Spændingsniveauer Ekstra lav spænding: Under 25 volt AC eller 50 volt DC Lav spænding: Op til 1000 Volt AC eller 1500 Volt DC. Høj spænding: Over 1000 Volt AC eller 1500 Volt DC. 1

Lukkede batteri-kasetter

Battery Pack 88 Cells of 3.7 Volt 12 Modules (10 x 8 Cell, 2 x 4 Cell) 88 cells of 3.7 volt make a battery pack of 325,6 volt, but commercially we talk about a 330 volt battery. (the cells are all in series). The cells are grouped in 10 modules of 8 cells and 2 modules of 4 cells, so 12 modules make the total battery pack. The cells can be placed in any position the 10 modules at the front and 10 at the rear are placed on the side, the two modules in the middle are positioned bottom down. Each module has several temperature sensors and each individual cell has a connection with the CMU for a voltage check. The Battery Management Unit BMU has CAN connection with the CMU cell monitoring unit called battery CAN. The CMU can also be directly accessed with M.U.T.-III. If after 10 or more years a 100% charge results in a 70% driving distance of the initial distance this indicates that the battery has to be replaced. The 12 volt battery will be charged by the 330V battery via the DC-DC converter but only in “READY” status. During charging of the 330 Volt battery the 12V battery will also be charged. If the 12 Volt battery is fully drained the 330 Volt battery can not be charged with the normal 220 volt charging connection, the reason for this is that the CAN bus system is down therefore charging can not be started. The best solution is to charge the 12 volt battery with a normal battery charger for about 20 minutes, afterwards EV battery charging can start. 12 Modules (10 x 8 Cell, 2 x 4 Cell) Battery consists of 88 cells arranged in 12 modules. Total voltage when fully charged = 365 Volts (315 Volts discharged)

Batteri med afdækket poler

Batteri med frie poler

Indvirkninger på kroppen HPFI-relæ frakobler ved 30 mA 6

Når skaden er sket !!!!!! - Afbryd spændingen / stands ulykken - Giv livsreddende førstehjælp - Ring 112 - Giv almindelig førstehjælp 7

Livsreddende førstehjælp Skab frie luftveje

Livsreddende førstehjælp Hjertemassage

L-AUS BESTEMMELSER EUCSYD 2005 11

L-AUS BESTEMMELSER EUCSYD 2005 12

Forudsætninger for sikkert arbejde Arbejdsstedets indretning Tekniske hjælpemidler Arbejdsteknik Arbejdets tilrettelæggelse Forudsætninger for sikkert arbejde

Safety!!!!! i MiEV uses potentially lethal voltages 330 Volt DC & AC A human body cannot withstand a lot of current. The current is depending on the voltage, the wetness and thickness of the skin, the area of contact and the length of the flow trough the body. Make sure that your body is never part of a conductance circle! Protect yourself sufficient! In the human body muscles are activated with very small currents send from the brain. If a current is applied from the outside the muscles react the same, they contract which means that is becomes more and more difficult to break free from the current. i MiEV uses potentially lethal voltages 330 Volt DC & AC Observe all safety precautions! Use protective clothing and tools!

Use of warning signs While working on I-MiEV use signs to warn others present in the workshop! Keep Out! Take note of local requirements regarding this subject. High Voltage!

Livsvigtigt !!!!!!!!!! Kontroller altid om systemet er spændingsløs inden arbejdet påbegyndes

Hvad forstås ved L-AUS arbejde? L-AUS BESTEMMELSER Hvad forstås ved L-AUS arbejde? Ved arbejde på eller nær ved lavspændingsanlæg under spænding (L-AUS) forstås arbejde, der udføres under berøring af spændingsførende dele af et lavspændingsanlæg eller i nærved-zonen omkring sådanne dele. Afstanden DL Afstanden i luft, som angiver den ydre grænse af farezonen For lavspænding er DL = 0 mm Afstanden DV Afstanden i luft, som angiver den ydre grænse for nærved-zonen For lavspænding er DV = 500 mm EUCSYD 2005 17

L-AUS værktøj / udstyr

Fuld-isoleret

Brugs-isoleret

Hånd-isoleret

Valg af måleudstyr !!!!!!

