Audi 739 964 User manual

Operating instructions for the system
739 964 Automotive high-voltage systems trainer
As of production year 2018
Audi AG
Hindemithstraße 27
85045 Ingolstadt
E-Mail:
wertschöpfung.berufsausbildung-
[e-mail]
Web: www.group-training-
online.com
Manufacturer:
Audi AG
Auto-Union-Straße 1
85045 Ingolstadt

Table of content
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1Important key information...............................................................................................5
1.1 Scope of delivery....................................................................................................5
1.2 Responsibilities ......................................................................................................5
1.2.1 Responsibilities of the system builder .......................................................5
1.2.2 Responsibilities of the operator.................................................................5
1.3 Legal information....................................................................................................5
1.4 Documentation .......................................................................................................5
1.4.1 Background information on content and structure.....................................5
1.4.2 Content and structure ...............................................................................5
1.5 Addresses ..............................................................................................................6
1.6 Safety Instructions..................................................................................................6
2Safety................................................................................................................................9
2.1 Convention for safety instructions...........................................................................9
2.2 Behaviour in an emergency....................................................................................9
2.3 Intended use of the entire system...........................................................................9
2.3.1 Area of application....................................................................................9
2.3.2 Requirements for the personnel..............................................................10
2.3.3 Safety-relevant environmental conditions................................................10
2.3.4 Safety instructions for certain phases of life ............................................10
2.4 Possible misuse ...................................................................................................10
2.5 Compliance with the operating instructions...........................................................11
2.6 Safety marking of the system ...............................................................................11
2.7 Protective devices ................................................................................................11
2.8 Residual hazards and protective measures..........................................................12
2.9 Life phase: Operation ...........................................................................................12
2.9.1 Life phase: Operation..............................................................................12
2.9.2 Life phase: Operation..............................................................................12
2.9.3 Life phase: Operation..............................................................................13
2.9.4 Life phase: Operation..............................................................................13
2.9.5 Life phase: Operation..............................................................................13
2.9.6 Life phase: Operation..............................................................................14
2.10 Life phase: permanent condition...........................................................................14
2.10.1 Life phase: permanent condition .............................................................14
2.10.2 Life phase: permanent condition .............................................................15
2.10.3 Life phase: permanent condition .............................................................15
2.10.4 Life phase: permanent condition .............................................................15
2.10.5 Life phase: permanent condition .............................................................16
3Technical data................................................................................................................17
3.1 Overall system......................................................................................................17
3.2 Equipment............................................................................................................18
3.3 Components.........................................................................................................18
3.3.1 Power supply (=voltage source)..............................................................18
3.3.2 PTC heater (inactive)..............................................................................18
3.3.3 A/C compressor (inactive).......................................................................18
3.3.4 Power electronics (Inactive)....................................................................18
3.3.5 Charger (inactive) ...................................................................................18

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3.3.6 HV battery housing (inactive without battery)..........................................18
3.3.7 Cable set ................................................................................................18
4System description........................................................................................................19
4.1 Set-up ..................................................................................................................19
4.1.1 Main components ...................................................................................19
4.1.2 Operator workstations.............................................................................19
4.2 Functional description...........................................................................................19
4.2.1 System ...................................................................................................19
4.2.2 Main components ...................................................................................19
5Delivery, internal transport, unpacking........................................................................20
5.1 Safety...................................................................................................................20
5.2 Delivery ................................................................................................................20
5.3 Internal transport ..................................................................................................20
5.4 Unpacking ............................................................................................................20
6Storage conditions ........................................................................................................21
6.1 General safety......................................................................................................21
7Set-up conditions ..........................................................................................................21
7.1 Safety...................................................................................................................21
7.2 Total space requirement.......................................................................................21
7.3 Dimensions and weights.......................................................................................21
7.4 Foundation and flooring........................................................................................21
7.5 Ambient conditions ...............................................................................................21
7.6 Supply connections ..............................................................................................22
7.7 Customer safety precautions................................................................................22
7.8 Local requirement for delivery ..............................................................................22
8Assembly and installation, initial commissioning.......................................................22
8.1 Safety...................................................................................................................22
8.2 Assembly and installation .....................................................................................23
8.3 Initial commissioning ............................................................................................23
9Operation........................................................................................................................23
9.1 Safety...................................................................................................................23
9.2 Operating elements ..............................................................................................23
9.3 Displays................................................................................................................23
9.4 Operating modes..................................................................................................23
9.5 Special tools, equipment, materials ......................................................................23
9.6 Commissioning.....................................................................................................23
9.6.1 Restarting after a longer standstill of the system.....................................23
9.7 Operation .............................................................................................................24
9.8 Inspection and maintenance.................................................................................25
10 Troubleshooting ............................................................................................................25
10.1 Safety...................................................................................................................25
10.2 Service address....................................................................................................25
10.3 Location and marking of fuses..............................................................................25
10.4 Fault condition detection.......................................................................................25

