Volkswagen ID.3: General information. High voltage

• Personal training profiles and focal points
• Packaging critical high-voltage batteries with “Warning” status - module
• Packing defective high-voltage batteries with “normal” status, module
• Packaging high-voltage batteries in genuine part crate
• General information about packaging high-voltage batteries
• Classification of high-voltage batteries with aid of ODIS
• Fundamentals of classifying high-voltage batteries
• Quarantine arrangements
• Photographic documentation
• Qualifications and working for emergency service, authorised workshop and importer
• Packaging critical high-voltage batteries with “Warning” status, MEB batteries

Personal training profiles and focal points

Personal training profiles and focal points

Qualification VolkswagenDGUV-I 209-093ScenarioEIP (person with electrical training)Chapter 2Induction training for non-electrical work (< 60 VDC)HVT (high-voltage technician)Chapter 3.1 bWorking on inherently safe HV production vehicles

♦ Vehicles are de-energised exclusively with certification.

♦ Complete contact protection in place. HVE level 1 (high-voltage expert)Chapter 3.2 bWorking on not inherently safe HV production vehicles

♦ Vehicles are also de-energised without certification or there is no complete contact protection in place, e.g. in the event of an accident. HVE level 2 (high-voltage expert)Chapter 3.3Work on live accumulators

♦ Working on parts supplied with voltage, inevitably with no contact protection, for fault finding, component replacement, etc.

Packaging critical high-voltage batteries with “Warning” status - module

Packaging critical high-voltage batteries with “Warning” status - module

WARNING

Risk to health due to dust from expanded glass granules.

Risk of irreversible dust deposits in lungs, which could lead to respiratory problems.

– Wear a dust protection mask.

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Removing

– → Chapter „Classification of high-voltage batteries with aid of ODIS“.

Preparing transport container

For the consignment of classified high-voltage batteries with “WARNING” status, special transport containers are required and the currently applicable transport laws apply.

– Determine suitable transport container using → Chapter „Packaging overview“.

Packaging high-voltage battery

Packaging is described for left side of vehicle as an example.

For information about packaging in L container and LP container, see → Chapter „Packaging critical high-voltage batteries with “Warning” status, MEB batteries“.

– Secure all contacts of battery modules to prevent short circuit.

– Seal all openings for service fluids apart from electrolyte.

– Remove deposits of hazardous materials and electrolyte from outside of battery module.

– Package module air-tight with suitable packaging material, e.g. plastic bag and adhesive tape.

– Open fasteners of transport container.

– Remove lid of transport container.

– Remove bag with hollow glass granulate.

– Check seal -1- on pressure relief valves -2- for damage.

– Pour hollow glass granulate into transport container up to a layer thickness of at least 200 mm.

Important

● Multiple modules must be placed upright.

● Distance -a- between inner walls and modules must be at least 120 mm.

● Distance between modules must be at least 200 mm.

● Distance between module and upper edge of transport container must be at least 200 mm.

– Place module in transport container.

– Pour in hollow glass granulate so that gaps are filled and also entire transport container up to upper edge.

– Check circumferential rubber seal for damage.

– Fit cover on transport container.

Note

If it proves difficult to close the cover, turn the cover 180° if necessary.

– Seal the cover all around using the fasteners, and retension the fasteners if necessary.

– Fill in and insert transport documents.

– Apply the warning notice for hazardous materials and information label to both ends of the transport container.

♦ “Dangerous goods class 9”

♦ “UN number 3480”

♦ “Attention! Damaged lithium-ion battery”

♦ “This side up”

1 - “Protect against water”

2 - “Attention! Fragile”

3 - “This side up”

4 - “Maximum stacking load”

5 - “Hazardous material label: Hazardous material category 9 “Various hazardous substances and items” packaging group 2”

6 - “Type label with UN number UN 3480 for lithium-ion batteries”

Packing defective high-voltage batteries with “normal” status, module

Packing defective high-voltage batteries with “normal” status, module

Special tools and workshop equipment required

♦ Lifting aid -3033-

♦ Lifting aid -T10619-

♦ Workshop hoist -VAS 6100-

The description applies to defective high-voltage battery modules that are sufficiently stable for being transported.

