Electricdrivesystems -> 6.1.1 Fundamentals of classifying lithium-ion high-voltage batteries for Your Volkswagen Crafter Van Second Generation (2017-2025)

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High-voltage system - General information - Edition 02.2021  
6
High-voltage battery  
⇒ h6.1 igh-voltage battery”, page 26  
⇒ b6.2 attery handling and storage”, page 33  
⇒ h6.3 igh-voltage batteries”, page 34  
⇒ c6.4 ritical high-voltage batteries with Warning status”, page  
54  
⇒ i6.5 nformation on opening and bonding high-voltage batter‐  
ies”, page 77  
6.1  
Classifying high-voltage battery  
⇒ o6.1.1 f classifying lithium-ion high-voltage batteries”, page  
26  
⇒ o6.1.2 f lithium-ion high-voltage batteries with aid of ODIS”,  
page 30  
6.1.1  
Fundamentals of classifying lithium-ion  
high-voltage batteries  
Classifying lithium-ion batteries  
The lithium-ion high-voltage batteries that Volkswagen installs  
in electric and hybrid vehicles are highly complex components  
and systems that may not be immune to defects, failure or  
partial failure over the course of their service life.  
Lithium-ion high-voltage batteries can also suffer damage in  
traffic accidents.  
Since lithium-ion high-voltage batteries are deemed to be haz‐  
ardous materials on account of the substances inside them, the  
respective battery condition plays a decisive role in how high-  
voltage batteries are handled during service operations and the  
workshop process.  
This applies in particular to:  
♦ The qualification requirements of service employees (EIP,  
HVT, HVE)  
♦ The repairability of the lithium-ion high-voltage battery  
♦ The transport and packaging process for lithium-ion high-  
voltage batteries  
♦ The quarantine arrangements and reporting processes nec‐  
essary in special cases  
Rating and assessment criteria during classification  
To determine whether and to what extent the lithium-ion high-  
voltage battery poses a higher level of danger, it must be sub‐  
ject to classification.  
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High-voltage system - General information - Edition 02.2021  
3 statuses can be assigned to lithium-ion high-voltage batteries:  
1 - NORMAL (not critical)  
2 - WARNING (critical)  
3 - DANGER (dangerous)  
The rating is carried out based on the following assessment  
criteria:  
♦ Visual and sensory criteria  
♦ Functional and electrical criteria  
♦ Thermal criteria  
6. High-voltage battery  
27  
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High-voltage system - General information - Edition 02.2021  
Precise decoding and an overview of the criteria can be  
gleaned from the following matrix of classifications and meas‐  
ures.  
Classification matrix  
Assessment criteria  
Visual, sensory  
Classification  
Functional, electric Thermal  
♦ No relevant mechani‐ ♦ High-voltage bat‐ ♦ Temperature within • NORMAL  
cal damage  
tery can be diag‐  
nosed  
tolerance  
Not critical: No measures have  
to be taken.  
♦ No fluid leaks  
♦ No relevant en‐  
tries in event  
memory  
Fulfilment of ALL criteria results in classification “Normal” →  
♦ Relevant mechanical ♦ High-voltage bat‐ ♦ Temperature out‐  
• WARNING  
damage (e.g. dent,  
crack, opening, defec‐  
tive seal)  
tery cannot be di‐  
agnosed  
side tolerance  
Critical: Failure to observe the  
recommended measures may  
lead to fatal/serious injury.  
♦ Relevant entries  
in event memory  
♦ Corrosive damage  
♦ Pungent smell  
Fulfilment of ONE criterion results in classification “Warning” →  
♦ Fluid leak and/or sus‐  
pected fluid in high-  
Temperature ≥  
80 C  
• DANGER  
Dangerous: Failure to observe  
the recommended measures will  
lead to fatal/serious injury.  
