The HV battery is constructed in such a way that it can be disassembled in order to replace individual cells and sensors. In this way, the HV battery is diagnosed and repaired in an action and practice-oriented manner. Particular focus is placed on system-critical situations that can occur in the event of a malfunction in the hybrid and electric vehicle. In particular, faults are dealt with that occur on the vehicle but cannot be worked through independently during training. This includes not only the HV system and its control and protective devices, but also critical faults in the energy storage system itself. Diagnostics can be started practically using the integrated diagnostic tester. The diagnosis can be further deepened with the integrated and workshop-standard HV measuring equipment. This includes not only measurable faults in the HV safety systems, but also faults in the temperature sensors and battery cells, the practical replacement of which can be carried out. In this way, a qualification level for working in energy storage systems is also achieved.

Outstanding functions of the training system

Precharge and main relays with self-diagnosis function and provided with fault circuits.
16 battery modules, individually replaceable, digitally coded, provided with fault circuits.
8 battery temperature sensors, replaceable and provided with fault circuits.
Pilot line with diagnostic function and provided with fault circuits
Hall-effect current sensor for contactless measurement of charging and discharging processes
Real battery cell balancing with live data transmission to the diagnostic tester
Visualised display of the selected driving profile
Bidirectional energy flow display between drive and HV battery
CCS type 2 fast charging socket for DC and AC charging
Energy flow visualisation from charging ports to HV battery
Digitally networked CAN bus battery management system with measurement interface
CAN bus test sockets (3-fold, for signal tracking in the event of a fault)
50 fault switching options in the HV system and in the HV battery

Scope of supply:

CarTrain CO3221-6S “Diagnostics and maintenance of a high-voltage battery”
Interactive course on CD-ROM with LabSoft browser, course software and additional virtual instruments
Integrated diagnostic software
Lead set
- 4 × 2 mm safety measuring lead (yellow, 30 cm)
- 4 × 4 mm safety measuring cable (red, 100 cm)
- 4 × 4 mm safety measuring cable (black, 100 cm)
- 1 × 4 mm safety connecting plug (red)
- 1 × 4 mm safety connecting plug (brown)

Digital measuring instruments:

Digitally networked measurement capacity
4-channel oscilloscope
Voltmeter
Ammeter
Double voltage meter
Power meter

Training contents:

Understand customer complaints, carry out operational testing and determine diagnostics approach
Read out fault memory
Evaluate work safety
Check effectiveness of electrical safety measures on the high-voltage system
Replace high-voltage components
Become familiar with location of components in the motor vehicle
Determine faults and their causes with the aid of circuit diagrams and function plans
Draft an inspection protocol and document results
Understand measures taken to avoid hazards caused by voltage isolation faults
Learn about data communication between control units
Recognise repair needs and carry out repair options
Determine diagnostics and repair options based on a customer’s job order
Determine system operating states with the aid of the diagnostics systems, compare these to information in databases and evaluate results
Measuring and testing systems
- Determine the desired data
- Select measurement procedure and measuring instruments
- Document the measurement results
Determine the measurement results, compare these to the desired data and evaluate
Measure, check and evaluate signals at components and systems
Measure, test and evaluate electrical connections
Test high-voltage systems with diagnostics equipment, in particular perform measurements on isolation, equipotential bonding and voltage drops
Analyze and evaluate messages in data bus systems
Learn how battery cells are designed and function in the HV battery
Learn how temperature sensors are designed and function in the HV battery
Design and function of HV charging systems
Advantages and disadvantages of individual HV charging systems
Options to practically measure power consumption for different driving profiles
Measuring voltage characteristics in HV batteries for different charging and discharging cycles
How sensors and actuators interact
IPO principle
Open-loop control processes in the motor vehicle
Closed-loop control processes in the motor vehicle
Differences between open- and closed-loop processes

Components of the training-panel system:

Mains power switch
Emergency-stop safety switch
Ignition switch
Control unit BMS 1
Control unit BMS 2
Central control unit for BMS1 and BMS2
Pre-charging and main relay with self-diagnostic function
16 battery modules, interchangeable, digitally encoded, including fault simulation circuits
Active battery cooling
8 battery-temperature sensors, interchangeable
Pilot line with diagnostics function
Hall-effect current sensor for non-contact measurement of the charging and discharging processes
Real battery cell balancing
Selectable driving profile
- Incline
- Level
- Coasting
- Gradients with recuperation
- Electrical braking with recuperation
Visualised display of selected driving profile
Low-voltage service disconnect
High-voltage service disconnect
HV protection for emergency services
Combination instruments with
- Power meter – power display
- Speed indicator
- Battery charge indicator
- HV-ready and EPC warning light
- Charging station control light
- Warning light for power limitation
Rotating drive gear
Bidirectional power flow indicator between drive gear and HV battery
Type 1 charging plug for AC charging
CCS-type 2 rapid charging plug for DC and AC charging
Charge buttons for controlling charge initiation
Power flow visualisation from the charging plug to the HV battery
2-mm and 4-mm safety measurement sockets
Removable complete battery cover
Contact protection guards for battery cell terminals
Digitally networked CAN-bus battery management system with measurement interface
Test sockets for temperature sensors
Test sockets for CAN-bus
Test sockets for HV
Test socket battery module 1
Test socket battery module 2
Test socket 12V
Terminals for measuring equipotential bonding
Terminal designations according to DIN 72552
46 fault simulation options
USB connection socket

Supply voltage:

100-240 V AC 50-60 Hz

Operating voltage:

13.5V and 67V DC

Dimensions:

1010×320×805 (WxDxH)

My German Pavilion