination is absolutely essential after any electric shock.

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 First aid 6
Action following an accident caused by electricity 6.3

6.3 Action following an accident caused by electricity

• Stay calm.
• Report the accident
• Administer first aid
• Further actions, e.g.
– Brief fire crew or ambulance
– Turn away onlookers

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7 High-voltage safety measures
7.1 High-voltage safety measures

7 High-voltage safety measures

7.1 High-voltage safety measures

TT 08.00-009819-FA

The 7 high-voltage safety measures in the vehicle

• COLOR CODING AND WARNING NOTICES
– Orange high-voltage lines and warnings on high-voltage components for
greater awareness among workshop personnel
• CONTACT PROTECTION FOR LIVE COMPONENTS
– Measures for preventing inadvertent contact with live parts (direct/indi‐
rect)
• GALVANIC SEPARATION (POTENTIAL SEPARATION) HIGH VOLTAGE-LOW VOLTAGE (HV-LV)
– High voltage potentials are provided with all-pole insulation from the vehi‐
cle ground. In the event of a simple fault, this prevents the risk of an elec‐
tric shock.
• INSULATION RESISTANCE MONITORING
– Detection of insulation faults throughout the entire high-voltage on-board
electrical system
– Representation of faults in the display concepts taken into consideration
– Insulation monitor is in the battery management system control unit
– The insulation faults detected by the insulation monitor are divided up into
two stages:
YELLOW MESSAGE as a warning at 500-100 Ω/V
RED MESSAGE as an alarm at <100 Ω/V
– After ignition OFF, the vehicle no longer starts with a RED MESSAGE!
The contactors can no longer be switched on!
Diagnosis-based disabling of the high-voltage on-board electrical system
is no longer possible.

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 High-voltage safety measures 7
High-voltage safety measures 7.1

– The insulation resistance is evaluated in the battery management system

control unit. This is where the value can be read out using the diagnostic
tool.
– After remedying the fault, the battery management system control unit
carries out a test cycle. No driving enable is issued for the duration of the
test cycle.
• INTERLOCK CIRCUIT (HVIL)
– Conducting loop is routed across the access options of the entire high-
voltage on-board electrical system.
– The access options are electrical connections of the high-voltage compo‐
nents and also covers protected by jumpers. Removal of the electrical
connections or the cover interrupts the conducting loop of the HVIL.
– When the signal transmitted via the conducting loop is interrupted, the
contactors in the high-voltage battery open after running through a shut-
off strategy. The entire high-voltage on-board electrical system is shut
down.
– A distinction is made between the following instances:
If a fault occurs in the interlock circuit while driving (contactors closed
and ignition “ON”), closing of the contactors during the next ignition cycle
is prevented.
In HYBRID vehicles, the high-voltage on-board electrical system is shut off
when the selector lever is in position "N“ or "P“ for > 3 s and the vehicle
speed is < 5 km/h. The high-voltage on-board electrical system is also
switched off in selector lever position "D" if the engine hood is opened in
plug-In HYBRIDs.
If a fault occurs in the interlock circuit during charging or pre-entry cli‐
mate control (contactors closed), the contactors are opened immediately
and the high-voltage on-board electrical system is shut down.
– The following control units have resistors:
- Battery management system control unit, one resistor with 27 Ω
- Charger, one resistor with 27 Ω
- Power electronics control unit, one resistor with 27 Ω
• HIGH-VOLTAGE DISCONNECT DEVICE (THERE ARE VARIOUS DISCONNECT DEVICES AND
INSTALLATION LOCATIONS)
– Following diagnosis-based power disconnect as per the WIS document,
the shutoff of the entire high-voltage on-board electrical system is ensur‐
ed (interlock circuit and circuit 30c open) and the system then secured
against being switched back on through "ignition ON".
– Through the insertion/connection of the high-voltage activation lock, the
high-voltage on-board electrical system is additionally secured to prevent
reactivation.
• SHUTOFF OF THE HIGH-VOLTAGE ON-BOARD ELECTRICAL SYSTEM IN THE EVENT OF A CRASH
– Via triggering of the pyrotechnical separators which are actuated by the
supplemental restraint system control unit in the event of crash recogni‐
tion

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7 High-voltage safety measures
7.1 High-voltage safety measures

– Power from all power sources and storage units is interrupted by the con‐
tactors
– Deactivation of generator operation (both the electrical machine and the
DC/DC converter)
– Discharge of the intermediate circuit capacitors below a hazardous volt‐
age range
– A distinction is made between two stages:
1. If only the emergency tensioning retractors are deployed, the high-volt‐
age shut-off is reversible. When the ignition is switched off and on again,
the high-voltage on-board electrical system is started up again if no insu‐
lation fault is present.
2. If the airbags are also deployed, the high-voltage shutoff is irreversible.
– If a repair order has been issued for the vehicle, after an accident with
pyrofuse deployment (irreversible shutoff of high-voltage on-board electri‐
cal system) the high-voltage battery must be replaced in accordance with
SI54.10-P-0035A.
• SHUT-OFF OF THE HIGH VOLTAGE ON-BOARD ELECTRICAL SYSTEM BY RESCUE SERVICES, STORAGE OF
INFORMATION IN THE VEHICLE FOR RESCUE SERVICES

