2017-2025 Volkswagen Crafter Van Electricdrivesystems -> 6.4.1 Packaging critical high-voltage batteries with "Warning" status, module User Manual
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Electricdrivesystems -> 6.4.1 Packaging critical high-voltage batteries with "Warning" status, module for Your Volkswagen Crafter Van Second Generation (2017-2025)

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High-voltage system - General information - Edition 02.2021  
6.4  
Packaging critical high-voltage batter‐  
ies with “Warning” status  
⇒ c6.4.1 ritical high-voltage batteries with Warning status, mod‐  
ule”, page 54  
⇒ c6.4.2 ritical high-voltage batteries with Warning status, Golf  
GTE / Passat GTE / Jetta Hybrid”, page 60  
⇒ c6.4.3 ritical high-voltage batteries with Warning status, e-  
Golf / e-up!”, page 70  
6.4.1  
Packaging critical high-voltage batter‐  
ies with “Warning” status, module  
DANGER  
Danger to life from high voltage.  
Severe or fatal injury from electric shock.  
– Wear protective clothing against the thermal hazards of an  
electric arc.  
– Wear an insulated helmet with visor.  
– Wear protective gloves.  
– Wear safety shoes.  
NOTICE  
♦ Only after receiving induction training (for respective, certi‐  
fied transport crate), at least one responsible high-voltage  
expert (or higher qualification) or employees of Volkswa‐  
gen AG who have received induction training.  
♦ Hazardous material induction training also required.  
♦ Lithium-ion high-voltage batteries and lithium-ion high-volt‐  
age battery modules may only be packaged if they are  
prepared for carriage. See carriage regulations D/BAM/  
GGVSEB.  
Described in this workshop manual are the packaging process‐  
es of high-voltage batteries that are classed as critical with the  
status “Warning”.  
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 ⇒ page 26 .  
54  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
Procedure based on central arrangements for Europe  
Part 1  
1. - High-voltage battery rated critical.  
2. - Quarantine high-voltage battery or vehicle ⇒ page 17 . At‐  
tach measuring strips to document transportability of high-volt‐  
age battery.  
3. - HVE makes contact with service provider and arranges  
appointment for transportation container (after first consulting  
international product support).  
4. - For at least 5 days, high-voltage battery does not react and,  
in particular, has no increase in temperature.  
5. - Appoint service provider  
Part 2  
6. - Delivery of transportation container inc. expanded glass  
granules.  
7. - Once properly trained, HVE packages high-voltage battery.  
8. - Info sent to [email protected].  
6. High-voltage battery  
55  
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High-voltage system - General information - Edition 02.2021  
9. - Packaged high-voltage battery is taken away and transpor‐  
tation container is reconditioned.  
10. - Invoice to importer  
Transportation container  
A special transportation container is required for the dispatch  
of lithium-ion high-voltage batteries classed as critical from Golf  
GTE, Passat GTE, e-Golf, e-up! and Jetta Hybrid models.  
The containers are currently available in 2 sizes: M and XL.  
Description  
A high-voltage battery of the following models can be dispatch‐  
ed with transportation container size M:  
♦ Golf GTE  
♦ Passat GTE  
♦ Jetta Hybrid  
♦ Individual or several modules  
Batteries of the following models can be dispatched with trans‐  
portation container size XL:  
♦ e-up!  
♦ e-Golf  
♦ Golf GTE  
♦ Passat GTE  
♦ Jetta Hybrid  
♦ Individual or several modules  
Packing  
Special tools and workshop equipment required  
♦ Qty. 8 temperature measurement strips (irreversible) for  
temperature range: at least 40 to 60°C  
56  
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High-voltage system - General information - Edition 02.2021  
♦ Warning sign “Warning! Dangerous batteries” -VAS 6786-  
♦ Warning sign “Warning! Dangerous electrical voltage” -VAS  
6649-  
♦ High-voltage barrier tape -VAS 6884-  
♦ Personal protective equipment  
Procedure  
– Make all contacts of the battery modules safe to prevent  
short circuit.  
– Seal all openings for service fluids apart from electrolyte.  
– Remove deposits of hazardous materials and electrolyte  
from outside of battery module and lithium.  
Apply temperature measurement strips to battery module  
– Attach at least 5 temperature measurement strips -1- to bat‐  
tery module housing as shown in diagram.  
NOTICE  
Risk of damage to battery modules  
– Protect modules against heat and direct sunlight.  
6. High-voltage battery  
57  
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High-voltage system - General information - Edition 02.2021  
