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Urban mobility, EV vehicles. Safety processes before, during work and tooling

Watch the film above and follow the text. Then click on the button test your understanding to see how much you can remember. You then need to click on the battery change button to see the next film and answer the questions about that film. Transscript:

Here is a Honda Insight hybrid. We are going to prepare the workspace for a routine operation on the electric parts of this car. The procedure is the same for all electric vehicles, although where you find parts can vary from make to make. When the car is brought into the workshop, you have to evaluate the work that has to be done.

Work without live wires

For example changing components in the inverter

No Voltage

To ensure that neither you, nor the vehicle you are working on, become damaged it is safest to work on EVs in a no-voltage situation, if this is possible. The work will generally be faster as you will be able to work without bulky protection equipment. The first consideration before you work on the car is, therefore, can the work be performed in a no-voltage situation. If the answer is yes you need to ensure that all of the components in the car are voltage free (not live). The battery pack should be disconnected in such a way that it cannot be reconnected without your knowledge while you are working. All areas where it is possible to reconnect the battery pack should be clearly marked with a suitable, approved sign, which shows that work is being done on the car. The sign may only be removed by the person working on the car. You must always check that all components are not live before starting or resuming work. Measure the voltage using a multi-meter or a voltmeter; remember to check that your measuring device is working correctly. This can be done by measuring the level of voltage in the 12 volt battery. You can also use a non-contact voltage tester.

Working close to live wires

For example: Ordinary service, working on the brakes etc.

When working close to live wires you have to be sure that you dont touch or get too close to them with anything that can carry current. This can be done by encapsulation or covering up the wires that are close to where you are working with insulating mats. Theclose-to-zonewith cars is defined as 0.5 meter from live wires. If you are working within this zone you must follow the correct safety procedures. If you havent made sure that all of the live wires and connections are covered with an insulating material then the work is considered to the same as working with live wires and the necessary precautions should therefore be taken.

Working with live wires

For example

Trouble shooting within the electric motor, working on the battery pack

There are very few situations where it is necessary to work on a live system in a car. The risk of electrocution is extremely high, therefore, there has to be a really good reason to work on the system with the battery pack connected. If you have to work in a live situation then the work should be planned carefully step by step down to the smallest detail before you start. This careful planning, preferably written, will help to reduce the risks of unforeseen dangerous situations during the work. The person doing the work must be trained in this type of operation. You need to know how the system is constructed and how to break the circuits in an emergency situation. Never work on the high-voltage parts of the car alone. Make sure that there is at least one other person close by who can assist you in an emergency, and who is familiar with the safety procedures involved and the necessary first aid that could be required in the event of an accident. Your work area should allow you to have both hands available to work with. You should remove any unnecessary conductors such as watches and jewellery that could cause dangerous situations.

Conditions for safe working conditions

There are four areas that we need to consider.

Workplace layout

Technical aids

Work procedure

Working method

Under workplace layout you should think about where you place the car in the workshop. No one in, or passing, the workspace can be harmed if anything goes wrong.

Technical aids such as tools and personal protection equipment should be checked for holes and damage in the insulating material. The area has to be cordoned off to keep nosey people away.

Work procedure must be very well planned. The planning should also include the order in which you will be carrying out the task. You should have an emergency procedure plan ready in case of accidents. You must also make an accident risk assessment.

Working method covers your professional pride and your own safety. Remember to use common sense and the right safety equipment. Look out for yourself and the customers carYour own safety is always your first priority.

Included in the group Evs and Hybrids are electric scooters, golf carts and electrically driven trucks. Always remember to lift the wheels that are connected to the drivetrain off the ground. Electric motors make no sound and there is a small, but not insignificant danger of a short circuit starting the motor, thus moving the car. Even if you are just measuring the motor output or the battery voltage on the 12 volt battery you must lift the car. Remember that the motor can be activated without turning the key!

The area should be cordoned off with safety tape

A warning sign should be displayed, informing passersby that there is work being carried out on an electrical system. The switch sign should be set up when you have disconnected the battery pack. The person working on the vehicle is the only person that should move these signs.

Manuel disconnection of the battery

In order to work safely on an EV the battery should always be disconnected. It is worthy to note that there can be a residual high-voltage current within the system for up to 10 minutes after disconnecting the battery pack. There is no standard fitting for EVs as yet, but in the Honda insight you can see there is a switch. It is under the carpet in the boot.

Toyota Prius

The following procedure must be adhered to when disconnecting the battery pack:

Use approved, insulated safety gloves during the whole of the procedure.

The key should be removed from the ignition

The negative (ground) terminal should be disconnected from the 12 volt battery

Remove the cover from the bottom of the boot

Remove the service plug and place it in your pocket so no one accidentally reconnects the battery pack while you are working on the car.

The service plugs exposed end should be securely covered over with insulating material for example a rubber mat.

A warning sign should be displayed, informing passersby that there is work being carried out on an electrical system

During work and tools

Depending on the job in hand the following equipment should be used:

Personal protection equipment, i.e. rubber gloves that are certified EN 609003, safety glasses, full-face visor, insulated helmet.

Insulated tools that are certified EN60900, i.e. screwdrivers, ratchet sets, pliers, torches, measuring equipment etc.

insulating mats and covers, i.e. leather covers, rubber mats etc..

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