High Voltage

Electrically Instructed Personnel

(EIP) Training
Introduction to Electric Vehicle Technology and Safety
Course Overview:

• What is an EIP?
• Understanding the potential risks when exposed to electrical hazards
• Awareness of different HV layouts
• Identify the features of Electrical/Hybrid system components and operation
• Warnings and hazard avoidance
• Reducing risk for yourself and others when working on Electric/Hybrid vehicles
What is an EIP?
Who can work with High Voltage vehicles?

NON-EIP – Persons NOT Allowed to work on HV vehicles

EIP - Electrically Instructed Personnel - person who are authorised to perform maintenance and
other general work only on a “De- Energized” (non-active)
HV vehicle as directed by a HVT high-voltage technician.

HVT – High Voltage Technician – Only authorized person to deactivate and activate the HV
System. Authorized to work on de-energized HV vehicles systems.

HVE – High Voltage Expert – Manufacturer Specialist that can diagnosis HV Battery, its
handling, transport and disassembly.
HV Qualification for Persons handling HV components
IMPORTANT:

The high-voltage system must always be de-energised in order to

perform non-general maintenance work.

Only HVT or HVE can deactivate the HV system.

The minimum qualification for all work on a high-voltage vehicle is that the personnel be certified as “Persons
with electrical training” (EiPs) provided he is under the direct supervision of an High Voltage technician (HVT).

Non-qualified personnel is not authorised to perform work on HV vehicles.

 
Understanding the potential risks when exposed to
electrical hazards
High voltage - what is it?

The term "high voltage" (HV) has a specific use in the automobile industry. It
refers to electric voltages which exceed certain thresholds.

In a passenger vehicle, the voltage thresholds for high-voltage are found at:

Note:
The following information primarily given to service technicians during an EIP training.
Dangers of working with electrical currents
Electromagnetic Compatibility and Influence on Workshop Employees

Remaining in direct vicinity of an activated electric machine or High Voltage systems can impair function of
electronic life-support system

These includes

1. Internal Analgesic Pumps.

2. Implanted Defibrillator.
3. Cardiac Pacemakers
4. Brain Pacemakers.
5. Insulin Pumps.
6. Hearing Aids.

Note:
The following information primarily given to service technicians during an EIP training.

Also applies to all Emergency Services Personnel

Effects of Electric Current on the human
body
 Dangers of working with electrical currents

800 V System

800 mA

80mA - FATAL THRESHOLD

80 mA
Dangers of working with electrical currents
2.1 Effects of Electric Arcs

What are the possible effects of an

electric arching shown in the illustration?

• Acoustic Effects

• Thermal Effects

• Toxic Effects

• Electro Dynamic Forces

Dangers of working with electrical currents
 What should you do in case of accidents
involving High Voltage?
1. Keep Calm, Think First, then Act!

2. Look over the area of the incident carefully, guarantee your own safety, never expose yourself
to electric shocks

3. Always switch off the power supply when an emergency rescue is undertaken, whenever this is
possible (i.e. ignition off, unplug service disconnector)

4. Check for the source of the electrical shock. Look to see if the victim is still in contact with the
source. Remember that electricity can flow through the victim and into you.

• Never use water, even if there is a fire, as water can conduct electricity.
• Never enter an area where electrical equipment is used if the floor is wet.
• Use a fire extinguisher made for electrical fires (i.e. Foam).
• Call the emergency services
 What should you do in case of accidents
involving High Voltage?

5. Separate the victim from the source. Don’t touch the victim, even with a non-conducting instrument, if the electricity
hasn’t been shut off. Once you’re sure there is no current, use you’re a non-conductive wood or safety rescue hook to
separate the victim from the source.

6. Place the victim in the recovery position. Placing the victim of electrical shock in the recovery position will ensure that
her airway remains clear. Follow these steps to properly put the victim in the recovery position:
• Place the arm nearest to you at a right angle with her body.
• Place the other hand under the side of her head. The back of the hand should touch the cheek.
• Bend the farthest knee at a right angle.
• Roll the victim on the side. The top arm will support the head.
• Lift the chin of the victim and check the airway.
• Stay with the victim and monitor her breathing.