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10.5 First measures to eliminate the fault .....................................................................25
11 Dismantling and disposal..............................................................................................27
11.1 Dismantling ..........................................................................................................27
11.2 Disposal ...............................................................................................................27
11.2.1 Basic instruction......................................................................................27
11.2.2 Description of the disposal work .............................................................27
12 Plans and other information .........................................................................................28
12.1 Drawings and layouts ...........................................................................................28
12.2 Spare parts and consumables..............................................................................30
12.3 Electrical documentation ......................................................................................31

Important key information
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1 Important key information
1.1 Scope of delivery
With the purchase of the e-tron system trainer you receive
the e-tron system trainer itself,
the operating instructions for the e-tron system trainer
the power supply cable
a set of 2 ignition keys
a set of two switch keys
a tool for the service plug
1.2 Responsibilities
1.2.1 Responsibilities of the system builder
CE declaration of conformity: All directives applicable for the product are fulfilled. Within
the scope of CE certification, only the RoHS 2011/65/EU directive is relevant for the
product.
1.2.2 Responsibilities of the operator
The operating instructions of the manufacturer must be complied with. All safety
precautions must not be switched off or bypassed by the operator. The product may only
be used in its entirety, i.e. no components may be added or removed. The sale or misuse
of the components is prohibited.
1.3 Legal information
The e-tron system trainer complies with the requirements of EU Regulation 765/2008
1.4 Documentation
1.4.1 Background information on content and structure
The CE certification was carried out with the aid of certification software from WEKA.
Some of the content was used from the safety instructions of the power supply unit (see
chapter in the appendix)
1.4.2 Content and structure
The documentation is divided into:
- Cover sheet
- Important, fundamental information
- Safety
- Technical data
- System description
- Delivery, internal transport, unpacking
- Storage conditions
- Set-up conditions
- Assembly and installation, initial commissioning

Important key information
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- Operation
- Troubleshooting
- Maintenance
- Dismantling and disposal
- Supplementary documents for the superordinate system documentation
- Component documentation
- Safety instructions of the power supply unit
1.5 Addresses
1.5.1 Manufacturer’s address
Audi Academy
Vocational training
Hindemithstraße 27
D-85045 Ingolstadt
1.5.2 Service address
LD Didactic GmbH
Leyboldstr. 1
D-50354 Huerth
1.6 Safety Instructions
We accept no liability for damage to property or personal injury that is caused by improper
handling or failure to observe the safety instructions. In such cases, the warranty becomes
void.
Read the following information carefully. Keep it or forward it to other users of the product
(=e-tron system trainer).
a) General
- Due to safety and approval reasons, unauthorised conversion and/or modification of
the product is not permitted. Maintenance, adjustment, or repair work should only be
carried out by an expert/professional workshop that is familiar with the associated
dangers or relevant regulations.
- The product is not a toy. It may only be used by authorised persons.
- Do not expose the product to extreme temperatures, direct sunlight, or strong
vibrations. Protect the product from dust or dirt.
- Do not operate in environments with a high dust content, with flammable gases,
vapours, or solvents. There is a risk of fire/explosion!
- Never connect the product to the voltage/power supply immediately after it has been
brought from a cold room into a warm room (e.g. during transport). The resulting
condensation water can possibly lead to an electric shock! Allow the product to come
to ambient temperature first. Wait until the condensation has evaporated, this can take

