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

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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

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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

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 Carrying out resistance measurements on the not enabled and not freely measured system
 Fault switching with active voltage or active fault 24
 Removal of covers except required in the experiment manual
 Removing or adding components
 Short-circuiting of cables and components
 Consumption of liquids and food in the vicinity of the e-tron system trainer
 Increasing the potential danger by introducing external voltages through connection of the
charging socket
 Wearing jewellery
 Resistance measurements on the system for as long as the protective contact plug of the
connection cable is plugged into the household socket outlet
 Voltage measurements with switched fault 24 (= contactor sticker)
2.5 Compliance with the operating instructions
To avoid material and personal damage, please observe and follow the operating
instructions. Failure to do so will result in loss of warranty.
2.6 Safety marking of the system
The system may only be operated by instructed personnel, and this must be clearly
marked. Among others, with the following symbols:
2.7 Protective devices
Contact protection is provided on all active components.
The operating voltage is limited to 70 V DC on the operating side and therefore falls under
the guideline for protective extra-low voltage IEC60449
The supply via a residual current circuit breaker with all-pole disconnection for personal
protection must be ensured.

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2.8 Residual hazards and protective measures
Secondary accidents can occur in the event of a fall (e.g., improperly laid connection
cable) or impact due to startling effect in the event of an electric shock. To minimise these,
the system trainer may only be used in suitable locations.
In the event of a negligently caused short circuit, burns can occur on a highly heated short
circuit bridge. The user must therefore be instructed before use.
2.9 Life phase: Operation
2.9.1 Life phase: Operation
Hazard location Hazard group Hazard consequence Hazard origin
Training room Electrical hazards Leakage current live parts; faulty insulation
Description of the hazard
Defective insulation can lead to a fault current can flow via the equipotential bonding conductor.
Endangered group of persons
Operating personnel
Protection goal
Prevent leakage current
Protective measures
Design solution:
A residual current circuit breaker with all-pole disconnection is installed
Residual risk
Defective residual current circuit breaker / non-use or bridging of the circuit breaker
2.9.2 Life phase: Operation
Hazard location Hazard group Hazard consequence Hazard origin
Training room Electrical hazards Stored charges Live parts: parts that have
become live in the fault condition;
electrostatic processes
Description of the hazard
Due to stored charges, a voltage can be present in the system even when the system is switched off due to a fault
Endangered group of persons
Operating personnel
Protection goal
Prevent unwanted voltages
Protective measures
Touch protection, discharge resistance, discharge time <5 sec
Use touch-proof measuring equipment
Residual risk
Voltage can still be conducted in a switched-off state wait for discharge time
Electrically instructed personnel

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2.9.3 Life phase: Operation
Hazard location Hazard group Hazard consequence Hazard origin
Training room Electrical hazards Arcing Arcing; live parts; parts that have
become live in the fault state;
short circuit; faulty insulation
Description of the hazard
Arcing due to improper operation or error
Endangered group of persons
Operating personnel
Protection goal
Preventing arcing
Protective measures
Design solution:
Touch protection Residual current Circuit breaker
Residual risk
Incorrect operation / vandalism can still cause an electric arc to occur
2.9.4 Life phase: Operation
Hazard location Hazard group Hazard consequence Hazard origin
Training room Electrical hazards Electric shock Live parts; faulty insulation; parts
that have become live in the fault
condition
Description of the hazard
Electric shock may occur due to improper operation
Endangered group of persons
Operating personnel
Protection goal
Avoid electric shock during proper operation
Protective measures
Design solution, technical protective measure:
Installation of a PE conductor, insulation sufficient
Residual risk
Electric shock is still possible, if the PE conductor is not properly attached to the battery housing or if the earthing of all parts
under mains voltage in the event of a fault is not ensured.
2.9.5 Life phase: Operation
Hazard location Hazard group Hazard consequence Hazard origin
Training room Electrical hazards Fire on the 70-volt DC side live parts: parts that have become
live in the fault state; short circuit;
faulty insulation
Description of the hazard
In the event of fault currents/short circuit, a fire is possible on the 70 V DC side