Krav til måleudstyrs isolation Teknologisk Institut anbefaler min. CAT III til måling på EL- og Hybridbiler

Sikkerheds afbryder Under førersæde 88 cells of 3.7 volt make a battery pack of 325,6 volt, but commercially we talk about a 330 volt battery. (the cells are all in series). The cells are grouped in modules of 4 cells so 22 modules make the total battery pack. The cells can be placed in any position the 10 modules at the front and 10 at the rear are placed on the side, the two modules in the middle are positioned bottom down. A battery cell monitoring system (CMS) monitors all 88 cells and can pin point a specific cell by fault code. It is not possible to replace a cell the battery is sealed and is a black box. There is no logic in combining a brand new cell with already aged cells. There are 12 CMS units located inside the battery pack. The Battery Management unit BMU has CAN connection with the CMU cell monitoring unit called battery CAN. The CMU cannot directly be accessed with MUT-III. If after 10 or more years a 100% charge results in a 70% driving distance of the initial distance this indicates that the battery has to be replaced. The 12 volt battery will be charged by the 330V battery via the DC-DC converter but only in “READY” status. During charging of the 330 Volt battery the 12V battery will also be charged. If the 12 Volt battery is fully drained the 330 Volt battery can not be charged with the normal 220 volt charging connection, the reason for this is that the CAN bus system is down therefore charging can not be started. The best solution is to charge the 12 volt battery with a normal battery charger for about 20 minutes, afterwards EV battery charging can start.

Service plug (electric shock!) Battery Service Plug Service Plug Bridge First always remove Service plug (electric shock!) Always apply double safety! Insulated gloves and insulated tools Check for voltage! The Service/Safety plug is located under the left front seat. There is a cover fitted with two nuts which have to be removed before the safety plug can be removed. During the removal of the cover and the safety plug insulated hand gloves should be used. High voltage gloves need to be checked on pinholes, roll up the gloves and see if air escapes. If the EV system is not active the main relays inside the battery are open and no power can be found anywhere outside the battery but MMC insists on double safety so always remove safety plug before any work is done with or close to orange cables!! The connectors on the high tension wiring harness have a locking mechanism.(white or green part) Always first unlock the locking mechanism by pulling it backwards (see picture below) then disconnect the connector itself. If the safety plug lever is not fully down the EV system will not start up, in this case the EV system-warning lamp on the dash will be on. A fault code “interlock switch” will be set. The service plug isolates the battery from the rest of the vehicle. A bridge is used to allow the EV-ECU to detect that the plug is locked in place.

Sikkerhed afbryder Fjern altid sikkerhedsafbryderen; inden der arbejdes på bilen. Der anbefales brug af gummihansker ved afmontering og montering af sikkerhedsafbryder Magnet Stikforbindelser og kabelsko på de orange kabler kan og må ikke repereres / udskiftes The Service/Safety plug is located under the right front seat. There is a cover fitted with three bolts which have to be removed before the safety plug can be removed. During the removal of the cover and the safety plug insulated hand gloves should be used. High voltage gloves need to be checked on pinholes by roling the gloves and see if air escapes. If the EV system is not active the main relays inside the battery are open and no power can be found anywhere outside the battery but MMC insists on double safety so always remove safety plug before any work is done with or close to orange cables!! The connectors on the high tension wiring harness have a locking mechanism.(green part) Always first unlock the locking mechanism by pulling it backwards (see picture below) then disconnect the connector itself. If the safety plug lever is not fully down the EV system will not start up, in this case the EV system-warning lamp on the dash will be on. A fault code “interlock switch” will be set. Hall sensor

Toyota Prius