Level 2 Outline and OutcomesThe outcomes of the Pro+ training Level 2 course is designed to provide instructors and service professionals with information and skills that are inclusive of technical metrics governed in core technologies and industry standards of:
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High Voltage Battery and Control Systems
- When documenting vehicle High Voltage Battery Pack systems information students shall be able to use proper vehicle electrification terminology and acronyms
- When provided physical Battery Packs or pictures/graphics of Battery Packs the students will be able to identify the Battery Pack type, how it is mounted in specific vehicle types, cooling system type, and kW-h rating
- When provided a physical component or graphic diagram of a High Voltage Battery Pack, students will be able to identify each major component and define its function
- Remove and replace an Electric Vehicle, Hybrid Electric, Plug-In Hybrid, or Fuel Cell EV Battery Pack from a vehicle using the prescribed OEM procedures, processes, tools, and equipment
- Determine High Voltage Battery Pack SOH, with the Battery Pack installed in the vehicle, using a Scan Tool and Specialized Testing Tools
- List the major failure modes, and the causes of each, for NiMH and Lithium based battery chemistries
- When provided with Battery Pack module/cell Power Tests and Capacity (Energy) test signatures, the Students will be able to determine module/cells SOH
- Leak test a High Voltage Battery Pack using OEM procedures and specialized tools and equipment, and articulate why leak testing is required
- Disassemble and reassemble High Voltage Battery Pack, using OEM and battery industry service and technical information
- Articulate how the High Voltage Battery Pack SOC% level can effect the electric propulsion, HVAC, and Charging systems
- Perform Isolation Tests on the High Voltage Battery Pack systems using an Insulation Meter
- Describe the difference between a High Voltage Fuses vs. Pyro Fuses
- Articulate how High Voltage Contactors internally quench electrical arcs
- Compare and Contrast battery module/cell connection methods when battery cells are connected in series & parallel during manufacturing
- Explain how the battery pack is used as a structural member of the vehicle body & chassis system
- Define how the High Voltage Battery Pack Contactor and Pre-Charge Contactor system operates by listing its sequencing during a vehicle Power ON cycle
- Articulate how the High Voltage Battery Pack SOC% level can effect the electric propulsion, HVAC, and Charging systems
- Summarize the control and diagnostic system for the High Voltage Battery Contactor system when provided a Contactor software timing diagram
- Explain the operation of the High Voltage Battery Pack Current Sensor during propulsion and regenerative braking, including providing the resolution (scaling) of the sensor
- Summarize the rationale for the use of insulated tools during High Voltage Battery Pack servicing, and cite the requirements standards
Outline of Training
High Voltage (HV) Battery Pack and Control Systems
- HEV & BEV Systems
- Battery Pack Power & Physics
- Battery Power & Capacity Specifications: kW vs. kW-h vs. A-h
- Battery Module & Cell Configurations
- Shielded Cable and Connectors
- Manual Service Disconnect (MSD), Fuse, and Pyro Fuse Systems
- Battery Cell and Module Bus Systems (Bus Bar, Ω Weld, Laser Bus Bar, Laser Wire Bond)
- HV Contactor and Pre-Charge Circuits and Controls
- Sensors: Temp, Air, Voltage, and Current
- Battery Module & Cell Ratings
- Nickel-Metal Hydride (NiMH) Technology (HEV only)
- Cylindrical & Prismatic
- Lithium-Ion Battery Cell Technologies (HEV & BEV)
- NCA, NMC, LiFePO4, LTO, LMO, & Solid State
- 18650, 2170, 4680 Cylindrical; Pouch; Prismatic
- Battery Management Systems (BMS): NiMH & Lithium
- NiMH BMS Systems
- Lithium Family BMS Systems
- Major Sub-Topics for NiMH & Lithium
- Voltage Sensing Electronic Circuits & Isolation ICs
- Cell Balancing Systems: Amplifier, Transistor, & Resistor Systems
- Opto-Isolating or DC-DC Converter IC HV to LV Isolation Systems
- Multiplexing, Microcontroller, and Software Controls
- Battery State Estimator (BSE) State-of-Charge (SOC%) Estimation
- Displayed vs. Actual SOC% / Usable SOC% vs. Displayed
- Cell & Module Failure Modes, Aging, Power Fade, and Capacity Fade / Loss
- Cell Material, Geographic, Terrain, Driving Cycle, and Aging Functions
- NiMH and Lithium Specific Failures and Failure Modes
- Battery Testing and Diagnostic Methods: HEV, PHEV, & BEV
- OEM On-Board Diagnostics: Strengths, Weaknesses, and Limitations
- On-Board & Road Testing (Stress Testing Method and Metrics)
- Battery Pack Loading on Stress Test
- Battery PID Data During Testing
- Battery Cell Technology vs. PID Data
- Off-Board Testing: Power & Capacity Testing, IR, & Thermal Testing
- Power Test Standards (HEV, PHEV, BEV)
- Power Test Signatures
- Capacity Testing Standards
- Capacity Test Signatures
- NiMH & Lithium Families (NCA, NMC, LiFePO4, LMO, LTO)
- Thermal Testing/Monitoring: During Power, Capacity, & Off-Board Charging
- Internal Resistance (IR) During Power Testing
- Required Tools & Equipment to perform Servicing & Standardized Testing
- On-Board Diagnostics
- Scan Tool PIDs & DTCs
- Scan Tool Special Functions or Output Controls
- Battery Pack Field Special Service Considerations
- Battery Controller Replacement: Capacity Relearn Function
- HEV & PHEV; EREV & BEV
- Rebuilding & Remanufacturing (Pros; Cons; Process)
- Introduction to High Voltage Battery Pack Heating & Cooling Systems
- Air & Liquid Heating & Cooling
- PTC Heating
- A/C Cooling
- Isolation Fault Testing (On-Board & Off-Board)
- Leak Testing (Pressure/Smoke Testing)
- Equipment
- Ingress Protection - IP67 & 68 Requirements
- Battery Pack Repurposing and Recycling