Once in recovery position, don’t move the victim, as this can cause further injury.

Apply CPR, if needed. Only after being separated from the electrical source, check the victim’s vital signs. Perform CPR or
rescue breathing if breathing has stopped or seems slow.
Note:
The following information primarily given to service technicians during an EIP training.
Awareness of different HV layouts
Electric Vehicle Drive Concepts

+ + + +
Definition: What is a Battery Electric Vehicle (BEV)?

A battery electric vehicle (BEV), also called pure electric vehicle, only-

electric vehicle, fully electric vehicle or all-electric vehicle is a type of 
electric vehicle (EV) that exclusively uses chemical energy stored in 
rechargeable battery packs, with no secondary source of propulsion (e.g.
hydrogen fuel cell, internal combustion engine, etc.).
+
BEVs use electric motors and power controllers instead of 
internal combustion engines (ICEs) for propulsion.

They derive all power from battery packs and thus have no internal combustion
engine, fuel cell, or fuel tank.
Example: VW e-Golf BEV -MEB

Power Electronics

E-Drive Machine E-Drive Machine

High Voltage Battery

MEB - Modular electric drive matrix
Definition: What is a Hybrid Electric Vehicle (HEV)?

A hybrid car uses more than one means of energy, combining a petrol or
diesel engine with an electric motor, and the two systems work with each
other to move the vehicle.
+
This allows the car to burn less gasoline, achieving better fuel efficiency
than a traditional engine that solely uses fuel does. Electric power serves
to boost the performance of the engine. Hybrids, except for plug-in
hybrids, charge the battery through its internal system, so they do not need
recharging
Example: Audi Q7 e-Tron Hybrid

Internal Combustion Engine

E-Machine
Definition: What is a Plug-In Hybrid Electric Vehicle (PHEV)?

Plug-in hybrid electric vehicles (PHEVs) use batteries to power an electric

motor and another fuel, such as gasoline, to power an internal
combustion engine (ICE).

The vehicle typically runs on electric power until the battery is nearly + +
depleted, and then the car automatically switches over to use the ICE.

A plug-in hybrid electric vehicle is a hybrid electric vehicle whose battery

pack can be recharged by plugging a charging cable into an external
electric power source, in addition to internally by its on-board internal
combustion engine-powered generator.
Example: Porsche Panamera Plug-In E- Hybrid (PHEV)

Internal Combustion E-Machine

Engine

Plug-In Charge Socket

 Identifying the features
of
Electrical/Hybrid system
components and operation
What are the signs that a particular vehicle has a high-voltage system?
What are the signs that a particular vehicle has a high-voltage system?

The following features may indicate a vehicle with a high-voltage system:

• Hybrid, Electric Drive, or other markings, e.g. on the fenders.

• the absence of an exhaust pipe in battery-only electric vehicles
• an electrical charging connector (possibly with a second “fuel cap”)
• manufacturer’s specific design elements
• orange high-voltage cables
• warning stickers on high-voltage electrical components presence in the vehicle of charging cables or
similar equipment
• a charge indicator in the instrument cluster and/or indicator of the vehicle’s operational status

Note:
The following information primarily given to service technicians during an EIP training.
How can I Identify High-Voltage Vehicle in the Workshop?

In the workshop the following can also be seen indicating High

Voltage in the vehicle.

1. Yellow and Black barricade tape

2. Warning Signs and prohibition signs on the vehicle
3. Warning Signs and prohibition signs on components of the
vehicle
4. Orange- colored cables and components
How can I Identify High-Voltage Vehicle in the Workshop?