– Classify high-voltage module → Chapter „Classification of high-voltage batteries with aid of ODIS“.

All vehicles (continued)

Removing new module from packaging

Do not damage the packaging when opening and removing the stickers. Do not peel off the adhesive tape.

– Cut adhesive tape with a cutter knife and open packaging.

– Remove existing stickers or make them unrecognisable.

Continued

– Secure mounting bracket -T10619- to module.

– Secure lifting tackle -3033- to workshop hoist -VAS 6100-.

– Position workshop hoist -VAS 6100- centrally above module.

– Secure lifting tackle -3033- to mounting bracket -T10619-.

– Use workshop hoist -VAS 6100- to lift module out of cardboard box, and place module on suitable surface.

Preparing packaging

UN stickers must not be pasted over.

– Remove cardboard insert from packaging.

– Turn packaging over.

– Use adhesive filament tape -2- to close packaging -1- with overlaps as shown in illustration.

Filament adhesive tape, refer to → Electronic parts catalogue (ETKA)

Packing defective module with “normal” status

– Use adhesive tape to protect all contacts of battery modules against being short-circuited.

Packing with hollow glass granulate or vermiculite

– Use filament adhesive tape -2- to close overlap -arrows- at bottom of packaging.

WARNING

Risk to health due to dust from expanded glass granules.

Risk of irreversible dust deposits in lungs, which could lead to respiratory problems.

– Wear a dust protection mask.

– Wear a face mask.

– Fill hollow glass granulate or vermiculite into packaging with an even layer thickness of 2 cm.

– Secure mounting bracket -T10619- to module.

– Use workshop hoist -VAS 6100- to lift module, and position it centrally above packaging.

– Pull plastic bag over module.

Plastic bag, refer to → Electronic parts catalogue (ETKA)

– Use workshop hoist -VAS 6100- to place module centrally and at an even distance from outer walls in packaging.

– Remove mounting bracket -T10619- from module.

– Fold plastic bag sideways, and seal it with adhesive tape so that no liquid can escape.

– Pour in hollow glass granulate or vermiculite so that gaps are filled and also entire packaging up to upper edge.

All vehicles (continued)

Packing with hollow glass granulate bag (if available on site)

– Place small hollow glass granulate bag in packaging and distribute contents evenly.

– Secure mounting bracket -T10619- to module.

– Use workshop hoist -VAS 6100- to lift module, and position it centrally above packaging.

– Pull plastic bag over module.

Plastic bag, refer to → Electronic parts catalogue (ETKA)

– Use workshop hoist -VAS 6100- to place module centrally and at an even distance from outer walls in packaging.

– Remove mounting bracket -T10619- from module.

– Fold plastic bag sideways, and seal it with adhesive tape so that no liquid can escape.

– Place large hollow glass granulate bag onto module.

– Distribute contents evenly so that a layer thickness of 2 cm is ensured above module and that cavities of packaging are filled.

All vehicles (continued)

– Put classification protocol in packaging.

– Use adhesive filament tape -2- to close packaging -1- with overlaps as shown in illustration.

– Apply the warning notice for hazardous materials and information label to both ends of the packaging.

♦ “Dangerous goods class 9”

♦ “UN number 3480”

♦ “Attention! Damaged lithium-ion battery”

♦ “This side up”

1 - “Protect against water”

2 - “Attention! Fragile”

3 - “This side up”

4 - “Maximum stacking load”

5 - “Hazardous material label: Hazardous material category 9 “Various hazardous substances and items” packaging group 2”

6 - “Type label with UN number UN 3480 for lithium-ion batteries”

Packaging high-voltage batteries in genuine part crate

Packaging high-voltage batteries in genuine part crate

Special tools and workshop equipment required

♦ Anhaengevorrichtung -T10616-

♦ Holding strap -T40155A-

♦ Lift arm extension/workshop hoist -VAS 6101-

♦ Lifting ring -VAS 501 013-

♦ Scissor-type assembly platform VAS 6131B 208 - 230V -VAS 6131B-

♦ Shackle -VAS 691 009A-

♦ Workshop hoist -VAS 6100-

Mounting points 55 kWh and 62 kWh

Important

● The mounting points shown -arrows- must be used.