– In high voltage vehicles, there is a separating point for shutting off the
high-voltage on-board electrical system for emergency services. The inter‐
lock circuit and terminal 30c are disconnected at this connecting point,
e.g., by cutting them using side cutting pliers.
– The rescue card is only present as a non-permanent component of the
vehicle if the customer obtains it and carries it in the vehicle. Further‐
more, it is not kept at a standardized position in the vehicle and can
therefore be easily lost. That is why all Mercedes-Benz and smart vehicles
have a QR code in two locations in the area of the fuel filler flap and the B-
pillar on the opposite side since September 2013. The QR code is deco‐
ded and the relevant rescue card called up using a smartphone. The res‐
cue card is filed on a server.

For the vehicles Atego and FUSO, a high-voltage battery circuit breaker is addi‐
tionally used. When it is actuated, the high-voltage battery circuit breaker discon‐
nects the supply voltage of the high-voltage relays, thus opening the high-voltage
relays.

The rescue card is only present as a non-permanent component of the vehicle if the
customer obtains it and carries it in the vehicle. Furthermore, it is not kept at a stand‐
ardized position in the vehicle and can therefore be easily lost. That is why all Mer‐
cedes-Benz and smart vehicles have a QR code in two locations in the area of the fuel
filler flap and the B-pillar on the opposite side since September 2013. The QR code is
decoded and the relevant rescue card called up using a smartphone. The rescue card
is filed on a server.

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 High-voltage safety measures 7
Prerequisites for working on high-voltage vehicles 7.2

7.2 Prerequisites for working on high-voltage vehicles

Potential high-voltage safety measures in the organization:
• Training
– High-voltage training and product training with high-voltage awareness
training for workshop personnel for working with electrical voltages in the
defined high-voltage range and new technology in the vehicles
• Marking of the vehicle and status of the high-voltage on-board electrical system
– Power disable event log easy to see in the vehicle interior (in front of in‐
strument cluster)
• Observe the safety rules for working on high-voltage on-board electrical system
(VDE 0105/ECE R100)
– Disconnect power
– Prevent from being switched on again
– Determine disconnected state
– Ground and short circuit
(not necessary for automotive applications)
– Cover and place barrier around adjacent live parts
(not necessary for automotive applications)
• Diagnostic system
– Check all features relevant to the high-voltage status and create an out‐
put of the current high-voltage status
– Print out a power disable event log after determining the high-voltage sta‐
tus via the electronic diagnostic system
– Provide safety information for the diagnosis process through the electron‐
ic diagnostic system or workshop literature
• Workshop information
– Provide safety information and repair instructions in the event that the
removal, installation or exchange of one or more high-voltage components
is necessary
– Provide process description and procedural instructions from the manu‐
facturer for how to proceed in disconnecting vehicle power and conduct‐
ing repairs
– Function descriptions, diagnostic instructions and safety information for
faults in the high-voltage system

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7 High-voltage safety measures
7.3 Safety precautions in TN/IT networks

7.3 Safety precautions in TN/IT networks

Basic functions of high-voltage safety measures and precautions are explained using a
TN network by way of an introduction (e.g. house wiring).

7.3.1 TN network principle (TN = Terra Neutral = common ground)

TT_08_00_009822_FA

Path from the power generator to the

A 2 Transformer
transformer
Path from the transformer to the
B 3 House fuse box
building
C Building mains supply 4 Consumer
1 Power generator

Ground fault circuit breaker

A ground fault circuit breaker (ground fault circuit interrupter) is an electrical protec‐
tive device in low-voltage systems (household installations). EU standards commonly
employ the English term "RCD" (Residual Current Device).

If a certain differential current, in households and public buildings usually 30 mA, is

exceeded, the ground fault circuit breaker disconnects the monitored electric circuit
at all poles, that is, all conductors except for the protective earth conductor are dis‐
connected from the rest of the supply network.

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 High-voltage safety measures 7
Safety precautions in TN/IT networks 7.3

TT_08_00_025032_FA

7.3.2 IT network principle (IT = Isolated Terra = single ground)

The following points are performed in the vehicle:
• Protection against direct or indirect contact
• Insulation monitoring
• Protection by electrical separation
• Protection by shutting off
• Check of safety precautions
• High-voltage interlock

TT_08_00_009823_FA

A Insulation monitoring D DC/DC converter

B High-voltage components G High-voltage battery
C Power electronics M Alternating-current machine

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7 High-voltage safety measures
7.4 High-voltage interlock

7.4 High-voltage interlock

The interlock signal is a low-voltage signal and is routed through the connecting points
of the high-voltage components via a conducting loop. The interlock signal is gener‐
ated by the battery management control unit.

