Christiani HV-Trainer
Training System on Electric Drives and High-Voltage Systems in Motor Vehicles

Item No.: 107777

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Training System Christiani HV Trainer

Electric drives and HV systems in Vehicles

Modern electric drive technology in motor vehicles requires workshop staff to obtain additional qualifications. Furthermore, those involved in the manufacture and development of such systems using high-voltage technology must be qualified as a “Competent Person for High-Voltage Systems (FHV)” in accordance with the German DGUV Information 209-093. All the qualification levels required for this can be covered in terms of content using the Christiani HV Trainer.

The training system for electric drives and high-voltage systems in motor vehicles consists of a drive module and a power supply and control module. The HV system operates at a system voltage of 96 volts. It comprises a complete power supply unit with an electronic battery management system (BMS), an integrated charger for the HV battery, DC/DC converters, a switch box, all necessary safety components and a charging port (Type 2).

The HV system can be de-energised either via a service disconnect in the 12 V circuit or via a service disconnect in the HV circuit (in the HV battery). In addition, the training system features an emergency disconnect point to simulate the de-energisation of a vehicle involved in an accident.

To enable realistic learning scenarios, the training model features a Wi-Fi fault circuit with a total of 25 faults. These can be activated easily and safely using the tablet supplied. A further 5 faults are also integrated, meaning a total of 30 fault simulations can be demonstrated.

To combine theory and practice, a virtual learning package (e-learning + virtual application) is included free of charge as a one-year licence.

The Power Supply and Control Module

The power module consists of 32 LiFePO4 cells, which generate a system voltage of 96 volts. This forms the basis of the HV battery, which is equipped with a battery management system. The battery management system can show the status of the HV battery on the central display.

The 7-inch touchscreen combines the necessary operating displays with the diagnostic unit for the electric drive and the battery management system.

This provides all operational displays, and the diagnostic system can also be accessed via the screen. Consequently, no separate diagnostic unit is required.

In addition to the screen, the control panel features a potentiometer for regulating the motor speed, a switch for selecting drive modes (D, N, R), a switch for activating and deactivating energy recovery, and a switch for activating and deactivating Eco mode.

The energy module consists of:

DC/DC converter
AC/DC converter
Type 2 charging port
Residual current circuit breaker for the charger
Main contactor
Pre-charge relay
Fuses
12-volt battery
Control panel with 7-inch touchscreen and additional controls
Battery management system
Wi-Fi fault circuit
Central measurement panel with 4 mm safety test sockets for high-voltage measurements and 2 mm test sockets for 12 volts For safety reasons, an emergency stop switch is fitted above the control panel on the energy module.

The drive module consists of:

Inverter
15 kW asynchronous electric motor
Hydraulic braking unit
Wi-Fi fault circuit
Central measurement panel with 4 mm safety test sockets for high-voltage measurements and 2 mm test sockets for 12 volts

Work that can be carried out on the high-voltage functional model:

De-energising the high-voltage circuit using the hv-serviceconnect
De-energising the high-voltage circuit using the lv-serviceconnect
De-energising the high-voltage curcuit using the emergency disconnect
Verifying that the circuit is de-energised
Securing against reconnection
Measuring the charging and discharging curves of the DC link capacitor
Locating faulty battery cells using measurement techniques
Installing and replacing battery modules and battery cells
Checking the contact resistance of cell connectors between cells
Testing the motor encoder and motor temperature sensor
Simulating a load (uphill drive)
Measuring and testing phase voltage and phase signals (U, V, W) for the electric motor
Measuring and testing the 12 V on-board electrical system voltage
Measuring and testing the HV battery voltage
Equipotential bonding measurement
Insulation resistance measurement
Measuring and testing the insulation monitor signal (PWM signal)
Measuring and testing the inverter DC link voltage
Measurement and testing of the safety line (interlock signal voltage)
Measurement and testing of the DC/DC converter input (positive and negative)
Measurement and testing of the DC/DC converter output (positive and negative)
Testing of the temperature and voltage of an individual battery cell (via BMS)
Measuring and testing data bus signals (CAN)
Measuring and testing electric motor speed and temperature sensor signals

All labels on the measurement panels and on the display are in English The user manual is available in German and English

Compliance with accident prevention regulations
Avoiding hazards when handling electrical current and hazardous substances
Selection of suitable and safe test and measurement equipment
Handling and use of safety equipment
Application of manufacturer-specific test procedures
De-energising high-voltage components, securing them against re-energisation, and ensuring they are voltage-free
Recognising hazards posed by electrical storage devices (capacitors, high-voltage batteries)
Recognising the general principles of electrical engineering
Drawing up system and block diagrams
Identifying the effects of electrical quantities on the human body
Troubleshooting and interpreting the diagnostics of affected systems
Analysing the function and interaction of components, taking into account the exchange of information between the control units involved
Identifying system interrelationships with the aid of circuit diagrams and functional diagrams
Analysing time-dependent variables and evaluating signal waveforms
Applying knowledge of the principles of voltage generation (induction), rectification (single- and multi-path rectification), the electromotive principle and the storage of electrical energy
Assessing hazards during live measurements, deriving protective measures and verifying the effectiveness of the high-voltage system’s electronic protective measures
Carrying out measurements on live circuits (insulation, equipotential bonding and voltage drop measurements, battery cell voltages, temperature determination)
Functional testing of high-voltage systems (control signals for the electric motor during driving)
Assessing measured values and signals for plausibility and drawing up test reports
Planning the diagnosis and repair of the high-voltage system and its components