Mounting points 82 kWh

Important

● The mounting points shown -arrows- must be used.

All vehicles (continued)

Preparing for lifting (shown on 82 kWh)

– Secure extension for lifting arm/workshop hoist -VAS 6101- -A- at position -arrow- to workshop hoist -VAS 6100- -B-.

Removing new high-voltage battery from genuine part crate

– Open genuine part crate -2-.

– Loosen bolts -4-.

– Remove nuts and washers.

– Position workshop hoist -VAS 6100- -B- centrally above high-voltage battery -1-.

– Secure retaining strap -T40155A- -F- with shackle -VAS 691 009A- -H- and ring -VAS 501 013- -G- to lift arm extension/workshop hoist -VAS 6101- -A- and workshop hoist -VAS 6100- -B-.

– Secure retaining strap -T40155A- -F- with shackle -VAS 691 009A- -D- to mounting bracket -T10616- -E-.

CAUTION

Risk of injury caused by moving components.

Risk of hands being crushed.

– Never reach in between workshop hoist and high-voltage battery.

– Raise high-voltage battery.

– Place high-voltage battery on suitable surface.

– Detach shackle -VAS 691 009A- -D- from mounting bracket -T10616- -E-.

– Unscrew mounting bracket -T10616- -E-.

Removing high-voltage battery and placing in genuine part crate

– Assess condition of high-voltage battery in installed state → Chapter „Classification of high-voltage batteries with aid of ODIS“.

– Remove high-voltage battery → Electric drive, rear-wheel drive EIP220 and all-wheel drive EIA200, EIP220; Rep. gr.93; High-voltage battery unit; Removing and installing high-voltage battery 1 [AX2], 82 kWh; Removing and installing high-voltage battery 1 [AX2].

– Support high-voltage battery on scissor-type assembly platform -VAS 6131B-.

– Lower high-voltage battery -1- into genuine part crate -2-.

Important

● Connector housing -6- must point towards opening -7- of genuine part crate -2-.

● Locking pins -5- must be inserted in associated holes of high-voltage battery -1-.

– Insert locking pins -5- in associated holes of high-voltage battery -1-.

– Position high-voltage battery -1- at support points -3- in genuine part crate -2-.

– Detach shackle -VAS 691 009A- -D- from mounting bracket -T10616- -E-.

– Unscrew mounting bracket -T10616- -E-.

Securing high-voltage battery in genuine part crate

Detailed view

1 - Bolt

2 - Nut

3 - Small washer

4 - Large washer

5 - High-voltage battery

6 - Genuine part crate

7 - Small washer

8 - Nut

9 - Genuine part crate

– Secure high-voltage battery -5-.

Sealing genuine part crate and preparing for transport

– Fit lid on genuine part crate.

– Attach tensioning straps.

– Affix and check hazardous material label and consignment code.

– Fill in and insert transport documents.

1 - “Protect against water”

2 - “Attention! Fragile”

3 - “This side up”

4 - “Maximum stacking load”

5 - “Hazardous material label: Hazardous material category 9 “Various hazardous substances and items” packaging group 2”

6 - “Type label with UN number UN 3480 for lithium-ion batteries”

Placing new high-voltage battery on scissor-type assembly platform -VAS 6131B- and installing

– Support high-voltage battery.

– Place high-voltage battery on scissor-type assembly platform -VAS 6131B-.

– Install high-voltage battery → Electric drive, rear-wheel drive EIP220 and all-wheel drive EIA200, EIP220; Rep. gr.93; High-voltage battery unit; Removing and installing high-voltage battery 1 [AX2], 82 kWh.

