Get Electricdrivesystems -> 6.4.1 Packaging critical high-voltage batteries with "Warning" status, module Guide for 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 .

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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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♦ 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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– 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

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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