TT_00_00_041545_FA

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 High-voltage safety measures 7
High-voltage interlock 7.4

1 12-V plug connection N83/5 Charger

2 High-voltage connection N129/1 Power electronics control unit
3 Terminal 30 S7 High-voltage disconnect device
Transmission/frame floor assembly
A9/5 Electric refrigerant compressor X22/4
connecting point
Engine compartment/frame floor as‐
A79/1 Electric machine X25/7
sembly connector
A100 High-voltage battery module X58/23 Charger feed-in socket
A100g1 High-voltage battery X183 Pyrofuse electrical connector
Electrical fuse (high-voltage PTC heat‐
F1 er/electric refrigerant compressor) X999 High voltage power distributor
(replaceable)
Electrical fuse (for high-voltage dis‐
F2 tributor plate on power electronics A Interlock signal line
control unit) (replaceable)
Electrical fuse (for charger) (replacea‐
F3 B Circuit 30c (signal line)
ble)
Electrical fuse (for DC/DC converter
F4 C Electrical line (high voltage)
control unit) (replaceable)
F34/6 High-voltage distributor plate D Circuit 30 line
f63 Pyrofuse E Vehicle ground
Supplemental restraint system con‐
N2/10 IG Interlock alternator
trol unit
N33/5 High-voltage PTC heater IL Interlock evaluation
Battery management system control
N82/2 L Phases L1-L3
unit
N83/1 DC/DC converter control unit PE Protective earth conductor

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8 High-Voltage Components
8.1 General

8 High-Voltage Components
8.1 General
High-voltage components include all components that, according to ECE R100 , carry
voltages higher than 60 volts DC and/or 30 volts AC.
The main components are:
• High-voltage battery
• Electric motor
• Power electronics (AC/DC converter)
• DC/DC converter
• High-voltage lines
Depending on the model series, other components may be added, such as:
• Electric compressor
• High-voltage distributor

TT_08_00_025037_FA

1 Electric motor 3 Electric power steering pump

2 Electric refrigerant compressor

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 High-Voltage Components 8
Battery types 8.2

8.2 Battery types

The energy accumulator is an important component on electric and hybrid vehicles.
Selection criteria for this component are:
• Energy density
• Power density
• Energy efficiency
• Self-discharge
• Cyclic lifetime
• Environmental compatibility
• Costs and availability
To achieve a long emissions-free range, the battery should combine the highest power
density and energy density possible. In addition, especially for hybrid vehicles, the bat‐
tery should be capable of highly dynamic charging and discharging processes. This
makes it possible to achieve functions such as the boost effect and regenerative brak‐
ing.

8.2.1 Accumulator comparison, specific energy vs. specific power

The following figure shows an overview of the different battery types in relation to
their energy density and power density:

TT_08_00_009661_FA

1 Lead acid 5 Lithium-ion (Li-ion)

2 Nickel metal hydride (NiMh)
3 Molten salt (Na/NiCI2)
4 Lithium polymer (Li-poly)
6 Lithium ion (Li-ion), high performance
Lithium ion (Li-ion), extremely high
7
performance

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8 High-Voltage Components
8.2 Battery types

8.2.2 Accumulator comparison, battery types

Lead acid Lead gel

Operating tempera‐ up to 45°C Operating tempera‐ up to 45°C
ture: ture:
Cell voltage: 2.0 V Cell voltage: 2.0 V
Energy content: 22 - 28 Wh/kg Energy content: 22 - 28 Wh/kg

Nickel metal hydride (NiMh) Molten salt (Na/NiCI2)

Operating tempera‐ up to 60 °C Operating tempera‐ 270 - 355 °C
ture: ture:
Cell voltage: 1.2 V Cell voltage: 2.6 V
Energy content: 28 - 37 Wh/kg Energy content: 65 - 85 Wh/kg

Lithium-ion (Li-ion) Lithium polymer (Li-poly)

Operating tempera‐ up to 50 °C Operating tempera‐ up to 55°C
ture: ture:
Cell voltage: 3.6 - 4.2 V Cell voltage: 2.5 – 3.7 V
Energy content: 200 - 300 Wh/kg Energy content: 200 - 400 Wh/kg

Note: 1 kg gasoline has an energy content of 12,000 Wh/kg.

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 High-Voltage Components 8
Lithium-ion battery 8.3

8.3 Lithium-ion battery

A conventional lithium-ion cell delivers a rated voltage of 3.6 V, i.e. three times that of
a nickel metal hydride accumulator.
Advantages of lithium-ion batteries:
• Extremely high power density and energy density
• Rapid charging capacity and high discharge currents possible
• The self-discharge of the lithium-ion battery in the vehicle lies at approximately
1% of the state of charge (SOC) per week at a battery temperature of 25 °C
• Very high cycle numbers
• No escape of H2 when supercharged
• Long service life
• No memory effect

Aging of lithium-ion batteries

Aging of the lithium-ion battery is caused by cell oxidation. This is when the electrodes
oxidize. They lose the capacity to store lithium ions, which are required for the current
flow.

