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Operating instructions for the system
739 964 Automotive high-voltage systems trainer
Audi AG
Hindemithstraße 27
85045 Ingolstadt
As of production year 2018
Manufacturer:
Audi AG
Auto-Union-Straße 1
85045 Ingolstadt
E-Mail:
wertschöpfung.berufsausbildung-
in@audi.de
Web: www.group-training-
online.com
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Table of Contents
Summary of Contents for Audi 739 964
- Page 1 Operating instructions for the system 739 964 Automotive high-voltage systems trainer As of production year 2018 Manufacturer: Audi AG Auto-Union-Straße 1 85045 Ingolstadt E-Mail: wertschöpfung.berufsausbildung- Audi AG in@audi.de Hindemithstraße 27 Web: www.group-training- 85045 Ingolstadt online.com...
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Page 2: Table Of Contents
Table of content Important key information ....................5 Scope of delivery ....................5 Responsibilities ...................... 5 1.2.1 Responsibilities of the system builder ............5 1.2.2 Responsibilities of the operator ..............5 Legal information ....................5 Documentation ....................... 5 1.4.1 Background information on content and structure ........5 1.4.2 Content and structure ................ - Page 3 Table of content 3.3.6 HV battery housing (inactive without battery) .......... 18 3.3.7 Cable set ....................18 System description ......................19 Set-up ........................19 4.1.1 Main components ................... 19 4.1.2 Operator workstations ................19 Functional description................... 19 4.2.1 System ....................19 4.2.2 Main components ...................
- Page 4 Table of content 10.5 First measures to eliminate the fault ..............25 11 Dismantling and disposal....................27 11.1 Dismantling ......................27 11.2 Disposal ....................... 27 11.2.1 Basic instruction..................27 11.2.2 Description of the disposal work ............. 27 12 Plans and other information ..................28 12.1 Drawings and layouts ...................
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Page 5: Important Key Information
Important key information Important key information Scope of delivery With the purchase of the e-tron system trainer you receive the e-tron system trainer itself, the operating instructions for the e-tron system trainer the power supply cable a set of 2 ignition keys ... -
Page 6: Addresses
Maintenance Dismantling and disposal Supplementary documents for the superordinate system documentation Component documentation Safety instructions of the power supply unit Addresses 1.5.1 Manufacturer’s address Audi Academy Vocational training Hindemithstraße 27 D-85045 Ingolstadt 1.5.2 Service address LD Didactic GmbH Leyboldstr. 1... - Page 7 Important key information a few hours. Only after this has been done can the e-tron system trainer be connected to the voltage/power supply and put into operation. Do not overload the product. Pay attention to input/output voltages and currents. Handle the product with care, it can be damaged by bumps, knocks or a fall from an even low height.
- Page 8 Important key information Never pour liquids over or next to the product. There is a high risk of fire or life- threatening electric shock. Should liquid still get into the interior of the device, immediately switch off all poles of the operating voltage. Contact a specialist and do not operate the product any longer.
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Page 9: Safety
Safety Safety Convention for safety instructions The e-tron system trainer meets the criteria of IEC60449 on the operating side Behaviour in an emergency In case of a defect, immediately switch off the e-tron system trainer and disconnect from voltage source, if possible. Then contact the service partner. The system trainer must be protected against being switched on again by third parties and visually, unmistakably marked as a hazard. -
Page 10: Requirements For The Personnel
Safety 2.3.2 Requirements for the personnel persons Authorised The following persons are authorised to handle the product: Transporter (activity, required qualification): Transport of the packed e-tron system trainer, none Operator (activity, required qualification): Measurements on the e-tron system trainer, sensitised for activities in the high-voltage range ... -
Page 11: Compliance With The Operating Instructions
Safety Carrying out resistance measurements on the not enabled and not freely measured system Fault switching with active voltage or active fault 24 Removal of covers except required in the experiment manual Removing or adding components ... -
Page 12: Residual Hazards And Protective Measures
Safety Residual hazards and protective measures Secondary accidents can occur in the event of a fall (e.g., improperly laid connection cable) or impact due to startling effect in the event of an electric shock. To minimise these, the system trainer may only be used in suitable locations. In the event of a negligently caused short circuit, burns can occur on a highly heated short circuit bridge. -
Page 13: Life Phase: Operation
Safety 2.9.3 Life phase: Operation Hazard location Hazard group Hazard consequence Hazard origin Training room Electrical hazards Arcing Arcing; live parts; parts that have become live in the fault state; short circuit; faulty insulation Description of the hazard Arcing due to improper operation or error Endangered group of persons Operating personnel Protection goal... -
Page 14: Life Phase: Operation
Safety Endangered group of persons Operating personnel Protection goal Prevention of fire on the 70 VDC side Protective measures Design solution: Installation of a fuse to limit the short-circuit current Protective encapsulation through metallic enclosure of the components There is no residual risk 2.9.6 Life phase: Operation Hazard location... -
Page 15: Life Phase: Permanent Condition