Important key information
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a few hours. Only after this has been done can the e-tron system trainer be connected
to the voltage/power supply and put into operation.
- Do not overload the product. Pay attention to input/output voltages and currents.
- Handle the product with care, it can be damaged by bumps, knocks or a fall from an
even low height.
- In commercial facilities, the accident prevention regulations of the German Federation
of Institutions for Statutory Accident Insurance and Prevention (Verband der
gewerblichen Berufsgenossenschaften) for electrical systems and equipment must be
observed.
- Do not use the product if damaged. (See 9. Operation) Do not use the product any
longer, but take it to a professional workshop or dispose of it according to legal
regulations
- Do not leave the packaging material lying around carelessly, since this can lead to a
risk of injury due to tripping, etc.
b) Connection to the mains voltage
- Inappropriate handling of products that are operated at mains voltage may result in
danger to life due to electric shock.
- If the product or the connection cable is damaged, do not touch it, there is a danger to
life from electric shock. First switch off all poles of the mains voltage for the product
(e.g., pull out the fuse, then switch off the RCD). Check that there is no voltage by
using a suitable measuring instrument
- The mains supply must be protected by a residual current circuit breaker (RCD) with a
tripping current <= 30mA.
c) Mains cable (=connection cable)
- The mains cable must not be crushed or damaged by sharp edges. Do not place any
objects on the power cord, do not step on it. Place the power cable in a way that
nobody can trip over it. Do not place the power cord under a carpet or the like.
- The mains socket must be located near the product and must be easily accessible, as
the e-tron system trainer may only be plugged into the socket for voltage
measurements.
- Always pull the mains plug out of the socket only by the grip surfaces provided; never
pull the mains plug out of a mains socket by the cable.
- When the mains cable can be unplugged, the damaged mains cable must be replaced
by an identical mains cable with the same nominal data (e.g., cable cross-section).
Repairing a damaged mains cable is not permitted.
- Only use the mains cable that was supplied!
- Under no circumstances should a charger or other voltage sources except measuring
devices be connected to the system's own charging socket
d) Protective earth
- The product has Protection Class 1. The PE protective conductor must be firmly
connected between the power supply unit and the HV battery housing. Disregarding
this may result in danger to life due to electric shock in the event of a fault.
e) Indoor operation
- The product may only be connected, mounted, and operated in accordance with its
degree of protection. In the event of improper handling, there is a danger to life due to
electric shock

Important key information
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- Never pour liquids over or next to the product. There is a high risk of fire or life-
threatening electric shock. Should liquid still get into the interior of the device,
immediately switch off all poles of the operating voltage. Contact a specialist and do
not operate the product any longer.
- The product must not become damp or wet. Never operate the product in the
immediate vicinity of a bath.
- The product must never be touched, operated, plugged in, or unplugged with wet or
damp hands. There is a hazard to life due to electric shock.
f) Set-up
- The product must be placed on a horizontal, stable, level surface of sufficient size.
Never place the product on carpets.
- Protect valuable surfaces from pressure marks or scratches with a suitable base.
g) Fuses
- Disconnect all poles of the product from the operating voltage prior to changing the
fuse.
- Never bypass a defective fuse since there is a risk of fire and a life-threatening electric
shock.
- Replace the defective fuse only with a new fuse of the same design and rating.
- If the fuse trips again, disconnect all poles of the product from the operating voltage
and then have it checked by a specialist.
h) Maintenance and cleaning
- The product does not require any maintenance on your part. Leave maintenance or
repair to a specialist. Disconnect all poles of the product from the operating voltage
before cleaning. You can use a clean, soft, dry cloth for cleaning. Dust can be easily
removed with a clean, soft brush and a hoover. Do not use any aggressive, chemical,
or abrasive cleaning agents, as this may cause discolouration or even material
changes.
i) Disposal
- Do not dispose of product in household waste. Dispose of the product at the end of its
service life in accordance with the applicable legal regulations. Dispose of it at an
appropriate collection point, for example. The components of the e-tron system trainer
may only be used in the e-tron system trainer itself and may under no circumstances
be sold or used elsewhere. Disassembly of the product is only permissible as it is
getting ready for disposal