The cell oxidation is affected by various factors such as the charge level and temper‐
ature:
• Charge level:
– The final charging voltage can extend up to 4.2 V. The cut-off voltage is
2.5 V
– To extend the lifetime of the battery, it is only partially charged and dis‐
charged at frequent intervals. This means, the battery is operated in a
charge range of e.g., 30% to 80%.
This increases the number of possible charge and discharge cycles. Deep
discharging leads to a loss in capacity and irreversible damage
• Temperature:
– Cell oxidation occurs at an accelerated pace at high temperatures. For
this reason, the battery is cooled using air, coolant, or A/C refrigerant.

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 8 High-Voltage Components
8.3 Lithium-ion battery
Example of application
Lithium-ion battery using a HYBRID as an example
TT_00_00_025582_SW
1 Cooling jacket
2 Lithium-ion cells
3 Battery management system
4 Coolant connection
5 High-voltage connection
6 Cell voltage monitoring
42
Lithium-ion battery using a PLUG-IN HYBRID as an example
TT_54_10_035050_FA
A100 High-voltage battery module
A100s1 Contactor
A100g1 High-voltage battery
N82/2 Battery management system control unit
1 Battery management system plug connection
2 Coolant supply
3 Coolant drain
4 Degassing pipe
5 High-voltage connection (charger)
6 High-voltage connection (DC/DC converter)
7 High-voltage connection (power electronics)
T0001F <> Participant Document
 High-Voltage Components 8
Battery contactors 8.4

8.4 Battery contactors

8.4.1 Definition:
The contactor is an electrically actuated switch for high performance, similar to a
relay. The contactor has two switching positions and switches to the stable, open
switch position when de-energized. Contactors were developed to allow consumers
with a large power consumption (e.g. motor) to be switched on via a manual switch
with a minimum switching capacity. Contactors enable faster and safer switching op‐
erations than are possible with purely mechanical or manual switching designs.

The following characteristics distinguish contactors from relays:

• Relays are designed for a lower switching capacity.
• Relays often use a hinged armature, while contactors use a tie rod for a larger
mechanical switching force, which is necessary for the higher switching capaci‐
ties and more massive contacts used.

Use of contactors in high-voltage batteries:

Contactors are used in high-voltage batteries to establish the connection between the
high-voltage system and the high-voltage batteries. The objective is to achieve a clean
breakaway, without arcing.

To guarantee the spark breakaway when connecting or disconnecting the high-voltage

battery, three contactors are installed in the battery:
• Contactor K1 connects the negative connection of the high-voltage battery to the
high-voltage system.
• Contactor K2 connects the positive connection of the high-voltage battery to the
high-voltage system.
• Contactor K3 connects the positive connection of the high-voltage battery to the
high-voltage system via a resistor.
• A capacitor, which is preloaded via pre-load contactor K3, is connected between
the positive and negative poles in the intermediate circuit of the high-voltage sys‐
tem.

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8 High-Voltage Components
8.4 Battery contactors

Exercise 12 Function of contactors in high-voltage batteries:

Complete the text below.

TT_08_00_009758_SW

The closing process of the contactors occurs as follows:

Contactor ________ (negative) is closed.

Contactor ________ is closed.

This connects the high-voltage battery via the damping resistor.

Together with the high-voltage system capacitor, the current is maintained at a low
value as ________ closes.

This prevents arcing.

Contactor ________ is closed.

The high-voltage system is now energized.

The contactors open in the reverse order.

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 High-Voltage Components 8
Handling high-voltage batteries 8.5

8.5 Handling high-voltage batteries

High-voltage batteries are classified as dangerous goods according to international
dangerous goods regulations (see workshop literature).
The workshop literature contains a high-voltage battery analysis sheet for each vehicle
model series to determine the transportability of high-voltage batteries. This enables a
distinction between batteries that are safe for transport and those that are unsafe
for transport.

8.5.1 High-voltage batteries that are safe for transport

High-voltage batteries that are safe for transport may only be transported in their orig‐
inal packaging, provided that the high-voltage battery is packaged as received on de‐
livery.
The following minimum requirements must be fulfilled:
• The high-voltage battery must be protected against an external short circuit, e.g.
using the terminal cap
• All openings on the high-voltage battery, especially the coolant connections,
must be securely closed
• The exterior of the high-voltage battery housing must be kept free of hazardous
contaminants
• The packaging must be marked according to dangerous goods regulations
The required documentation must be enclosed.