Tightening torques

ComponentSpecified torque Mounting bracket -T10616- to high-voltage battery50 Nm

General information about packaging high-voltage batteries

General information about packaging high-voltage batteries

The procedure described here is based on the European agreement concerning the international carriage of dangerous goods by road (ADR). Country-specific legislation must be observed. According to ADR regulations, the listed high-voltage batteries come under category UN 3480. For the latest packaging instructions and special regulations, see the hazardous materials table of the ADR.

The procedure is orientated around the classification status of the high-voltage battery.

For transporting high-voltage batteries with the status “WARNING”, the currently applicable transport laws apply.

It is not permissible to transport high-voltage batteries with the status “DANGER”.

Start situationExecution of classificationClassification statusAssignment of packaging regulationBatteries that are new, in use or used but functional, e.g. warranty case due to low residual capacity.HVT or HVE

♦ Technically OK

♦ “NORMAL” status P 903 / LP 903 transport in genuine part crate (protect battery against short circuit and slipping). If the battery is to be disposed of or recycled, SV 377: P909 => e.g. genuine part crate labelled accordingly: LITHIUM BATTERIES FOR DISPOSAL or LITHIUM BATTERIES FOR RECYCLINGBatteries damaged/defective but safe for transport, e.g. defective cell controller, triggered pyrofuse without other defects.HVE

♦ Technically not OK

♦ “NORMAL” status SV 376: P 908 / LP 904 applies, carton according to packaging group, inner packaging (individually in inner packaging) and outer packaging required (>30 kg= only one battery per outer packaging), foil around battery/electrolyte leakage must be prevented, ventilation if necessary, e.g. inner packaging required (inc. non-flammable, non-conductive heat insulation). Protect battery against short circuit. Consignment label: DAMAGED/DEFECTIVE LITHIUM-ION BATTERIES or DAMAGED/DEFECTIVE LITHIUM METAL BATTERIES, reference in transport documents: TRANSPORT AS PER SPECIAL REGULATION 376Batteries heavily damaged and transport critical SV 376 (e.g. leaking electrolyte, relevant cell defects).HVE, consultation with importer if necessary

♦ Technically not OK

♦ “WARNING” status P 911 / LP 906 special transport container required (see overview). Packaging approved by relevant authority. The applicable transport laws apply. Packaging according to packaging group I, consignment label: DAMAGED/DEFECTIVE LITHIUM-ION BATTERIES or DAMAGED/DEFECTIVE LITHIUM METAL BATTERIES, reference in transport documents: TRANSPORT AS PER SPECIAL REGULATION 376Battery reactive (heat development/fire/smoke, noise etc.).Maintain distance, call fire service if necessary.

♦ Technically not OK

♦ “DANGER” status Do not consign

Classification of high-voltage batteries with aid of ODIS

Classification of high-voltage batteries with aid of ODIS

Special tools and workshop equipment required

♦ Diagnosis interface VAS 6154A -VAS 6154A-

♦ High-voltage diagnostics box -CN- -VAS 5581A-

Assessing condition

With high-voltage battery installed:

– → Vehicle diagnostic tester Connect.

– Carry out classification with → Vehicle diagnostic tester.

Continued

With high-voltage battery removed:

– Connect high-voltage diagnostics box -CN- -VAS 5581A- using vehicle-specific test adapters to communication connector of high-voltage battery.

– Switch on high-voltage diagnostics box -CN- -VAS 5581A-.

– Connect to → Vehicle diagnostic tester via diagnostics interface -VAS 6154A- or USB cable.

– Carry out classification with → Vehicle diagnostic tester.

Fundamentals of classifying high-voltage batteries

Fundamentals of classifying high-voltage batteries

The installed high-voltage batteries are highly complex components and systems that could be affected during their service life by defects, failure and partial failure.

The high-voltage battery could be damaged in a road traffic incident.

The substances contained in high-voltage batteries are hazardous materials.

The state of the high-voltage battery impacts the following service requirements and workshop processes:

♦ Special qualification requirements of service employees EIP, HVT and HVE.

