Electricdrivesystems -> 6.4.3 Packaging critical high-voltage batteries with "Warning" status, e-Golf / e-up! for Your Volkswagen Crafter Van Second Generation (2017-2025)

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High-voltage system - General information - Edition 02.2021  
6.4.3  
Packaging critical high-voltage batter‐  
ies with “Warning” status, e-Golf / e-up!  
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 .  
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.  
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High-voltage system - General information - Edition 02.2021  
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].  
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  
6. High-voltage battery  
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High-voltage system - General information - Edition 02.2021  
♦ 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  
♦ Workshop hoist -VAS 6100-  
♦ Support bracket -10 - 222 A-  
♦ Hook -10-222A/10-, qty. 6  
♦ Shackle -10-222A/12-, qty. 2  
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High-voltage system - General information - Edition 02.2021  
♦ Towing bracket -T10528-  
♦ Locking pin -T10528/3-  
♦ Lifting eye bolt -T10528/5-  
♦ Supplement -T10528/7-/10-  
♦ Shackle -VAS 691 009A-  
♦ High-voltage tool set -VAS 6762-  
♦ Qty. 8 temperature measurement strips (irreversible) for  
temperature range: at least 40 to 60°C  
♦ Warning sign “Warning! Dangerous batteries” -VAS 6786-  
6. High-voltage battery  
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High-voltage system - General information - Edition 02.2021  
♦ Warning sign “Warning! Dangerous electrical voltage” -VAS  
6649-  
♦ High-voltage barrier tape -VAS 6884-  
♦ Personal protective equipment  
Procedure  
– Make all contacts of high-voltage battery 1 -AX2- safe to  
prevent short circuit.  
– Seal all openings for service fluids apart from electrolyte.  
– Remove deposits of hazardous materials and electrolyte  
from outside of high-voltage battery 1 -AX2-.  
Apply temperature measurement strips to battery  
e-Golf battery  
e-up! battery  
– Attach at least 8 temperature measurement strips to high-  
voltage battery 1 -AX2- as shown in diagram.  
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NOTICE  
Risk of damage to battery modules  
– Protect modules against heat and direct sunlight.  
– Directly after applying the strips and before dispatching, re‐  
cord the values in writing or take pictures.  
– Before transport, the high-voltage battery 1 -AX2- must be  
kept under observation for at least 5 days.  
– Record the temperature of the high-voltage battery 1 -AX2-  
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.  
6. High-voltage battery  
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– Take up weight of high-voltage battery 1 -AX2- as described  
in chapter ⇒ h6.3 igh-voltage batteries”, page 34 .  
– Place high-voltage battery 1 -AX2- in transportation contain‐  
er.  
– Distance -a- from side edges and high-voltage battery 1  
-AX2- should be at least 120 mm.  
– Check that there is a space of at least 200 mm between  
the high-voltage battery 1 -AX2- 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.  
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♦ “Dangerous goods class 9”  
♦ “UN number 3480”  
♦ “Beware! Damaged lithium-ion battery”  
♦ “This side up”  
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”  
6.5  
Supplementary information on opening  
and bonding high-voltage batteries  
Only applies to e-up! and e-Golf  
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.  
Special tools and workshop equipment required  
6. High-voltage battery  
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