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Endangered group of persons
Operating personnel
Protection goal
Prevention of fire on the 70 VDC side
Protective measures
Design solution:
Installation of a fuse to limit the short-circuit current
Protective encapsulation through metallic enclosure of the components
There is no residual risk
2.9.6 Life phase: Operation
Hazard location Hazard group Hazard consequence Hazard origin
Training room Functional safety and
reliability
System error Short circuit; overload; live parts;
parts that have become live in the
fault state; faulty insulation;
damage; voltage source
Description of the hazard
Danger due to short circuit and associated high currents
Endangered group of persons
Operating personnel
Protection goal
Avoid hazards due to excessive currents
Protective measures
Design solution:
Installation of a fuse
Residual risk
Bypassing the fuse or installing the wrong fuse
2.10 Life phase: permanent condition
2.10.1 Life phase: permanent condition
Hazard location Hazard group Hazard consequence Hazard origin
Training room Electrical hazards Power supply Voltage source
Description of the hazard
Danger due to voltage source
Endangered group of persons
All
Protection goal
No danger from voltage source
Protective measures
Certified connection cable, proper warning of the voltage source hazard, only allow power supply during voltage
measurements Residual current Personal protection
There is no residual risk

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2.10.2 Life phase: permanent condition
Hazard location Hazard group Hazard consequence Hazard origin
Training room Other hazards Fire Damage
Description of the hazard
In the event of fault currents/short circuit, a fire is possible on the 230 V AC side
Endangered group of persons
Operating personnel
Protection goal
Prevention of a fire
Protective measures
Design solution:
Installation of a PE conductor, installation of a fuse in the cold appliance coupling connection, visual inspection of the
connection cable before use
Residual risk
The PE conductor can be damaged, the fuse can be damaged
2.10.3 Life phase: permanent condition
Hazard location Hazard group Hazard consequence Hazard origin
Training room Other hazards Interruption of the power
supply
Voltage source
Description of the hazard
The instrument can be permanently live
Endangered group of persons
All
Protection goal
Preventing permanent power supply
Protective measures
Design solution:
On-Off switch between the system and the voltage source and operating instruction to insert the plug into the socket only
when measuring the voltage.
Residual risk
Do not operate the off switch after the measuring process or do not pull the earthing contact plug out of the socket
2.10.4 Life phase: permanent condition
Hazard location Hazard group Hazard consequence Hazard origin
Training room Other hazards Ergonomics Posture
Description of the hazard
Since the e-tron trainer is exceptionally low, it is important to pay attention to ergonomics when measuring for long periods of
time
Endangered group of persons
All

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Protection goal
Avoiding ergonomic damage
Protective measures
-
Residual risk
Ergonomic measurement not possible over a long period of time
2.10.5 Life phase: permanent condition
Hazard location Hazard group Hazard consequence Hazard origin
Training room Functional safety and
reliability
Equipment design Arcing; electrostatic processes;
live parts; parts that have become
live when faulty; short circuit;
faulty insulation; sharp parts;
falling objects; gravity; lack of
stability/safety; moving parts;
rough, slippery surface; sharp
edges; electrostatic processes;
lightning strike
Description of the hazard
Faulty design which can lead to faults of any kind
Endangered group of persons
All
Protection goal
Construction of the e-tron system trainer in a way that it is almost impossible to use it incorrectly.
Protective measures
Design solution:
Proper construction and assembly of the e-tron system trainer and provision of sufficient user information
Residual risk
There is a residual risk if the user information is ignored

Technical data
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3 Technical data
3.1 Overall system
General description of the product
With the Audi e-tron system trainer, it is possible to simulate insulation faults in the HV
lines and components. This allows systematic troubleshooting to be trained and improved
in a targeted manner. In comparison to the Audi e-tron vehicle, all installed HV
components are easily accessible. In the event of a fault, only a detectable HV voltage is
present, the current-carrying capacity of which is extremely low. The system provides an
overview of all installed HV components. The work that is needed for disconnection can
be carried out identically for the vehicle under simpler conditions. The system trainer
removes the daunting complexity of HV vehicle technology through its clear and easy-to-
understand structure. Application and haptics correspond to the real vehicle.
Spatial limits
 Required floor space: 120 cm x 90 cm
 Installation limits: level, horizontal, solid floor
 Movement space at the workstations: 220 cm x 190 cm
Use in dry closed rooms only
 A 115/230 V AC 50/60 Hz socket must be available for plugging in the e-tron system trainer.
The e-tron system trainer must not be exposed to splashing water
The e-tron system trainer must not be exposed to vibrations and direct sunlight
Interfaces
 Human - Product: Switch box
 Product power supply: Connection cable between AC socket and e-tron system trainer
 Product building: Item racks on wheels
Environmental limits
 Temperature range (°C): +10 °C to +35 °C
 Relative humidity (%): 70% non-condensing
 Altitude above sea level (m): 1000
 Cleanliness (cleanroom or cleanroom class): Cleanliness level SaS1 (clean room according to
VDA 19.2)
 The e-tron system trainer should not be placed or stored in areas where there is a risk of fire
The mains supply must be protected by a residual current circuit breaker (RCD) with a tripping
current <= 30mA
Material limits
Installed materials:
 Machine frame: Aluminium
 Connecting elements: Steel, stainless steel
 Electrical and electronic equipment: Copper lines
 Seals: Rubber
Other limits
The location of the e-tron system trainer must be chosen in such a way that secondary
accidents are minimized or completely avoided. For this purpose, it is necessary to place