8.5.2 High-voltage batteries that are unsafe for transport

The following criteria can be used to determine whether a high-voltage battery is un‐
safe for transport:
• Check with Xentry:
– High-voltage battery cannot be diagnosed
– Presence of insulating faults (clear assignment to the high-voltage battery,
storage of fault code)
– Contactors are closed (after circuit 15 off, storage of fault code)
• Physical test:
– Housing is cracked
– Deformed housing
– Tarnished housing
– Electrolyte leakage
– Damage to high-voltage contacts
– Thermal test
The model series-specific WIS documentation is always the decisive factor for deter‐
mining the transport safety classification.
High-voltage batteries that are unsafe for transport may only be transported by road
or sea with an exemption from the responsible national authorities.

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8 High-Voltage Components
8.5 Handling high-voltage batteries

Further information on the management of dangerous goods can be found under the
following link: http://gms.aftersales.daimler.com

High-voltage battery packaging

TT_00_00_009693_FA TT_00_00_025579_SW

Note
When working on the high-voltage battery, the safety precautions required as per
the WIS documentation must be observed.

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 High-Voltage Components 8
High-voltage charger 8.6

8.6 High-voltage charger

The high-voltage charger allows the high-voltage battery to be charged via an external
voltage source. The control unit for the high-voltage charger (AC/DC) converts AC
voltage current from the socket into DC voltage and conveys it to the high-voltage
distributor or the high-voltage battery.

High-voltage charger of a plug-in vehicle P_54_10_402176_FA

Control unit plug connection (charger

1 4 DC high-voltage connection
feed-in socket)
2 Control unit plug connection (vehicle) 5 Coolant return flow
3 AC high-voltage connection 6 Coolant feed

ECE charger feed-in socket TT_54_10_039231_FA

1 Left LED (lock LED) N Neutral conductor

2 Right LED (charge indicator LED) PE Protective earth conductor
CP Control Pilot PP Proximity
L1/L2/L
Phases L1, L2, L3 X58/23 Charger feed-in socket
3

8.6.1 Charging
When charging Plug-In HYBRID and electric vehicles, there are three external charging
options:
• Power socket (mode 2)
• Wallbox charging station (mode 3)

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8 High-Voltage Components
8.6 High-voltage charger

• Charging station (mode 3)

Depending on the selected charging type, the provided charging cable must be used.
A distinction is made between modes 2 and 3.

Mode 2 charging cable

The mode 2 charging cable includes an in-cable control box with a ground fault circuit
breaker and Control Pilot in accordance with IEC 61851. It has a power supply plug at
one end and a 5-pin socket at the other end.
The charge cable plug is locked at the vehicle end when charging.

TT_54_10_039229_FA

Mode 3 charging cable

The mode 3 charging cable does not contain an in-cable control box. The protection
functionality is provided by the charging station or wallbox charging station. The
charging cable has a 7-pin socket at both ends. When charging, the charging cable
connector is locked at the vehicle side and the charging station side.

TT_54_10_039230_FA

Charging options
The charging options are shown on the smart fortwo electric drive by way of ex‐
ample.

The specified vehicle-related values vary between model series.

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 High-Voltage Components 8
High-voltage charger 8.6

Mains socket charging

TT_00_00_017771_FA

Wallbox charging
Charging using the Wallbox "Basic"

TT_00_00_017775_FA

Charging using Wallbox "Connected"

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8 High-Voltage Components
8.6 High-voltage charger

TT_00_00_017778_FA

1 Daimler vehicle back-end

Wallbox charging station and wallbox charging station service 2016

The objective of the improved wallbox charging station service is to offer the cus‐
tomer an attractive solution for safe, quick and convenient charging at home via
the dealer.

In addition to the purchase of the wallbox charging station, the dealer can also
offer the customer a chargeable voucher for the installation by a service provider
as a user-friendly solution. The installation service offers various types of services
such as an installation check and/or the installation of the wallbox charging sta‐
tion. This offer is an all-round carefree package for the customer because he/she
can order the complete service (hardware and installation voucher, etc.) from a
single source. When doing this, the dealer is provided with professional support
via the wallbox charging station service tool of Mercedes-Benz Accessories
GmbH. The actual installation of the wallbox charging station on site at the cus‐
tomer is performed by "The Mobility House" without any dealer involvement.

Public charging

TT_00_00_017793_FA

1 Authentication via root certificate 3 Charging

2 Payment

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 High-Voltage Components 8
High-voltage charger 8.6

App “Charge & Pay for Mercedes-Benz” Find your power source via smartphone

Anyone wishing to charge an E-vehicle in the public sector can now find about 3000
charging locations, 230 operators, countless charging cards and payment systems.
In order to make this easier in future, Mercedes-Benz offers “Charge & Pay for Mer‐
cedes-Benz”.

Mercedes-Benz and smart customers can find free charging columns and control the
charging and billing process using this App.

Payment is simple and transparent using PayPal.

Special feature
“Charge & Pay for Mercedes-Benz” operates without a contract and a basic fee.
The app has been available free of charge for the iOS and Android operating sys‐
tems since December 2014.