voltage battery system  
♦ Smoke/vapour  
♦ Fire, sparks  
♦ Noise (hissing, crack‐  
ling)  
Mechanical damage  
with exposed, acces‐  
sible contacts/conduc‐  
tors  
Fulfilment of ONE criterion results in classification “Danger” →  
Matrix of measures  
Classification  
Immediate meas‐  
ure  
Other measures and processes  
Repair *  
Intermediate stor‐  
Packaging and  
age/quarantine  
transport  
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NORMAL  
♦ None required ♦ Repair, if neces‐ Intermediate stor‐ ♦ Original pack‐  
sary  
age:  
aging  
♦ Original pack‐  
aging  
♦ Well clear of  
roads/traffic  
♦ Not stacked, flat  
on ground  
♦ Stored under‐  
cover outside  
and protected  
against rain  
↑ Transfer to not  
critical status possi‐  
ble through repair  
WARNING  
♦ Quarantine  
♦ Implement dis‐  
posal measures  
if repair not pos‐  
sible  
♦ Inform responsi‐ ♦ Special trans‐  
ble party in ac‐  
cordance with  
reporting proce‐  
dure  
port crate re‐  
quired (may  
need to be dis‐  
mantled)  
♦ Immediately  
bring outside,  
into quarantine  
area/quarantine  
cabinet  
♦ Move vehicle/  
high-voltage  
battery to suita‐  
ble outside  
♦ May only be  
packaged by  
trained person‐  
nel  
♦ Use PPE if nec‐  
essary  
area/space  
♦ Water-protec‐  
tion for removed  
high-voltage  
battery  
Carry out additional actions as instructed by HVE  
↑ Transfer by  
qualified personnel  
DANGER  
♦ Keep a safe dis‐ ♦ Not relevant  
tance  
♦ Quarantine ve‐ ♦ Do not package  
hicle/battery  
♦ Do not transport  
and call fire  
service if neces‐  
sary  
♦ Call fire service  
immediately if  
necessary (e.g.  
in event of fire).  
♦ Keep high-volt‐  
age battery un‐  
der observation  
♦ Do not inhale  
smoke/gas.  
♦ Cordon off a  
wide area and  
inform responsi‐  
ble party in ac‐  
cordance with  
reporting proce‐  
dure (e.g. su‐  
pervisor, HVT,  
HVE, importer).  
♦ Quarantine ve‐  
hicle/battery if  
possible.  
1) As per workshop manual/extent of repair  
6. High-voltage battery  
29  
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High-voltage system - General information - Edition 02.2021  
Classification procedure  
♦ Classification is carried out with software-support by means  
of “Guided Functions” via ODIS (Offboard Diagnostic Infor‐  
mation System).  
♦ Among other things, measured values of cell voltages and  
temperature sensors are collected, the event memory is in‐  
terrogated and communication with the battery regulation  
control unit is checked.  
♦ Classification via ODIS can be carried out not only with the  
lithium-ion high-voltage battery fitted in the vehicle but also  
with the high-voltage battery removed.  
♦ Execution in the latter case requires additional, model-spe‐  
cific adapters (tools) (see Part 2 “Classification of lithium-ion  
high-voltage batteries with aid of ODIS”).  
♦ In all instances, only the HVE is able to reclassify the battery  
according to specific assessment scenarios.  
♦ Further details can be gleaned from the respective workshop  
manual.  
Procedural diagram  
Visual,  
Criteria:  
1 Signs of fire?  
2 Sparks, smoke, vapour noticeable?  
3 Noise from high-voltage battery (e.g. crackling)?  
4 Pungent smell?  
sensory,  
function,  
electric  
and ther‐  
mal as‐  
sessment  
5 Fluid leak or suspected fluid in high-voltage bat‐  
tery system?  
6 Severe mechanical damage to high-voltage bat‐  
tery?  
7 Temperature and cell voltage measurement?  
8 Functional check in high-voltage battery?  
Rating NORMAL (not critical)  
WARNING (critical)  
DANGER (dangerous)  
6.1.2  
Classification of lithium-ion high-volt‐  
age batteries with aid of ODIS  
To classify the condition of a lithium-ion high-voltage battery  
that has been removed and isolated from the vehicle system,  
the following special tools are required:  
Special tools and workshop equipment required  
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