Electricdrivesystems -> 6.1 Classifying high-voltage battery 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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♦ High-voltage diagnostic box -VAS 5581-  
♦ “Professional” diagnosis unit -VAS 6150E-  
♦ Adapter cable -VAS 5581/1-1- or adapter cable -VAS  
5581/1-1A-  
♦ Adapter cable -VAS 5581/3- or adapter cable -VAS 5581/3A-  
♦ Adapter cable -VAS 5581/5-  
Procedure  
Assessment of condition – high-voltage battery fitted in vehicle  
– Connect ⇒ Vehicle diagnostic tester to vehicle.  
Procedure in ODIS  
– Open ODIS.  
– Continue with Start diagnosis .  
– Select manual in the window for manual entry of the basic  
vehicle characteristics.  
– Remove tick from Work with Guided Fault Finding .  
– Select “8C Hybrid battery management” entry from control  
unit list.  
Right-click to call up options.  
– Select 8C-Assessment of condition .  
– Confirm with Run .  
Following the instructions and answer the questions about the  
condition of the high-voltage battery all the way to the end.  
– Select Protocol .  
– Select Save .  
– Select Long protocol in dialogue window.  
Note  
The long protocol includes the interrogated measured values.  
– Confirm with OK .  
– Save the protocol as an HTML file along with all of the nec‐  
essary data.  
6. High-voltage battery  
31  
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High-voltage system - General information - Edition 02.2021  
Assessment of condition – high-voltage battery removed from  
vehicle  
Note  
The following process steps exemplify the initial steps of diag‐  
nosis for assessment of a removed lithium-ion high-voltage bat‐  
tery with the aid of ODIS.  
– Connect high-voltage diagnostic box -VAS 5581- -3- with  
vehicle-specific test adapters -2- to communication plug of  
high-voltage battery -1-.  
– Switch on high-voltage diagnostic box -VAS 5581- -3-.  
– Activate terminal 15 F1 .  
– Activate terminal 30 F2 .  
– Set CAN-R select to “120-R” using the F3 button.  
– Connect to ⇒ Vehicle diagnostic tester via remote diagnosis  
head -VAS 5054A- or USB cable.  
Note  
Instructions are provided to the user via ⇒ Vehicle diagnostic  
tester on how to proceed with assessment of the condition of  
the high-voltage battery removed from the vehicle.  
Perform all work steps as described on ⇒ Vehicle diagnostic  
tester.  
Procedure in ODIS  
– Open ODIS.  
– Continue with “Start diagnosis”.  
Note  
The system automatically searches for the corresponding VIN.  
However, since battery diagnosis is being carried out on a re‐  
moved high-voltage battery, no VIN can be found.  
– Confirm the fault message with request to identify vehicle  
manually with OK .  
– Select manual in the window for manual entry of the basic  
vehicle characteristics.  
32  
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High-voltage system - General information - Edition 02.2021  
– Enter VIN from vehicle.  
– Remove tick from Work with Guided Fault Finding .  
– Confirm message for confirmation that “Guided Fault Find‐  
ing” should be deselected with Yes .  
– Select “8C Hybrid battery management” entry from control  
unit list.  
Right-click to call up options.  
– Select Guided Functions .  
– Select Identify control unit to facilitate communica‐  
tion.  
Note  
If the control unit is not found, identify manually.  
– Right-click on “8C Hybrid battery management” to call up  
options again.  
– Select Assessment of condition of high-voltage  
battery .  
– Confirm with Run .  
Following the instructions and answer the questions about the  
condition of the high-voltage battery all the way to the end.  
– Select Protocol .  
– Select Save .  
– Select Long protocol in dialogue window.  
Note  
The long protocol includes the interrogated measured values.  
– Confirm with OK .  
– Save the protocol as an HTML file along with all of the nec‐  
essary data.  
6.2  
High-voltage battery handling and stor‐  
age  
The lithium-ion high-voltage batteries are deemed to be hazard‐  
ous materials. Transport and storage are subject to certain re‐  
strictions that may vary depending on country-specific require‐  
ments. Different types of packaging are required according to  
the lithium-ion high-voltage battery classification.  
Intermediate storage of lithium-ion high-voltage batteries  
♦ The lithium-ion high-voltage battery must not be intermedi‐  
ately stored in the open or directly in the working area.  
♦ The lithium-ion high-voltage battery must be protected  
against mechanical and thermal influences as well as mois‐  
ture.  
♦ When the battery is intermediately stored, it must be in a  
location which is not accessible to non-authorised workshop  
personnel or customers. (e.g. storeroom/warehouse)  
6. High-voltage battery  
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