FIA FORMULA E CHAMPIONSHIP TEAM esafety and checklists. Season

Transcription

1 FIA FORMULA E CHAMPIONSHIP TEAM esafety and checklists Season

2 CONTENTS MANDATORY TEAM EQUIPMENT FORMULA E CAR & ELECTRICAL HAZARD SAFETY DATA SHEET PRESENTATION ELECTRICAL RISK AND SAFETY DEVICES SAFETY CHECKS ON THE CAR HV SAFETY CHECKLISTS

3 FIA FORMULA E 1 st ever 100 % electric single-seater

4 MANDATORY TEAM EQUIPMENT The following equipment must be present in front of each team garage at all times during the event (before unloading the cars): Emergency EVAC KIT 3x class 0 gloves 3x leather gloves 3x respirator masks Emergency medical kit Trauma first aid kit Automatic defibrillator Facial shield 2 rescue hooks HV insulation blankets RESS extinguisher Fire extinguisher

5 MANAGING THE ELECTRICAL HAZARD FOR STAFF When connecting/disconnecting the battery to the charger you must: Wear Personal Protective Equipment (PPE): Class 0 gloves and eye protection Have someone standing behind you with a hook

6 ELECTRICAL POWERTRAIN LAYOUT This document is generic and applies to all cars whatever powertrain is used It is the responsibility of each powertrain manufacturer to adapt this training to the specificities of its material

7 RESS Lithium NMC Rechargeable Energy Storage System, RESS Structural carbon safety shell between monocoque and transmission with burst discs Maximal RESS voltage: 800 V (Orange HV cables) Energy Content: 32 kwh (28 kwh useable) Mechanical circuit breakers LV panel and cooling ports HVDC socket with pilotcontacts Burst discs

8 ELECTRICAL HAZARD Average resistance of human body 1500 (Rtot) Maximum RESS voltage: 800 V (OCV) 800 V / 1500 = 533 ma The level of current will depend upon resistance Higher resistance = safer 800 V / 240 k = 3.3 ma Pain threshold : ma Specific equipment is mandatory

9 ELECTRICAL HAZARD - The severity of the electric shock depends on the current through the human body and should be limited to less than 10 ma

10 ELECTRICAL HAZARD Access to live parts This is when live parts become accessible. This can be the case when enclosures are damaged or removed. The risk appears for instance when two parts become live and are touched by someone

11 Insulation loss ELECTRICAL HAZARD This is when an accessible part of the system loses the nominal insulation. The risk appears for instance when two parts become live due to multiple insulation failures

12 RESS SAFETY LIGHTS Always pay attention to the car s RESS safety light GREEN / RED / BLUE

13 RESS SAFETY LIGHTS GREEN RESS is safe RED RESS is NOT safe Insulation may be broken Risk of electrical shock Immediately report to Spark Do not touch any part of the car!

14 CONDITION LIGHTS Condition lights are located at the top of the main roll hoop (white) and at the rear crash cone (red): Active when the car is energized and HV is on the DC-Bus Flashing cyclic 0.5s ON, 0.5s OFF when the car is in P2 but no HV on the DC-Bus Flashing 0.05s ON, 2s OFF when the car is charging.

15 COCKPIT Driver Master Switch (DMS): located on the left panel in the cockpit Emergency Stop Switch (ESS): located on the right panel in the cockpit Service Disconnect (SD): located on the left panel in the cockpit Extinguisher button: located on the right panel in the cockpit marked with the sign

16 COCKPIT

17 NEUTRAL & EXTINGUISHER Neutral switch(ns): at the front of the driver monocoque - marked with the sign Emergency switch hooks located on both sides of the roll hoop marked with the sign

18 MAIN PROTECTION Equi-potential bonding When accessible conductive parts are strongly connected to CHASSIS GROUND there is no risk of an electric shock Double insulation Insulation monitoring When the system loses insulation, the RESS Status light turns to RED and the RESS is isolated High Voltage Inter Lock (HVIL) When any connector of the power circuit is disconnected, the connector terminals are not live

19 IN CASE OF FIRE In case of car fire or fire around the car, call firefighters and have the area quickly evacuated, whenever possible use CO 2 fire extinguishers or, alternatively, powder extinguishers. Whenever possible, activate an emergency cut-off before using fire extinguishers. If the fire reaches the traction battery area, wear the protection equipment and try to activate the car extinguisher by pulling one of the Emergency switch hooks Whenever possible, connect the specific nozzle water extinguishers to one of the water ports.