♦ Repairability of high-voltage battery

♦ Packaging and transport process for high-voltage batteries

♦ Quarantine and reporting processes to be carried out

Important

● To assess the hazard potential of the high-voltage battery, classify the high-voltage battery.

The high-voltage battery can be assigned to 3 states:

1 - “NORMAL”, not critical: no measures need to be taken.

2 - “WARNING”, critical: failure to observe the recommended measures may lead to fatal/serious injury.

3 - “DANGER”, dangerous: failure to observe the recommended measures will lead to fatal/serious injury.

Carry out assessment based on classification matrix.

Classification matrix

Assessment criteriaClassification Visual, sensoryFunctional, electricThermal

♦ No relevant mechanical damage.

♦ No fluid leaks.

♦ High-voltage battery can be diagnosed.

♦ No relevant entries in event memory.

♦ Temperature within tolerance.

♦ NORMAL Not critical: No measures have to be taken.Fulfilment of ALL criteria results in classification “NORMAL”.

♦ Relevant mechanical damage, e.g. dent, crack, opening, defective seal.

♦ Corrosion damage.

♦ Pungent smell.

♦ High-voltage battery cannot be diagnosed.

♦ Relevant entries in event memory.

♦ Temperature outside tolerance.

♦ WARNINGCritical: Failure to observe the recommended measures may lead to fatal/serious injury.Fulfilment of ONE criterion results in classification “WARNING”

♦ Fluid leak, suspected fluid in high-voltage battery system.

♦ Sparks, smoke or vapour.

♦ Signs of fire.

♦ Unusual noises inside the high-voltage battery, e.g. crackling or hissing.

♦ Mechanical damage with exposed, accessible contacts/conductors.

♦ Accessibility of high-voltage battery for temperature measurements, e.g. due to missing or damaged body parts, surface temperature of high-voltage battery higher than 80°C.

♦ Temperature ≥ 80°C.

♦ DANGERDangerous: Failure to observe the recommended measures will lead to fatal/serious injury.Fulfilment of ONE criterion results in classification “DANGER”.

Matrix of measures

ClassificationImmediate measureOther measures and processesRepair according to Workshop ManualIntermediate storage/quarantinePackaging and transportNORMAL

♦ Not necessary.

♦ Repair if necessary.

♦ Original packaging

♦ Not stacked, flat on ground.

♦ Stored undercover outside and protected against rain.

♦ Original packaging WARNING

♦ Quarantine

♦ Bring outside or into quarantine area/quarantine cabinet.

♦ Use PPE.

♦ Implement disposal measures if repair not possible.

♦ Transfer to not critical status possible through repair.

♦ Inform responsible party in accordance with reporting procedure.

♦ Move high-voltage vehicle/high-voltage battery to suitable outside area/space.

♦ Protect removed high-voltage battery against moisture.

♦ Special transport crate required (may need to be dismantled).

♦ May only be packaged by trained personnel. Carry out additional actions as instructed by HVE.DANGER

♦ Keep a safe distance.

♦ Observe high-voltage vehicle/high-voltage battery.

♦ Have fire extinguishing equipment ready and at the first sign of fire immediately notify the fire service and evacuate the building.

♦ Do not inhale smoke/gas. Wear mask.

♦ If the high-voltage battery has suffered mechanical damage with exposed, accessible contacts or conductors, do not touch the vehicle or the high-voltage battery.

♦ Quarantine high-voltage vehicle/high-voltage battery if possible.

♦ Cordon off a large area and inform responsible party as per reporting procedure.

♦ Use PPE.

♦ Not relevant.

♦ Quarantine vehicle/battery and call fire service if necessary.

♦ Observe high-voltage vehicle/high-voltage battery.

♦ Do not package.

♦ Do not transport.

Classification procedure

♦ The classification is software-based and carried out with the aid of “Guided Functions” via ODIS.

♦ Measured values of cell voltages and temperature sensors are collected, the event memory is interrogated, communication with the battery regulation control unit is checked.