Technical data
HV- Trainer 18 of 34
the e-tron system trainer at a location without sharp edges, sharp corners or tripping
hazards (e.g., connection cable of the e-tron system trainer). Escape routes must be
marked and kept clear.
3.2 Equipment
A fault switch box (see 12) for simulating 24 individual possible insulation faults in all
HV components and lines
The system requires a mains connection of 115/230 volts AC at 50/60 Hz.
The charging socket is intended for testing purposes only (charging via this socket is
not possible)
The high-voltage battery contains a power supply unit that supplies the HV system
with 70 VDC nominal voltage
Two loads (PTC heater and air-conditioning compressor) are used for fault simulation
only
The e-machine is also simulated by open ends with measurement possibilities
Energizing the system using the ignition key is possible
The system is deenergized via the Service Disconnect
The system is made of aluminium profiles with four swivel castors with locking brakes
Dimension: Length 120 cm, width 90 cm, height 140 cm
Weight: approx. 90 kg
The system trainer is built according to the latest state of vehicle technology
These are components from the current e-tron programme of AUDI AG
3.3 Components
3.3.1 Power supply (=voltage source)
on the input side with IEC plug (fuse and on/off switch, PE conductor on HV battery
housing) and two connecting cables (phase and N conductor)
3.3.2 PTC heater (inactive)
3.3.3 A/C compressor (inactive)
3.3.4 Power electronics (Inactive)
3.3.5 Charger (inactive)
3.3.6 HV battery housing (inactive without battery)
3.3.7 Cable set
3.3.8 Connection cable

System description
HV- Trainer 19 of 34
4 System description
4.1 Set-up
4.1.1 Main components
Item rack
Fault switch box
Measuring sockets
Power supply unit (=voltage source) on input side with IEC plug (fuse and on/off
switch, PE conductor on HV battery housing) and two connecting cables (phase, N
conductor)
Connection cable with earthing contact plug on the socket side and cold appliance
coupler (C13) on the other side
HV components: Cable set, HV battery housing, charger, air-conditioning
compressor, power electronics, PTC heater (Inactive components)
4.1.2 Operator workstations
Environment of the e-tron system trainer (=training room)
4.2 Functional description
4.2.1 System
Fault switching of insulation faults on HV+ and HV- of the high-voltage system
Simulation of the isolation process of the high voltage system
4.2.2 Main components
Power supply unit: Voltage conversion from 115/230 V AC 50/60 Hz to 70 volts DC
Fault switch box: - Switching the various ISO faults
- Change of ISO resistance in case of fault switching
HV components: For troubleshooting
Measuring sockets: Measuring HV+, HV-, shield/ground

Delivery, internal transport, unpacking
HV- Trainer 20 of 34
5 Delivery, internal transport, unpacking
5.1 Safety
The cardboard pallet completely encloses the e-tron system trainer, which means that
there are no sharp corners and edges. The e-tron system trainer is securely fastened to
the cardboard pallet with tie-down straps. When unpacking, make sure that the e-tron
system trainer is not damaged and does not show any transport damage.
5.2 Delivery
The delivery is done either by delivery with a truck (option 1) or by self-pick-up (option 2).
In option 1, the e-tron system trainer is on a cardboard pallet and is firmly connected to it.
Pallet dimensions: Length 150 cm, Width: 115 cm, Height: 100 cm
Weight of the packaging unit: 25 kg
When picking up the e-tron system trainer yourself, it will be loaded by forklift truck. During
loading and unloading it must be ensured that the e-tron system trainer does not bump
into anything or get into an inclined position, fall, or be damaged in any other way. During
transport, the e-tron system trainer must stand on a flat, firm, horizontal surface.
Ensure that it is adequately secured for transport.
5.3 Internal transport
The e-tron system trainer can be moved around freely to the respective place of use since
the item frame is on four castors. It is important to observe the conditions of the location.
Special attention must be paid when driving over uneven surfaces and doorsteps. It is
also important to ensure that the castors are not driven over feet, etc. and that they are
locked again at the desired location.
5.4 Unpacking
Use a suitable tool to cut the lashing straps that create the force-fit connection with the
pallet and open the cardboard pallet by removing the cover. Do not work on the e-tron
system trainer with sharp or pointed objects. In addition, make sure that the tron system
trainer does not fall, bump, or get damaged at any time.