The service for Mercedes-Benz customers is provided by BOSCH Software Innovations

GmbH, and can be downloaded from apps.mercedes-benz.com/ or the App Store or
Google Play since December 2014.
The charging times shown only serve an example. They depend on the voltage,
the charging current and the battery capacity. The smart fortwo electric drive
also offers a larger optional onboard charger.

Charging times in minutes TT_00_00_041563_FA

The charging times also depend on the temperature and the charge level of the
battery.
The charging time increases at lower temperatures.

T0001F <> Participant Document 51

9 Information unit on electric machines
9.1 Direct-current machine

9 Information unit on electric machines

9.1 Direct-current machine

9.1.1 Definition
A direct-current machine is an electric motor that is operated by direct current or,
conversely, a generator that converts mechanical energy into direct current. In some
cases, a device can carry out both functions.

The direct-current machine consists of a fixed part, the stator, and a rotating part, the
rotor (armature). Most direct-current machines are designed as internal rotors. The
rotor is the internal part while the stator is the external part. On conventional direct-
current machines, the stator consists of a solenoid, or a permanent magnet, on small‐
er machines.

TT_00_00_025585_FA

1 Commutator 3 Slats
Rotor sheet pack with grooves and
2 Shaft 4
windings

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 Information unit on electric machines 9
Direct-current machine 9.1

9.1.2 Function
The excitation winding current generates an external magnetic field, which passes
through the armature coil at an approximately vertical angle. This applies force to the
armature coil, and thus a torque on the rotor, placing the latter component in motion.
After a 90° rotation, both forces cancel each other out, and the rotation would come
to a halt. To avoid this effect, the flow of current in the armature coil is reversed in
time to reverse both directions of force and allow the rotational motion to continue.
This continuous alternation of the current direction is effected in the electrical wires
to the armature coil by slip rings and brushes.

TT_00_00_025584_FA

The torque is proportional to the current; the rotational speed is proportional to the
voltage. A corresponding closed-loop control unit is simple and economical.

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9 Information unit on electric machines
9.1 Direct-current machine

9.1.3 Brushless direct-current machine

Friction on the slip rings and brush pairs of direct-current machines leads to power
loss and wear. One option to circumvent this problem is the use of brushless direct-
current machines (brushless DCs). On the brushless direct-current machine, the coils
are installed in the stator and the permanent magnets in the rotor.

Four windings - brushless direct-current machine (unipolar) TT_08_00_025060_FA

1 Stator with coils

2 Rotor

When electric current flows in the coils, a magnetic field is generated in the motor
stator. This magnetic field also cuts through the fields of the permanent magnets in
the rotor. Depending on the rotor position, a torque is applied to this component,
which causes it to rotate. The rotation ends when the rotor has positioned itself in line
with the magnetic field generated in the stator. To prevent the rotor from coming to a
halt, the flow of current in the stator coils must be switched in time for the generated
magnetic field to continue to rotate. This causes a continuous torque to be applied to
the rotor. In the figure, due to the four-phase coil system, the magnetic field can occu‐
py eight different positions. Positive or negative currents is applied to coils 1-4, allow‐
ing the desired switching of the magnetic field to continue.

Depending on the motor design and the control unit used, in practical operation, the
actuation of the coils is either unipolar (current flow only in one direction) or bipolar
(current flow in positive or negative direction). The control unit controls the strength
and direction of the current. The continued switching of the magnetic field occurs de‐
pending on the current rotor position. Its position is thus conveyed to the control unit
via an optical or magnetic sensor.

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 Information unit on electric machines 9
Direct-current machine 9.1

Example of application, electric bicycle

TT_08_10_009753_FA

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9 Information unit on electric machines
9.2 Alternating-current machine

9.2 Alternating-current machine

An alternating-current machine is an electric motor operated by alternating current or,
conversely, a generator that converts mechanical energy into alternating current. In
some cases, a device can carry out both functions. It consists of a fixed part, the sta‐
tor, and a rotating part, the rotor (armature). Most alternating-current machines are
designed as internal rotors. The rotor is the internal part while the stator is the exter‐
nal part.

Alternating-current machine TT_08_10_009772_FA

L1 Coil 1 N Neutral
L2 Coil 2 R Rotor
L3 Coil 3 S Stator

9.2.1 Design and function

On alternating-current machines, the stator usually consists of three coils offset at
120° and arranged in a star or a triangle pattern. The coil connections are designated
with U, V, and W. The rotor consists of either solenoids or permanent magnets. A dis‐
tinction is made between synchronous and asynchronous motors.

Asynchronous motors
On asynchronous motors, the rotor does not run in sync with the rotating field.

On the asynchronous motor, the rotor is composed of one or more closed-circuit rotor
coils, in which a voltage is induced through the stator coil. This produces a time-lag in
the magnetic field of the rotor coil. The consequence is that the rotor does not rotate
in sync with the rotating field of the stator. Since with hybrid drive systems the elec‐
tric motor must undergo continual and quick changes of rotational speed, no asyn‐
chronous motors are used in hybrid vehicles.

