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 High-Voltage Charger unit is connected to
the high-voltage battery. During the high-voltage
The Power Electronics convert the DC voltage supplied by battery charging cycle, the high-voltage charger
the high-voltage battery into an AC voltage for the unit is connected electrically to the charging
electric machine and, conversely, the alternating current column.
of the electric machine is converted to DC for charging the
high-voltage battery. The AC Compressor is driven by a high-voltage
motor.
The High-Voltage Battery acts as the energy accumulator
in the high-voltage system. The Electric Auxiliary heater runs on high
voltage.
The Electric Machine is a three-phase AC machine which
drives the vehicle, assists the internal combustion engine The Charging Socket is connected to the high-
as a starter motor and charges the high-voltage battery as voltage charger unit.
a generator including the 12-volt battery via the power
and control electronics). 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.