♦ Classification can be carried out with the high-voltage battery fitted in the vehicle or removed.

♦ Only an HVE may reclassify the battery based on an assessment specific to the case.

Procedural diagram

Visual, sensory, function, electric and thermal assessment.Criteria:1 Signs of fire?2 Sparks, smoke, vapour noticeable?3 Noise from high-voltage battery, e.g. crackling?4 Pungent smell?5 Fluid leak or suspected fluid in high-voltage battery system?6 Severe mechanical damage to high-voltage battery?7 Temperature and cell voltage measurement?8 Functional check of high-voltage battery?↓ ClassificationNORMAL (not critical)WARNING (critical)DANGER (dangerous)

Quarantine arrangements

Quarantine arrangements

Working on accident high-voltage vehicles

Important

● If a defective or accident high-voltage vehicle is delivered, inform high-voltage technician (HVT).

● Unload vehicles with high-voltage battery straight to a dedicated space.

● Authorised workshops should make immediate contact with the nearest high-voltage service partner or importer.

● Post a warning sign on the high-voltage vehicle reading “Warning! Hazardous voltage” -VAS 6649- or words to that effect. In the event of a quarantine, further signs will be necessary.

● Secure high-voltage vehicle to prevent unauthorised access.

● Protect severely accident-damaged vehicles and removed high-voltage batteries against rain and damp.

Arrangements for setting up quarantine area

The use of a sealed floor plate is recommended.

1 - Warning sign “Danger from batteries” -VAS 6786-

2 - Warning sign “Warning! Hazardous voltage” -VAS 6649-

3 - Prohibition sign “No fire” -VAS 6882-

4 - Prohibition sign “Access prohibited” -VAS 6881-

5 - Isolated area inc. hazard warning signs

6 - Outer safety zone

7 - Suitable open area, e.g. parking space.

Procedure (continued)

Important

● Record complaints in DISS.

● Perform a visual inspection of the accident vehicle and appraise its hazard potential by means of the following assessment criteria.

Important

● Use temperature gauge -VAS 6886- to measure temperature.

Assessment criteriaMeaningSigns of fire
Important

● If at least one assessment criterion applies: beware of hazard Follow measure a)

● If none of the assessment criteria apply, proceed with b) Sparks, smoke or vapourUnusual noises inside the high-voltage battery, e.g. crackling or hissing.Pungent smellFluid leak, suspected fluid in high-voltage battery system.Mechanical damage with exposed, accessible contacts/conductors.Accessibility of high-voltage battery for temperature measurements, e.g. due to missing or damaged body parts, surface temperature of high-voltage battery higher than 80°C.

a) Observe the following measures in the event of “BEWARE! HAZARD”:Keep a safe distance.Observe high-voltage vehicle/high-voltage battery.Have fire extinguishing equipment ready and at the first sign of fire immediately notify the fire service and evacuate the building.Do not inhale smoke/gas. Wear mask.If the high-voltage battery has suffered mechanical damage with exposed, accessible contacts/conductors, do not touch the vehicle or the high-voltage battery.Quarantine high-voltage vehicle/high-voltage battery if possible.Cordon off a large area and inform responsible party as per reporting procedure.Use PPE.

b) If the accident-damaged high-voltage vehicle is deemed to be non-hazardous based on the assessment criteria, the following steps must be taken: → Chapter „Classification of high-voltage batteries with aid of ODIS“.

Perform the work steps outside the buildings or in a suitable area if possible.

It may be necessary to repair the 12V onboard electrical system for a diagnosis.

Photographic documentation

Photographic documentation

Special tools and workshop equipment required

♦ Digital depth gauge -VAS 6087-

♦ Straightedge 500 mm -VAS 6075-

Procedure

– Carry out → Chapter „Classification of high-voltage batteries with aid of ODIS“.

– Remove rear centre underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing rear centre underbody cladding.

– Roughly clean entire area.

– Draw around dent and damaged area with a marker.