Safety
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2 Safety
2.1 Convention for safety instructions
The e-tron system trainer meets the criteria of IEC60449 on the operating side
2.2 Behaviour in an emergency
In case of a defect, immediately switch off the e-tron system trainer and disconnect from
voltage source, if possible. Then contact the service partner. The system trainer must be
protected against being switched on again by third parties and visually, unmistakably
marked as a hazard.
In the event of a short-circuit between HV+ and HV- lines, the short-circuit bridge can heat
up considerably and cause burns. If personal injury has occurred, first aid must be given
and a doctor consulted if necessary, taking personal protection into account.
The voltage between HV+ and HV- does not lead to a dangerous body flow when touched
(limit value of 120 V DC; here: 70 V DC). However, being startled by this, can lead to
secondary accidents (bumping, falling, etc.).
For relevant emergency situations, see points 2.9. to 2.19. Disregarding the operating
instructions and the general conditions can lead to an emergency.
2.3 Intended use of the entire system
Intended use
 For training purposes
 Measuring the applied voltage in the system
 Measure the insulation resistance in the enabled system
Under no circumstances should a charger be used at the charging socket!
Operating modes
Operating modes for use:
 Automatic operation: no
 Manual operation: yes
 On-site operation: yes
Operating mode to prepare:
 Setting mode: no
 Test mode: no
 Programming mode: no
Operating mode for maintenance:
 Maintenance operation (servicing, inspection, repair): no
2.3.1 Area of application
 Industrial sector: yes
 Business/commercial sector, small companies, training centres: yes
 Operation of the machine only by instructed personnel
 Operation of the machine only by mentally and physically suitable persons

Safety
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2.3.2 Requirements for the personnel
Authorised persons
The following persons are authorised to handle the product:
 Transporter (activity, required qualification): Transport of the packed e-tron system trainer,
none
 Operator (activity, required qualification): Measurements on the e-tron system trainer,
sensitised for activities in the high-voltage range
 Trainees/interns/pupils/students (activity, required qualification): Measurements on the e-tron
system trainer, sensitised for activities in the high-voltage range.
 General public, e.g., visitors, children, pedestrians, etc., (activity, required qualification): no
authority
 Especially vulnerable persons, e.g., pregnant women or people with reduced performance
(activity, required qualification: no authorisation)
2.3.3 Safety-relevant environmental conditions
Type of usage
The product is intended for use:
 outdoors (without protection from the weather): no
 on roofed surfaces (without walls): no
 in roofed and closed rooms: yes
 underground: no
 on/under/in water: no
 in potentially explosive atmospheres: no
2.3.4 Safety instructions for certain phases of life
Set-up conditions: level, firm, horizontal surface; the e-tron system trainer must be
secured against rolling away; maintain the working space around the system trainer; to
avoid scratches or pressure marks on the floor, protect it with a suitable underlay
Connection conditions: A standard household socket with 115/230 VAC and 50/60 Hz is
required.
Only use the connection cable that was supplied with the device
Operation: Operation by authorised personnel only; the operating instructions must be
complied with
Dismantling: The e-tron system trainer may not be dismantled, no components may be
opened or exchanged; the fuse may be changed by a qualified technician if necessary; do
not carry out your own repairs on the e-tron system trainer; in case of infringement, the
warranty expires
Disposal: The e-tron system trainer must be returned to the manufacturer and must not be
disposed of improperly.
2.4 Possible misuse
The following actions must be refrained from:
 Performing an amperage measurement on the e-tron system trainer
Connecting a charger to the charging socket: System is Inactive !
 Use of the e-tron system trainer as a storage area