EV Maintenance and Training Programs

Get Ready Central Florida
Stakeholders Meeting
Overview of National
Electric Vehicle Maintenance
and Training Programs
Training Type
EV – HEV – PHEV Technology
• Informal
– Books
– Workshops/ seminars
– Webinars
– Hands-on due-it-yourself
• Formal
– Business and Corporate Education
– Credited Educational Units
– University and College Degree
– Professional Education
– Trade Associations
Training Programs
Automotive Industry (OEM in-house)
Clubs and Associations
– Electric Auto Association
– Cal Start and California Energy Commission
– Electric Drive Transportation Association
– Plug-in American
– Plug-in Partners
– National Association of Fleet Administrators
– Electric Power Research Institute
Federally funded program
– National Alternative Fuels Training Consortium
– Clean Cities Program
– National Laboratories
National Standards Associations
– National Fire Protection Association
– Society of Automotive Engineer
– Institute of Electrical and Electronic Engineers
– Automotive Service Excellence
– Underwriters Laboratory
– International Code Council
Formal Degrees
Graduate Automotive Technology Education (GATE)
University of Alabama
University of Illinois
Virginia Polytechnic
Ohio State University
Pennsylvania State University
University of Tennessee
University of Michigan
National Research
U.S. Government Research Institutions
National Renewable Energy Laboratory
National Institute of Standards and Technology
Argonne National Laboratory
Idaho National Laboratory
National Energy Technology Laboratory
Oak Ridge National Laboratory
Brookhaven National Laboratory
Lawrence Berkeley National Laboratory
Future Car
Clean Cities
Alternative Fuel Data Center
• OEM factory - dealer
• Third party – repair shop - ASE
• Do-it-yourself
• Hybrid EVs with ICE are similar maintenance to
conventional vehicles
• All-electric vehicle typically require less maintenance
than conventional vehicles
• Braking systems typically last longer due to regenerative
• Electric System does not require scheduled maintenance
• Batteries have limited number of charging cycles based
on chemistry as defined by OEM
Safety Programs
EV Standards and Codes for OEM
• Must Meet Federal Motor Safety Standards by NHTSA
– www.access.gov/nara/cfr/waisidx_49/49cfr571_09.html
• Current FMVSS Title 49 standard 305 –
– www.nhtsa.gov/cars/rules/rulings/lsv/lsv.htm
• Safe Car Designs – www.safercar.gov
• Safety Citation – www.afdc.energy.gov/afdc/pdfs/48605.pdf
• Emergency –
• NFPA EV safety – http://evsafetytraining.org
Safety Practices
EV Standards and Codes for OEM
Undergo the same testing as conventional vehicles
Battery packs –encased, sealed, impact, stress
Test – overcharge, vibration, temperature, fire, collision
Wired for insulated high-voltage lines and color coded
Damage – safety deactivate electric systems
Limit electrolyte spillage from batteries during crash
Charging disconnects motor starter when plugged-in
Charging cable brake-away/disconnects from charger driving
Safety Design Factors:
High-Voltage Systems
Color Coding for Electric Drive Vehicles (NAFTC)
Low Voltage
High Voltage
DC ≤ 30V
DC > 30 ≤ 60v
DC > 60v
AC ≤ 15V
AC > 15 ≤ 30v
AC > 30v >>360
 Has two separate electrical systems
 A low-voltage system (12-volt DC) powers the accessories and
the SLI.
 A high-voltage system (>60 volts) powers the motor generator
 The high-voltage system can be up to several hundred volts
so never cut them.
Identification: Under the Hood
 Under the hood, the voltage inverter will have decals or markings as
 There may also be a marking or decal on the engine cover.
 Wires will be color coded
Safety Design Factors:
High-Voltage Interlock Circuits
Thermal Sensors
High-Voltage GFCI circuit
Inertia Switch
High-Voltage fuse
High-Voltage Service Disconnect
High-Voltage Warning Labels
General Reminders
 Even when the ICE is off, high voltage may be present.
 The ICE may start at any time unless disabled. (smartkey)
 HEVs can be treated much like any other vehicle in an
 Disconnecting the 12 volt battery disables high-voltage
Note: Do not assume that the vehicle is immobile
just because there is no key in the ignition.
Crash and Fire Procedures
 Vehicle fires can be handled like any conventional vehicle except in
the case of a battery fire.
 In the event of a battery fire of the high-voltage battery system, use
large volumes of water to help to cool battery cells around the
burning cells.
 Do not attempt to open the battery pack.
 Use extreme caution when working in wet or damp areas
 Do not cut any orange (high-voltage) cables.
Vehicle Occupant Safety
 Primary risks are the same as a conventional vehicle.
 The risk of exposure to toxic battery materials is low. Even
in the event of catastrophic battery damage, the release
of the electrolyte will be small.
 In the event of exposure, flush with water.
 Potential airbag deployment must be considered.
Grid-tied PV System EV Charger
Photovoltaics (PV)
In 2002, This is one of the PV buildings in the Million Solar Roofs Program
charges an electric vehicle in New Smyrna Beach.
Bill Young
Florida Space Coast Clean Cities Coalition
c/o Florida Solar Energy Center/UCF
1679 Clearlake Road
Cocoa, FL 32922
(321) 638-1443
Reception Sponsored By:

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