– Directly after applying the strips and before dispatching, re‐  
cord the values in writing or take pictures.  
– Before transport, the battery modules must be kept under  
observation for at least 5 days.  
– Record the temperature of the battery modules as well as  
the ambient temperature.  
– Should there be an increase in the temperature during this  
time, wait for the reaction to subside before keeping under  
observation again for at least 5 days.  
– Repeat this procedure until no further reactions are ob‐  
served.  
– Open fasteners of transportation container.  
– Remove cover of transportation container and take out bag  
of expanded glass granules.  
Quantity of PyroBubbles® is sufficient.  
– Visually inspect surrounding rubber seal -1- and also pres‐  
sure relief valves -2- for signs of external damage.  
– Pour expanded glass granules onto base of transportation  
container up to a level of at least 200 mm.  
– Place module in transportation container. If there are several  
modules, these must be placed on end.  
– Distance -a- to side edges and between modules should be  
at least 200 mm.  
58  
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High-voltage system - General information - Edition 02.2021  
– Check that there is a space of at least 200 mm between the  
module and the upper edge of the transportation container  
for a surrounding layer of expanded glass granules.  
– Pour in expanded glass granules so that the gaps and also  
the entire transportation container up to the upper edge are  
filled.  
Note  
♦ Ensure that surrounding rubber seals are not damaged.  
♦ If it proves difficult to close the cover, turn the cover 180° if  
necessary.  
– Place the cover on the transportation container and tightly  
secure the fasteners all around. Retension the fasteners if  
necessary.  
– Apply the warning notice for hazardous materials and infor‐  
mation label to both ends of the transportation container.  
♦ “Dangerous goods class 9”  
♦ “UN number 3480”  
♦ “Beware! Damaged lithium-ion battery”  
♦ “This side up”  
6. High-voltage battery  
59  
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High-voltage system - General information - Edition 02.2021  
Notes for transport preparation and hazardous material marking  
(Europe)  
1 - “Protect against water”  
2 - “Attention! Fragile”  
3 - “This side up”  
4 - “Maximum stacking load”  
5 - “Hazardous material label: Hazardous material category  
9 “Various hazardous substances and items” packaging  
group 2”  
6 - “Type label with UN number UN3480 for lithium-ion batter‐  
ies”  
6.4.2  
Packaging critical high-voltage batter‐  
ies with “Warning” status, Golf GTE /  
Passat GTE / Jetta Hybrid  
DANGER  
Danger to life from high voltage.  
Severe or fatal injury from electric shock.  
– Wear protective clothing against the thermal hazards of an  
electric arc.  
– Wear an insulated helmet with visor.  
– Wear protective gloves.  
– Wear safety shoes.  
NOTICE  
♦ Only after receiving induction training (for respective, certi‐  
fied transport crate), at least one responsible high-voltage  
expert (or higher qualification) or employees of Volkswa‐  
gen AG who have received induction training.  
♦ Hazardous material induction training also required.  
♦ Lithium-ion high-voltage batteries and lithium-ion high-volt‐  
age battery modules may only be packaged if they are  
prepared for carriage. See carriage regulations D/BAM/  
GGVSEB.  
60  
Rep. gr.93 - Electric drive systems  

Related Topics

Electricdrivesystems
1 Hazard classification for the high-voltage system 1.1 General information 1.2 Induction training/staff qualifications 2 Identification features of high-voltage vehicles 3 Working on high-voltage vehicles 3.1 Personal protective equipment (PPE) 3.2 Workshop procedure for high-voltage vehicles 4 Quarantine arrangements 5 Assessing accident-damaged vehicles 5.1 General information 5.2 Photographic documentation 6 High-voltage battery 6.1 Classifying high-voltage battery 6.1.1 Fundamentals of classifying lithium-ion high-voltage batteries 6.1.2 Classification of lithium-ion high-voltage batteries with aid of ODIS 6.2 High-voltage battery handling and storage 6.3 Packaging high-voltage batteries 6.3.1 Packaging high-voltage battery, e-up! 6.3.2 Packaging high-voltage battery, e-Golf 6.4 Packaging critical high-voltage batteries with "Warning" status 6.4.2 Packaging critical high-voltage batteries with "Warning" status, Golf GTE / Passat GTE / Jetta Hybrid 6.4.3 Packaging critical high-voltage batteries with "Warning" status, e-Golf / e-up! 6.5 Supplementary information on opening and bonding high-voltage batteries

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