Annex 4 - Annex 4 Topics covered by training for persons without prior electrical knowledge but with technical training
The topics indicted below serve as an example only and reflect the current state of the art of automotive HV technology. Topics irrelevant to the work to be carried out can be ignored. Other relevant topics must be added in their place if necessary.
Basic electrical knowledge
Electric voltage,
Electric current,
Direct current, alternating current, three-phase current,
Calculations involving powers of ten,
Power sources,
Electrical resistance:
Ohm's Law,
Connection in series,
Connection in parallel.
Electric power,
Forms of power generation,
Power sources:
Fuel cell, EDLCs, batteries (lithium-ion, nickel-metal hydride),
Charging regulations.
Coil,
Electric motor,
Three-phase asynchronous motor,
Three-phase generator,
Transformer,
Semiconductors, diodes, bipolar transistors,
Design of a relay,
Design of a capacitor,
Use of a capacitor to smooth undulating voltage,
Instruments and measurement methods:
Analogue and digital instruments,
Measurement of current, voltage and resistance,
Measurement errors,
Troubleshooting on vehicles,
Diagnostics.
Reading off and use of measurement results is practised in order for measurement displays to be read and interpreted correctly.
Measurement of V/R/I, use of voltmeters, ammeters and electronic boards.
Production/interpretation of V/I diagrams in preparation for the specialist module.
Estimation (by ratios) and calculation of voltages and resistances in series and parallel circuits.
Determining of potentials, voltage drops and currents in more complex circuits by means of the load/current arrow system.
Exercises in the calculation of power, work and efficiencies.
Reading of circuit diagrams, tracing of current paths.
Electrical hazards and first aid
Reading of circuit diagrams, tracing of current paths,
Stimulus thresholds,
Let-go threshold,
Cardiac fibrillation,
Burns,
Duration of the effect of current upon the human body,
Resistance of the human body,
Hazardous body currents,
Maximum touch voltage,
General information on first aid, behaviour in the event of fire,
Accidents caused by electric current,
Measures to be taken in the event of injury,
First aid in the event of injury caused by electric current,
Records of first-aid measures,
Reporting of accidents.
Measures for protection against electric shock and fault arcs
Classification of protective measures; key terms.
Protection against direct contact:
Protection by the insulation of live parts,
Protection by shrouding or encapsulation.
Protection against direct and indirect contact (extra-low voltage).
Protection against indirect contact (protection against hazardous electric shock in the event of a fault):
Protective insulation,
Protective separation,
Protection by disconnection:
Protective device,
Mains systems,
Protective measures in the IT system.
Function of potential equalization.
Requirements and suitable measures
Protective measures:
Overload protective devices,
Residual current devices.
Tests based upon DIN VDE 0100-600:
Visual inspection,
Measurements of the insulation resistance,
Function test.
Organization and documentation of the tests.
Organization of safety and health for electrical work
OSH system,
European legislation (EU Low-voltage Directive),
German legislation (German occupational safety and health act, German ordinance on industrial safety and health with TRBS),
Accident prevention regulations: BGV/GUV-A 1 governing principles of prevention, BGV/GUV-A 3, "Electrical installations and equipment",
Codes of good practice (DIN, EN, VDE, further standards, e. g. governing measurement),
Risk assessment,
Content of the BGV/GUV-V A3 accident prevention regulation, "Electrical installations and equipment", and of the DIN VDE 0105-100 standard governing measures for accident prevention: the five safety rules,
Repair, commissioning, maintenance and service,
Assurance of safety by personal protective equipment and other equipment,
Informative safety technology, warning signs.
Specialist and man-management responsibility
Delegated responsibility of managers,
Responsibility of the skilled electrical person,
Legal consequences.
Employee qualifications in the area of electrical engineering
Who is permitted to carry out work on the electrical system?
Instruction of electrical lay persons, tasking of workers.
Use of HV systems in vehicles
Introduction to the subject of alternative drives.
Structure, function and mode of operation of alternative drives
Fuel cell vehicles,
Hybrid drives,
Electric vehicles.
Fuel cell/hybrid vehicles: concepts and operating modes.
HV components: e. g. fuel cells, HV batteries, power electronics, DC/DC converters, three-phase, synchronous and asynchronous machines, other safety-critical components.
Federal ECE Rule 100.
Motor Vehicle Safety Standard 305 (FMV SS 305).
Measures to ISO 6469-3 and DIN EN 61140 (VDE 0140-1) for protection against electric shock.
Recording of energy flows during operation of the hybrid system in various modes.
Calculation of body currents in the event of insulation faults; hazards of such body currents.
Risk assessment for fuel cell/hybrid vehicles.
Protection classes/degrees of protection.
Determining the Ri of different NiMH cells.
Placing of hybrid vehicles in the non-live state.
Measurements on the HV system.
Replacement of installed components.
Commissioning with determining of the RISO of the HV system with/without faults in the HV system.
Measurements (voltage drop and potential) on high-resistance circuits on conventional vehicles in consideration of the Ri of the instrument.
Measurement of capacitance and inductance.
Measurement of pulse width and frequency on conventional vehicles.
Creation and understanding of circuits for transformation of direct current, with and without galvanic isolation.
Measurement exercises on hybrid vehicles: location of the components, connection and disconnection of the maintenance plug (service disconnect), checking of isolation, measurement of HV+ against HV- and against the vehicle earth.
Markings in accordance with vehicle standards/DIN VDE standards/accident prevention regulations.
Conductors and cables:
Cable core arrangements, core and outer insulation,
Core markings,
Proper electrical connections,
Preparation of fine- and ultra-fine-stranded conductors.