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Review: E-mobility in the independent car repair shop
In a well-attended webinar hosted by the Austrian Business Publishing House, high-voltage expert Deniz Kartal explained what skills independent workshops need in order to avoid having to send customers with hybrid and electric cars on. Here is the link to the video and the reading.
Review: E-mobility in the independent car repair shop
With over 100 participants, the Austrian business publisher's latest webinar was a complete success. The highly topical topic appealed not only to numerous automotive technicians and workshop operators, but also to tool, accessories and spare parts dealers from the automotive industry. The background: The number of electric vehicles on Austria's roads is increasing rapidly; in March of this year, the battery-electric Tesla Model 3 was even the best-selling car in Austria. Motor vehicle industry editor-in-chief Hans-Jörg Bruckberger moderated, Deniz Kartal, high-voltage trainer and managing director of Evalus Gmbh for occupational safety and health protection, answered the most important questions that arise in the course of upgrading and converting a workshop for electrified vehicles. The link to the video: https://youtu.be/EwQEFLysWfE
What know-how and certifications do I or my employees need to be able to carry out repairs and maintenance on high-voltage vehicles?
The basic rule is: Only specially trained specialist personnel may carry out maintenance, repairs and other services on electric vehicles. Without the appropriate qualifications, an automotive technician is not even allowed to change the tires on an electrified car. The reason: High-voltage systems cover a voltage range of 60 to 1,500 volts direct voltage (DC) or 30 to 1,000 volts alternating voltage (AC). Contact with the high-voltage circuit can have fatal consequences. The training is divided into three consecutive stages:
HV 1: With this training level, all non-electrical work on the vehicle such as oil changes, tire replacement or body work as well as all work on the conventional electrical system can be carried out.
HV2: With this training level, vehicles with high-voltage systems can be de-energized, measures can be taken to prevent them from being switched on again, the absence of voltage can be determined and electrical work can be carried out. In addition, other employees within the company may be trained in non-electronic activities.
HV3: With this training level, live work can also be carried out on the energy storage of electrically powered road vehicles with high-voltage systems.
How do I identify the high-voltage components in the vehicle?
All high-voltage components and systems are marked with yellow “Caution: dangerous voltage” signs; the corresponding live cables are colored orange. The high-voltage systems include a high-voltage battery, electric motor, power electronics, air conditioning compressor, heater and converter for the on-board electrical system. In vehicles whose electric motors are equipped with permanent magnets, special signs also prohibit the approach of people with pacemakers.
Which usual activities are eliminated with an electric vehicle and which ones are added?
The following are no longer necessary: oil and oil filter changes, spark plug changes, air filter changes, timing belt changes, clutch and exhaust system repairs.
In addition: HV component replacement, electrical measurements, maintenance work on the HV battery, battery module replacement, checking charging equipment, HV diagnosis.
What are the requirements for the employer?
The most important points of the Employee Protection Act that affect vehicle repair shops are summarized in the ÖVE Guideline R19:
- Stand der Technik: Arbeitgeber haben sich unter Berücksichtigung der bestehenden Gefahren über den neuesten Stand der Technik zu informieren.
- Unterweisung: Arbeitgeber sind verpflichtet, für eine ausreichende Unterweisung der Arbeitnehmer über Sicherheit und Gesundheitsschutz zu sorgen.
- Feststellung der Eignung von Arbeitnehmern: Arbeitgeber haben bei der Übertragung von Aufgaben an Arbeitnehmer deren Eignung in Bezug auf Sicherheit und Gesundheitsschutz zu berücksichtigen.
- Arbeitsplatzevaluierung: Arbeitgeber sind verpflichtet, die für die Sicherheit und Gesundheit der Arbeitnehmer bestehenden Gefahren zu ermitteln und zu beurteilen.
What requirements must a workplace for electric vehicles meet?
The electrical workstation must be clearly marked by a barrier using signal tape, and a warning triangle with a lightning symbol must also be placed on the roof of the electric vehicle. A battery workstation must also be clearly marked and cordoned off from unauthorized persons.
What technical equipment, protective equipment and tools are needed?
The most important tools include test devices specially developed for electric cars for measuring direct and alternating voltage, for resistance and continuity testing as well as for diode tests and non-contact voltage testing. All hand tools such as wrenches or pliers must be suitable for work under voltages of up to 1,000 volts (AC) and 1,500 volts (DC) and must be appropriately insulated. All employees working on electric vehicles or components must wear appropriate protective clothing, which includes, among other things, anti-static trousers and a jacket. These include safety shoes of metal-free safety class S3 and reliable voltage protection gloves. In order to be protected from arc flashes, face protection is also required.
Which training guidelines currently apply to high-voltage training in Austria?
The currently valid guideline ÖVE R19 is currently being amended and is expected to be replaced by a new guideline in the course of the second quarter of 2021. In this, the three-level training for workshop employees will be retained, and a level 0 will also be introduced, at which knowledge about the operation of electric vehicles including charging technology is imparted.
How much time and money should be expected when training workshop employees?
Training level 1 lasts up to four teaching units, which are completed in half a day. Training levels 2 and 3 each consist of 16 teaching units over two full days. The costs for training levels 2 and 3 are around 500 euros each.
What investments are necessary to set up an electrical workplace?
Depending on the size of the workshop, you can expect around 5,000 to 10,000 euros including tools, measuring devices, signs and barriers.
How do you, as an independent workshop, get manufacturer information for electric vehicles?
The manufacturers make this information available on platforms. Access, for example to the repair instructions, is regulated via a subscription model or similar.
How are electric vehicles that can no longer be repaired correctly disposed of?
In Austria, the disposal of electric vehicles is stipulated in the Waste Management Act and the End-of-Life Vehicle Regulations. A specialist in this area is the Saubermacher company, which has already gained a lot of experience with this topic.