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Learn key safety considerations when servicing a hybrid electric vehicle (HEV), including identifying high voltage systems, using proper gloves, tools, clothing, and multimeters. Follow manufacturer's guidelines for HEV maintenance.
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HEV Safety Considerations • HEVs are nothing more than a traditional automobile with advanced technologies that deliver the same end result as a traditional automobile, but with unique service hazards • Safety is of utmost importance when approaching a HEV • Isolation of HV systems for routine system service may be a necessity • ALWAYS refer to the manufacturer’s recommended isolation techniques when servicing an HEV
HEV Safety Considerations • When approaching an HEV, it is important to recognize the potentially high voltage you may be working around • Manufacturers have developed a way of identifying high voltage systems with brightly colored markings 2009 Prius A/C compressor with ORANGE sheathing surrounding HV supply to compressor
HEV Safety Considerations • Sheathing has been categorized into colors that indicate voltage levels present • Black – 12-42V • Yellow or Blue – ~42V • Orange– 144-650V Information courtesy of Jim Halderman
Colors-continued Information/images courtesy of Jim Halderman
HEV Safety Considerations • While hybrids may look and feel similar to traditional vehicles, the introduction of HV to the vehicle creates unique work risks • For example, the THS-II system on the 2004+ Toyota Prius can exhibit 500V under operation • Identifying the location of HV components on any HEV is key to working safely
HEV Safety Considerations • Gloves • Must be routinely inspected (as in EACH use!) • Must have a Class 0 rating (safe up to 1000V) • Should have protective capabilities beyond insulation, i.e., puncture resistance • This is why traditional HEV service gloves have a leather our glove and an insulating Class 0 rated primary glove • DISCARD if damaged! • Recommended replacement every 6 months • Do NOT gamble when dealing with high voltage!
HEV Safety Considerations • Testing gloves • Blow air into glove and roll it to inspect for fractures that may allow HV to penetrate • MUST be free from water, sweat, oil and other potentially conductive and combustible/flammable chemicals • Glove Dust may be used to reduce sweating in gloves
HEV Safety Considerations • Tools • Insulated tools, which commonly have been tested at 10kV, are recommended • Typically have a safe working voltage of 1000V • Are relatively inexpensive ($500-$1000 per set) • Should be routinely inspected • Should be used as recommended by the manufacturer
HEV Safety Considerations • Clothing • Sleeved shirts • Short sleeve vs. long sleeve • Jewelry should be removed as it is conductive • Should be free from water, sweat, oil and other potentially conductive and combustible/flammable chemicals
HEV Safety Considerations • Digital Multimeters • CAT III rating recommended • According to D. Marinucci (MOTOR, 2008), automotive manufacturers have not endorsed a particular rating • CAT III-CAT IV recommended by leading industry experts with extensive HEV service research experience • Rating will be indicated on the face of the meter • Gloves MUST be worn when testing HV circuitry
HEV Safety Considerations • Multimeters • A meter with insulation testing capabilities is also recommend to test HV insulation properties • Do NOT insulation test yourself as the meter supplies HIGH VOLTAGE and low current to check conductivity (Fluke 1587 outputs 1017VDC @ 1.60mA) • Leads must also be CAT rated appropriately for the systems you are evaluating • Test Voltage should be selectable • Fluke 1587 ranges are: 50V, 100V, 250V, 500V, 1000V
Measured Resistance HV Output Warning In Progress DMM Voltage Output
Oil change • On HEVs, it is important to note that some may start with the key in the proximity of the vehicle • Toyotas use a READY light to indicate the engine may start • MEA Article by Dave Scaler
Prius Smart Key • In the event the auxiliary battery dies, you can remove the lock cylinder key to enter the vehicle Chrome Toyota symbol identifies this key as a Smart Key
Prius Start-up • Brake pedal must be depressed to start Prius • Note READY light on dash
High Voltage Disconnect • Known good (tested and inspected gloves) must be used to isolate HV circuit • Refer to manufacturer’s information to locate the HV disconnect plug
Plug Removal Safety • Even though the plug may be removed mechanically, HV is still available at the battery terminals • NEVER service the HV system without first verifying HV is no longer present (with a properly rated DMM)
1. Pull Up 2. Rotate
3. Remove Wait 10 minutes, test for HV and proceed if no HV is present before servicing vehicle
Jump Startng a Hybrid • It is possible to charge a HV battery, but not very common • Typically, the 12V (auxiliary battery) will fail and cause a no start condition • Jump starting the 12V battery varies from mfr. to mfr.