Note:
The following information primarily given to service technicians during an EIP training.
Protective Safety Measures

IF YOU ARE NOT A HVT DO NOT APPROACH,

WORK OR TOUCH THE VEHICLE!
Note:
The following information primarily given to service technicians during an EIP training.
Protective Safety Measures
Ensure that the system is de-energized
Other Protective Markings
How can I Identify High-Voltage Components?
The High-Voltage System Components:
The Voltage Converter converts the high voltage to 12 V.
The Power Electronics convert the DC voltage supplied by the
high-voltage battery into an AC voltage for the electric machine
and, conversely, the alternating current of the electric machine is
converted to DC for charging the high-voltage battery.
The High-Voltage Battery acts as the energy accumulator in the
high-voltage system.
The Electric Machine is a three-phase AC machine which drives
the vehicle, assists the internal combustion engine as a starter motor
and charges the high-voltage battery as a generator including the
12-volt battery via the power and control electronics).
The High-Voltage Charger unit is connected to the high-
voltage battery. During the high-voltage battery charging
cycle, the high-voltage charger unit is connected
electrically to the charging column.
The AC Compressor is driven by a high-voltage motor.
The Electric Auxiliary heater runs on high voltage.
The Charging Socket is connected to the high-voltage
charger unit.
The Maintenance Connector serves to disconnect the
high-voltage system.
 Audi E-Tron High-Voltage System (BEV)
HIGH VOLTAGE SWITCHING UNIT REAR 3 PHASE CURRENT
CHARGE FRO HV BATTERY
VOLTAGE CONVERTER HIGH VOLTAGE CHARGER 1 DRIVE
CURRENT (E-BOX)
DISTRIBUTOR
HV CHARGING SOCKET 2

HIGH VOLTAGE
HEATER

FRONT 3 PHASE CURRENT

DRIVE

HIGH VOLTAGE CHARGER 2

HIGH VOLTAGE AC COMPRESSOR

HIGH VOLTAGE
HV CHARGING SOCKET 2 HIGH VOLTAGE
HEATER
BATTERY
 Identifying High-Voltage Lines:

1. Two lines (positive and negative) from the High-Voltage Battery to the Power Electronics (high-voltage DC).
2. Three lines from the Power Electronics to the Electric Machine (high-voltage AC).
3. A single line (with positive and negative) to the High-Voltage Charger (high-voltage DC).
4. A single line (with positive and negative) to the Electric AC Compressor (high-voltage DC).
5. A single line (with positive and negative) to the Auxiliary Heater (high-voltage DC).
6. A single line (with positive and negative) to the Voltage Converter (high-voltage DC).
7. A single line (with 1-3 phases, neutral and PE) from the High-Voltage Charger unit to the charging socket or Power
Distributor (AC voltage up to 230 V).
8. On models with a DC charging socket: two lines (positive and negative) from the DC charging socket to the switch box.
 Reducing risk for yourself
and others
when working on Electric/Hybrid vehicles
Working with High Voltage Vehicles:

1. Whenever performing work on a high-voltage vehicle, follow the instructions given in the Workshop Manual and
in Workshop Diagnostic Tester.

2. If you are performing work on a high-voltage system, the high-voltage technician (HVT) in your service centre
must de-energise the high-voltage system on the vehicle for you.

3. Once your high-voltage technician (HVT) has declared the high-voltage system to be de-energised and secured it
against restarting, only the high-voltage technician may instruct you to perform individual jobs on the high-voltage
system as per the Workshop Manual.

4. The high-voltage technician (HVT) marks the vehicle as de-energised by attaching various warnings. This serves
to ensure the safe handling of high-voltage vehicles within the workshop area.
IMPORTANT:

Before commencing work and after completing work on a high-voltage vehicle or on a vehicle with an
electric hybrid drive, always perform a thorough visual inspection of the high-voltage components in the
work area. The high-voltage lines are colour-coded orange and have a particularly high cross section.

Is the insulation on the high-voltage cable intact and undamaged?

Are the high-voltage cables unusually deformed?
 
Check the condition of the high-voltage cables by visual inspection only.

If high-voltage lines are damaged, notify your high-voltage technician.

These lines must be replaced.
 Working in the vicinity of high-voltage components

It is not permitted to perform work involving the use of metal cutting tools, shaping tools or sharp-
edged tools or heat sources such as welding, soldering, hot air or thermal gluing tools.

Do not touch the high-voltage lines and high-voltage components.

Do not rest your tools on high-voltage components.

Do not use pressure washer directly into HV lines when cleaning the
engine compartment, pressure washing has the potential to damage
high voltage electrical components and cables.
Thank you.