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 Information unit on electric machines 9
Alternating-current machine 9.2

Synchronous motors
On synchronous motors, the rotor runs in sync with the rotating field. The advantage
of a synchronous motor is a high torque from the starting speed. This is why the syn‐
chronous motor with permanent magnets is mainly used for vehicle propulsion sys‐
tems.

Three-phase AC voltage in three-phase machines TT_08_00_025061_FA

Example of application S 400 HYBRID (model series 221)

TT_08_00_025063_FA

1 Stator coils 4 Housing

1/1 Electrical connection B70 Temperature sensor
2 Stator frame L20 Position sensor
3 Rotor with permanent magnets

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10 Power electronics
10.1 Power electronics

10 Power electronics
10.1 Power electronics
The power electronics serves as the actuator between the high-voltage battery and
the electric motor. Depending on the vehicle, they also may be referred to as the con‐
verter or inverter. The power electronics must be designed as an AC/DC converter
or as a DC/DC converter, depending on the electric motor used. The phasing, fre‐
quency and current amplitude for operating the electric motor are correspondingly
controlled by the drive control system in the power electronics.

The alternating currents are generated in the three phases by power transistors con‐
necting the particular phase terminals according to precisely calculated patterns. The
aim is to generate sinusoidal current curves in each of the three phases.

TT_08_00_025065_FA

Design
The power electronics consists of the inverter with the control and the intermediate
circuit capacitor.

TT_08_20_009788_SW

A High-voltage battery
B Power electronics

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 Power electronics 10
Power electronics 10.1

Intermediate circuit capacitor

Switching the currents without buffering by the intermediate circuit capacitor would
result in high current peak loads of the battery. High levels of emitted interference
disrupting the overall vehicle electronics would also result. Intermediate circuit capac‐
itors are film capacitors, given the requirements on service life and temperature.

Discharge of the intermediate circuit capacitors

The intermediate circuit capacitor has two discharge types. Active and passive dis‐
charge.

Active discharge
After the high-voltage battery contactors are opened, switch S is closed and capaci‐
tor C is actively discharged via resistor R2. This process takes a maximum of
30 seconds.

TT_08_00_009790_FA

B Power electronics R1 Resistor 1

C Condenser R2 Resistor 2
M Electric motor S Switches

"Active discharge" generally occurs if the contactors of the high-voltage battery are
opened by the control unit. That is, with:
• Ignition off
• Interruption of the high-voltage interlock system
• Crash deployment

Passive discharge according to VDE 0113

After the high-voltage battery contactors are opened, the capacitor C can be dis‐
charged passively via the resistor R1. This process may not take longer than five
minutes. Afterwards, no more hazardous voltages may be present. Passive discharge
is purely a safety precaution should switch "S" not operate.

T0001F <> Participant Document 59

10 Power electronics
10.1 Power electronics

TT_08_00_009789_FA

B Power electronics R2 Resistor 2

C Capacitor S Switch
R1 Resistor 1 M Electric motor

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 DC/DC converter 11
DC/DC converter 11.1

11 DC/DC converter
11.1 DC/DC converter
The DC/DC converter is the actuator between the high-voltage side and the 12 V on-
board electrical system. It can be designed as a bidirectional or a unidirectional DC
voltage converter. Its tasks are among other things: Jump start, e.g., charging the
high-voltage battery via a low-voltage charger or an assistance vehicle (model ser‐
ies 221 HYBRID).

TT_08_00_025590_SW

A High-voltage battery C DC/DC converter

12 V (24 V) on-board electrical sys‐
B Power electronics AC/DC converter D
tem

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12 High-voltage power disconnect
12.1 High-voltage power disconnect on the vehicle, general

12 High-voltage power disconnect

12.1 High-voltage power disconnect on the vehicle, general

Basis for power disconnect according to VDE 0105 or ECE

The regulations contained in DIN VDE 0105 and ECE R 100 specify the rules and
guidelines for operating electrical systems. The following five steps apply for discon‐
necting power:

Step
Disconnect power
Prevent from being switched on again
Determine disconnected state
Ground and short circuit (not required in mo-
tor vehicles)
Cover and place barrier around adjacent or
exposed live parts (not required in motor vehi-
cles)
Explanation
Disconnecting the high-voltage on-board
electrical system
Use an activation lock
Secure the keys and components against un‐
authorized use
Check the test equipment (manual power
disconnect)
Determine disconnected state
Document disconnected state on the vehicle
Short circuit and ground the electrical lines
with sufficient cross-sections
Cover or place barrier around hazardous
areas
Clearly and adequately designate hazardous
areas

Power disconnect on high-voltage vehicles

The rules for disconnecting power in the automotive trade are based on specific vehi‐
cle conditions. Therefore, only the first three rules for disconnecting power are used.
The product-specific WIS documentation for each model series must be ob‐
served.

