Get Electricdrivesystems -> 6.4 Packaging critical high-voltage batteries with "Warning" status Guide for Volkswagen Crafter Van Second Generation (2017-2025)

Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2017 ➤, Golf Var ...

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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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

Rep. gr.93 - Electric drive systems

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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

Rep. gr.93 - Electric drive systems

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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

Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2017 ➤, Golf Var ...

High-voltage system - General information - Edition 02.2021

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.

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. High-voltage battery

61

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High-voltage system - General information - Edition 02.2021

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

♦ 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

62

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

♦ Workshop hoist -VAS 6100-

♦ Retaining strap -T40155A-

♦ Adapter -T10542A-

♦ Shackle -VAS 691 009A-

♦ High-voltage tool set -VAS 6762-

6. High-voltage battery

63

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♦ Qty. 8 temperature measurement strips (irreversible) for

temperature range: at least 40 to 60°C

♦ 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 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-.

64

Rep. gr.93 - Electric drive systems

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Apply temperature measurement strips -1- to high-voltage bat‐

tery 1 -AX2-

Jetta Hybrid battery

Passat GTE battery

Golf GTE battery

– Attach at least 8 temperature measurement strips -1- to

high-voltage battery 1 -AX2- as shown in diagram.

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.

6. High-voltage battery

65

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High-voltage system - General information - Edition 02.2021

– 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.

– Attach spindle -3033/8- to position -1- and -2- of lifting tackle

-3033-.

66

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

Note

Align high-voltage battery 1 -AX2- with adapter -T10542A-

attached in just one direction first and then attach adapter

-T10542A- in offset position (e.g. if battery is on flat ground).

– Attach lifting tackle -3033--2- to workshop hoist -VAS 6100-

-3-.

– Mount adapter -T10542A- -1- on outer lifting eyes offset at

front and rear on high-voltage battery 1 -AX2- and tighten to

20 Nm.

Note

♦ For high-voltage battery 1 -AX2- in Jetta models, first re‐

move retaining frame ⇒ Rep. gr. 93; High-voltage battery

unit; Assembly overview - high-voltage battery.

♦ If necessary, use workshop hoist -VAS 6100- and retaining

strap -T40155- to lift high-voltage battery 1 -AX2- of Jetta

into transportation container.

– Place high-voltage battery 1 -AX2- -1- centrally and diago‐

nally on end onto hollow glass granules.

6. High-voltage battery

67

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High-voltage system - General information - Edition 02.2021

– Distance from side edges should be at least 120 mm.

– If packing two batteries (Golf GTE and Passat GTE) in the

XXL transportation container, the distance of the batteries

from the sidewalls -a- should be at least 120 mm.

– Distance between batteries -b- must be at least 200 mm.

– Check that there is a space of at least 120 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.

68

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

♦ “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. High-voltage battery

69

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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.

70

Rep. gr.93 - Electric drive systems

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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

71

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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

72

Rep. gr.93 - Electric drive systems

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♦ 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

73

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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.

74

Rep. gr.93 - Electric drive systems

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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

75

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High-voltage system - General information - Edition 02.2021

– 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.

76

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

♦ “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

77

Electricdrivesystems -> 6.4 Packaging critical high-voltage batteries with "Warning" status for Your Volkswagen Crafter Van Second Generation (2017-2025)

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