Safety 2.10.2 Life phase: permanent condition Hazard location Hazard group Hazard consequence Hazard origin Training room Other hazards Fire Damage Description of the hazard In the event of fault currents/short circuit, a fire is possible on the 230 V AC side Endangered group of persons Operating personnel Protection goal... -
Page 16: Life Phase: Permanent Condition
Safety Protection goal Avoiding ergonomic damage Protective measures Residual risk Ergonomic measurement not possible over a long period of time 2.10.5 Life phase: permanent condition Hazard location Hazard group Hazard consequence Hazard origin Training room Functional safety and Equipment design Arcing;... -
Page 17: Technical Data
Overall system General description of the product With the Audi e-tron system trainer, it is possible to simulate insulation faults in the HV lines and components. This allows systematic troubleshooting to be trained and improved in a targeted manner. In comparison to the Audi e-tron vehicle, all installed HV components are easily accessible. -
Page 18: Equipment
Weight: approx. 90 kg The system trainer is built according to the latest state of vehicle technology These are components from the current e-tron programme of AUDI AG Components 3.3.1 Power supply (=voltage source) on the input side with IEC plug (fuse and on/off switch, PE conductor on HV battery housing) and two connecting cables (phase and N conductor) 3.3.2... -
Page 19: System Description
System description System description Set-up 4.1.1 Main components Item rack Fault switch box Measuring sockets Power supply unit (=voltage source) on input side with IEC plug (fuse and on/off switch, PE conductor on HV battery housing) and two connecting cables (phase, N conductor) ... -
Page 20: Delivery, Internal Transport, Unpacking
Delivery, internal transport, unpacking Delivery, internal transport, unpacking Safety The cardboard pallet completely encloses the e-tron system trainer, which means that there are no sharp corners and edges. The e-tron system trainer is securely fastened to the cardboard pallet with tie-down straps. When unpacking, make sure that the e-tron system trainer is not damaged and does not show any transport damage. -
Page 21: Storage Conditions
Troubleshooting Storage conditions General safety The e-tron system trainer should be stored in a dry, cool room. The storage temperature must be between +10 °C and + 40 °C. When the e-tron system trainer is not being used for voltage measurements, the plug must be pulled out and the power supply disconnected. -
Page 22: Supply Connections
Troubleshooting Supply connections The e-tron system trainer is supplied with a connection cable. The e-tron system trainer must be connected to a 115/230 V 50/60 Hz AC household socket. The power socket has to be easily accessible and must be close to the trainer. The mains supply has to be protected by a residual current circuit breaker (RCD) with a tripping current of <= 30mA. -
Page 23: Assembly And Installation
Troubleshooting Assembly and installation • Do not carry out any maintenance on the e-tron system trainer. • The e-tron system trainer is delivered fully assembled and can be rolled on castors after removing the packaging unit. Please ensure that surfaces are protected from scratches or dents by using suitable pads. -
Page 24: Operation
Troubleshooting Operation Do not connect a charger to the existing charging socket Check whether the HV trainer is in proper condition Do not use the HV trainer if any of the following apply: - Cables and plugs not in the intended place - Visible mechanical damage to the e-tron system trainer - Insulation visibly damaged - HV components opened or visibly damaged... -
Page 25: Inspection And Maintenance
Troubleshooting adhesive) Do not disconnect any cables and only carry out a voltage measurement at the designated points with a suitable measuring device. After the voltage has been measured, disconnect the system for further work. Voltage-free operation is guaranteed after a discharge time of approx. 1min When not in use, disconnect the mains supply from the HV Trainer. - Page 26 Troubleshooting Malfunction / error Possible cause(s) Remedy message When the ignition is switched Service Disconnect is open Close Service Disconnect on, there is no 70 V DC voltage between HV+ and When the mains switch is Ignition off Switch on ignition switched on, there is no 70 V DC voltage between HV+ and HV-...
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Page 27: Dismantling And Disposal
Dismantling and disposal Dismantling and disposal 11.1 Dismantling Basic instruction The e-tron system trainer must be dismantled properly by qualified personnel General safety instructions Before dismantling, disconnect all poles of the e-tron system trainer from the operating voltage source and check that all poles are de-energised. The e-tron system trainer should only be dismantled by qualified personnel. -
Page 28: Plans And Other Information
Plans and other information Plans and other information 12.1 Drawings and layouts HV- Trainer 28 of 34 26/10/2018... - Page 29 Plans and other information HV- Trainer 29 of 34 26/10/2018...
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Page 30: Spare Parts And Consumables
Plans and other information 12.2 Spare parts and consumables Damaged components can be acquired from the service address. Repair work on the HV components, apart from the cable sets, must be avoided. All other repair work and the exception mentioned may only be carried out by an expert/professional workshop that is familiar with the related dangers or relevant regulations. -
Page 31: Electrical Documentation
Plans and other information 12.3 Electrical documentation HV- Trainer 31 of 34 26/10/2018... - Page 32 Plans and other information HV- Trainer 32 of 34 26/10/2018...
- Page 33 Plans and other information HV- Trainer 33 of 34 26/10/2018...
- Page 34 Plans and other information HV- Trainer 34 of 34 26/10/2018...