Initial startup of high-voltage vehicles, general

Step Explanation
Remove power disconnect marking (power Remove the marking applied to designate
disconnect document) the disconnected vehicle state
Visual inspection of the vehicle and the high
voltage connections
Remove reclosing lockout Remove activation lock
Reconnect high voltage
Start up the vehicle Start up the vehicle
Create written restart procedure event log
Check vehicle for any faults that might be
present using XENTRY Diagnostics
Test run the vehicle

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 Basic legal principles 13
Regulations and guidelines 13.1

13 Basic legal principles

13.1 Regulations and guidelines

Work procedures TT_08_00_025600_SW

Four categories of accident prevention regulations of the statutory industrial accident

insurance institutions in Germany (BGV)
Category A General regulations and occupational safety and health organization at the
workplace
Category B Effects
Category C Type of operation and activities
Category D Workplace and work procedures

Excerpt from the regulations of the statutory industrial accident insurance

institutions in Germany (BGV)
BGV A1 Principles of prevention
BGV A2 Works doctors and work safety specialists (specific versions exist for the
individual trade associations)
BGV A3 Electrical systems and equipment (regulates the testing of electrical equip‐
ment used in companies)
BGV A4 Occupational Medicine (transitional rules for preventive occupational medi‐
cal examination ("G investigations" - to be integrated into BGV A1)
BGV A8 Health and safety labeling at the workplace (includes hazard symbols, man‐
datory and prohibitory signs as well as regulations regarding signs for es‐
cape routes, first aid facilities, etc.)

Content of BGV A3 (Electrical systems and equipment)

Section 1 Scope
Section 2 Terms
Section 3 Principles
Section 4 Principles in the absence of electrotechnical regulations
Section 5 Tests

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13 Basic legal principles
13.1 Regulations and guidelines

Section 6 Working on live parts

Section 7 Working in the proximity of live parts
Section 8 Permissible deviations
Section 9 Administrative offenses
Section 10 Ratification

BGG [BG Principle] 944 Training criteria for specified tasks as implementation
instructions for the BG regulation "Electrical systems and equipment"
1 Terms
2 Fundamental requirements for training
3 Training to level of specialist electrician for specified tasks within
the scope of the trade
4 Basic training
5 Company's own specialist training
6 Training to level of specialist electrician for specified tasks in the industry
and in other commercial sectors
7 Verification of training

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 Basic legal principles 13
Legal consequences 13.2

13.2 Legal consequences

The DIN VDE 1000 defines the following relevant terms for automotive companies:
Layperson A layperson is someone who is neither a specialist electrician nor has had any
electrotechnical training
EuP Person who has had electrotechnical training
e.g.: Automotive mechanic with training completed after 1973
EFK ffT Specialist electrician for specified tasks is somebody who, because of his/her
technical training, expertise and experience as well as knowledge of the regu‐
lations applying to these specified tasks, is able to evaluate the work assigned
to him/her and recognize potential hazards.
e.g.: Expert for work on intrinsically safe high-voltage series production vehi‐
cles
vEFK Responsible specialist electrician (with technical and supervisory responsibility
and/or with managerial responsibility for company or part of company)

13.2.1 Potential legal consequences resulting from breach of duty in industrial

safety
Liability
• Criminal law
– Fines
– Imprisonment
• Regulatory law
– Large fine
– Cautionary fine
• Civil law
– Compensation for e.g.
costs of treatment, pensions, property damage
– Compensation for injuries
Disciplinary consequences
• Occupational law
– Caution
– Reprimand
– Termination of contract

13.2.2 Liability in occupational safety and health

Whoever bears responsibility is liable under the general legal requirements for:
• Property damage (Section 823 BGB [German Civil Code]) according to "case law"
– willful (unrestricted 100%)
– with gross negligence (approximately 100%)
– with moderate negligence (50%)
– With ordinary negligence (0 % as per BAG [German Federal Labor Court]
Large Senate GS 1/89)
• Personal injury (Section 823 BGB [German Civil Code]) by way of exception if it

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13 Basic legal principles
13.2 Legal consequences

– was willfully caused

– was caused en route between the place of residence and the workplace
Whoever bears responsibility is liable under the general legal requirements pursuant
to:
• Criminal code without restriction (negligent bodily harm or homicide)
• Social law/labor law without restriction (on the basis of breach of contract)
Whoever bears responsibility is liable under the general legal requirements to:
• Imprisonment/fine
– of up to €10,000 for willful or negligent breach of accident prevention reg‐
ulations pursuant to Section 209 SGB [German Social Code] VII
– of up to €25,000 pursuant to Section 20 ArbSichG [German Occupational
Safety Act]
– of up to €50,000 (managerial staff) pursuant to Sections 130, 30 OWiG
[Administrative Offenses Act]
– imprisonment of up to 15 years depending on charge
• Rights to compensation for the trade association, for accident damage caused
willfully or with gross negligence.
A number of cases of liability may concur, which could result in criminal pun‐
ishment and/or a fine.

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 Basic legal principles 13
Legal consequences 13.2

Notes

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