Important

● The colour markings to be applied as follows for the photographic documentation must be made on the lower part of the battery housing. A drawing is not sufficient.

● The direction of travel must be identifiable on each photograph.

● If the lower part of the battery housing is damaged in more than one place, number the areas.

– Mark damaged area -4- with adhesive strips -1- to -3-.

♦ Adhesive strips -1- for length and width of damaged area

♦ Adhesive strip -2- with "F->" for direction of travel

♦ Adhesive strip -3- indicating where damage is deepest

– Align camera parallel to lower part of battery housing -1-.

– For a better overview, photograph the entire lower part of the battery housing. If larger areas are affected, take several photographs.

– Hold straight edge 500 mm -VAS 6075- above dent.

– Use electric torch to backlight area.

– Measure depth of dent with digital depth gauge -VAS 6087-.

– Take picture of measurement.

Qualifications and working for emergency service, authorised workshop and importer

Qualifications and working for emergency service, authorised workshop and importer

WorkEmergency serviceAuthorised workshopImporter/HV battery competence centre Electrically instructed person - EIPElectrically instructed person - EIPHigh-voltage technician - HVTHigh-voltage expert - HVEBreakdown assistanceyes---Service, standard repairs (not HV relevant), GFF-yesyesyesDeactivation of high-voltage system--Diagnostic and manual power disconnectionDiagnostic and manual power disconnectionFault finding and repairs on high-voltage system (apart from high-voltage repair)--yesyesRepairs on high-voltage battery---yes

Packaging critical high-voltage batteries with “Warning” status, MEB batteries

Packaging critical high-voltage batteries with “Warning” status, MEB batteries

WARNING

Risk to health due to dust from expanded glass granules.

Risk of irreversible dust deposits in lungs, which could lead to respiratory problems.

– Wear a dust protection mask.

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

– → Chapter „Classification of high-voltage batteries with aid of ODIS“.

Preparing transport container

For the consignment of classified high-voltage batteries with “WARNING” status, special transport containers are required and the currently applicable transport laws apply.

– Determine suitable transport container using → Chapter „Packaging overview“.

Packaging high-voltage batteries in LP container

– Secure all contacts of high-voltage battery to prevent short circuit.

– Seal all openings for service fluids apart from electrolyte.

– Remove deposits of hazardous materials and electrolyte from outside of high-voltage battery.

– Release cover of transport container and lift off.

– Place cover down on suitable surface.

– Remove bag with hollow glass granulate.

– Check circumferential seal and pressure relief valves of transport container for damage.

– Pour hollow glass granulate into transport container up to a layer thickness of at least 120 mm.

– Support high-voltage battery as described in → Chapter „Packaging high-voltage batteries in genuine part crate“.

Important

● Distance -b- between inner walls and high-voltage battery -1- must be at least 20 mm.

● Distance -a- between vents -3- and high-voltage battery -1- must be at least 50 mm.

● Distance between high-voltage battery -1- and upper edge of transport container must be at least 200 mm.

– Place high-voltage battery -1- centrally in transport container -2-.

– Pour in hollow glass granulate so that gaps are filled and also entire transport container up to upper edge.

– Remove hollow glass granulate from circumferential seal of transport container.

– Fit cover on transport container.

– Screw on lid of transport container.

– Fill in and insert transport documents.

– Apply the warning notice for hazardous materials and information label to both ends of the transport container.

♦ “Dangerous goods class 9”

♦ “UN number 3480”

♦ “Attention! Damaged lithium-ion battery”

♦ “This side up”

Notes for transport preparation and hazardous material marking (Europe)

1 - “Protect against water”

2 - “Attention! Fragile”

3 - “This side up”

4 - “Maximum stacking load”

5 - “Hazardous material label: Hazardous material category 9 “Various hazardous substances and items” packaging group 2”

6 - “Type label with UN number UN 3480 for lithium-ion batteries”

1-speed gearbox 0MH, rear, EQ310. Final drive, differential, differential lockElectric drive EIP220, EIA200, EIA210. Technical data