CarTrain "Diagnosis and Repair of HV Vehicles"

The CarTrain "Diagnosis and repair of HV vehicles" combines hardware with interactive e-learning and offers the ideal introduction to high voltage technology. It fully meets the requirements of DGUV 209-093 Level 2S and other internationally recognised qualifications.

Special features of the training system:

• Practical learning projects by transferring the complete action model to workshop situations
• Comprehensive testing of system main relays:
• Three relay types: HV+ pre-charging, HV- pre-charging and pre-charging by DC/DC converter via 12 V battery with testing of functional and defective relay assemblies in dismantled condition
• Testing for welded relays
• Replacement of faulty relays (energised)
• Working with real high voltage: 400V system voltage, protective impedances ensure maximum safety
• All common methods for vehicle isolation such as:
• High voltage service disconnect on HV battery
• 12 V service maintenance plug
• Emergency low-voltage disconnection point and fuse
• Scan tool guided isolation
• Live-Dead-Live-Testing
• Real repair processes supplemented by defective components included in the delivery:
• Defective high voltage fuses
• Defective 3-phase cable harness
• Defective DC wiring harness
• Defective air conditioning wiring harness
• 6 relay modules (1 each for fault switching and 1 as a spare part for each pre-charging variant)
• Defective potential equalisation cable
• Acoustic warning in the event of serious operating errors, e.g. opening the interlock when the high voltage system is active (can be deactivated)
• Testing the potential equalisation on real metal components
• Simulation of abnormal noises due to magnetic interference
• Touchscreen with virtual cockpit and HDMI output
• With power meter and energy flow analysis for various hybrid and electric vehicles, including fuel cells
• Integrated tester with fault diagnosis and live data streaming
• Use of test adapters for measuring motor and insulation faults
• Real HV signal measurements:
• High voltage voltages and currents in the HV system in all driving conditions
• Communication with charging stations
• Motor position sensors (resolver and Hall effect)
• DC/DC converter for 12 V system
• Jump start for high voltage vehicles with faults in the 12V system

Scope of delivery:

• Training system "CarTrain Diagnosis and Repair of HV vehicles"
• Project case with spare parts and work materials
• Operating instructions
• Interactive learning software on data carrier

Manufacturer independent vehicle configuration:

The vehicle configuration can be flexibly customised by replacing the main relays and adjusting the drive concept. The following drive concepts are available:

• Standard hybrid drive with plug-in
• Parallel hybrid drive with plug-in
• Series-parallel hybrid with plug-in
• Electric vehicle
• Fuel cell vehicle

Structure of the training system:

• 12.1" touch panel with virtual cockpit and integrated diagnostic tester. Display output possible via HDMI.
• Replaceable system main relay with safety cover including interlock
• 12V jump-start point
• Display of HV auxiliary units such as air conditioning and PTC heating
• Display of various drive concepts on ePaper display
• Smart key for activating the vehicle
• Rotary dial for controlling the vehicle speed
• Switch for controlling the driving profile between incline, flat and downhill
• Start and brake button to switch on READY mode
  • • Real HV fuse from the vehicle
    • Isolation variantions:
      • Emergency low-voltage cutting point and fuse
      • HV service plug
      • 12V service plug
    • Quick-release battery terminals for tool-free removal of the battery terminals
    • Metal components for measuring the potential equalisation
• Measuring points to verify the absence of voltage behind metal cover with interlock contact
• Safety measuring sockets with protective impedances for the safety of trainees
• Type 2 charging port for connection to a charging station
• Charging activation switch

Integrated measuring interface:

• Connection via USB
• Diagnostic scan tool
• 4-channel oscilloscope
  • Four voltage inputs up to 600 V AC/DC
• Voltmeter
  • Saving oscilloscope images in e-learning via copy & paste

Practical training content:

• • Correct selection and testing of suitable measuring and testing equipment
  • Applying service information
  • Carry out service work on the HV system
  • Charging the HV battery 
  • Measurement of equipotential bonding cables
    • Various methods for unlocking the vehicle:
• High voltage service disconnect on HV battery with live-dead-live test
• 12 V service plug
• Emergency low-voltage disconnection point and fuse
• Tester-guided activation
  • Commissioning of an HV system
  • Insulation tests and winding measurements with test adapters.
  • Insulation test for HV cable, AC compressor and drive motor faults

Course contents:

The scope of delivery includes an interactive training course with practical project work. This covers the following topics, among others:

• Basics of high voltage vehicles:
  • Term "high voltage"
  • Types of hybrid and electric vehicles
  • Operating modes of hybrid and electric vehicles
• Basics of high voltage technology and drives in motor vehicles
  • Voltage level in vehicles
  • Cell chemistries of high voltage batteries
  • Temperature control of high voltage batteries
  • Safety systems in high voltage vehicles and HV intrinsic safety
  • Isolating and reactivating of HV systems
  • Types of electrical machines
  • Motor position sensors in drive motors
  • Power electronics and voltage conversions
  • Regenerative braking
  • Control of electric drives
  • Charging electric vehicles and communicating with charging infrastructure

• Safe handling of high voltage vehicles:
  • Occupational safety
  • Dangers from high voltage systems
  • Current paths through the body
  • Selection and inspection of PPE
  • Safe working on high voltage vehicles
  • Dealing with damaged HV vehicles
  • Release points and safe handling of vehicles for first responders and emergency services
• Diagnostics and maintenance work on high voltage vehicles
  • Troubleshooting electric motors
  • Jump start for high voltage vehicles and troubleshooting on the 12V charging system
  • Localisation of insulation faults
  • Correct implementation of potential equalisation measurements
  • Checking the shielding and magnetic interference faults

Dimensions and power supply:

• Power supply: AC 230 V 50-60 Hz / 3 A
• Dimensions: 1000 x 800 x 220mm (WxHxD)
• Weight: approx. 38kg