20 IN CASE OF FIRE!

21 12 V BATTERY FIRE In case of car smoke coming from the 12 V battery in the cockpit: Disconnect any external supply Push the car out of the garage into the open air Put on a mask and remove the carbon seat Apply dry ice / water in profusion to cool down the battery

22 MEDICAL AND SAFETY INCIDENTS FIA-approved First Aid & Medical Support Team Present in the paddock during build, race weekend and site breakdown 24hr Telephone Support for URGENT MEDICAL ADVICE when offsite: Call

23 MEDICAL AND SAFETY INCIDENTS Emergency Response MEDICAL INCIDENTS BATTERY FIRE HEALTH & SAFETY EMERGENCIES Use TEAMS Channel on Formula E radios Begin message with: EMERGENCY, EMERGENCY Give your team s name, exact location and the incident Ensure you have received confirmation that the rescue-team are en route

24 MEDICAL AND SAFETY INCIDENTS Collect emergency equipment Provide emergency first aid

25 GENERAL SAFETY Always disconnect the 12 V Battery and the external power supply when working on a powertrain component. Always start by the negative pole. When reconnecting the 12 V battery, always start by the positive pole.

26 UNLOADING THE CAR It is mandatory to wear the PPE when unloading the car after transport

27 MANDATORY CHECKS The intention of the safety check is to ensure the correct function of the vehicle s electrical safety systems It s strictly forbidden to touch the car first without using HV gloves before the safety check has been completed successfully Carry out the safety checks by following the checklist every day before any team personnel can get in contact with the car The safety checks must be performed at the latest 60 minutes after the team personnel have entered the garage The daily signature by the Team Manager directly after finishing safety checks is mandatory It is extremely important that any damage of the electrical system is reported immediately by anyone working on the car

28 SAFETY CHECK 1. Inspect and wear the personal protective equipment (PPE) and long sleeves: Class 0 gloves and facial shield 2. Make sure extinguisher, hook and defibrillator are available and positioned nearby 3. Make sure you are 2 people

29 SAFETY CHECK 4. State of the car before starting: Safety barrier to restrict car access Service disconnect removed from the car High Voltage Inter Lock (HVIL) connector of the Snatch free DC connector disconnected Snatch free DC connector disconnected Neutral Switch (NS) open (released up) Emergency Stop Switch (ESS) open Driver Master Switch (DMS) in P0 2 RESS low voltage connectors disconnected

30 SAFETY CHECK 5. Check with the Voltage and Continuity Tester (VCT) that there is no voltage between the inverter casing and the bodywork in your working area, then remove bodywork 6. Inspect visually the state of DC Connectors, RESS casing, emotor housing, inverter casing 7. Visually inspect the DC and AC cables

31 SAFETY CHECK 8. Check with the VCT that there is no voltage between the inverter casing and the bodywork in your working area! "

32 SAFETY CHECK 9. Check the following voltages with the VCT Main lid aluminium frame Lower voltage panel of the RESS (1 screw by example) & Inverter casing

33 10.Connect the RESS low voltage connectors (red and blue) SAFETY CHECK 11.Let Spark personnel arm the battery (removing seals and pushing arming rods):

34 SAFETY CHECK 12. Switch ON the Emergency Stop Switch ESS (down) and close the NS (pushed down)

35 SAFETY CHECK 13. Put DMS in P1 (middle) and check RESS status light, which has to be green 14.Go to P0 (up) - Disconnect the 2 RESS low voltage connectors (red and blue)

36 SAFETY CHECK 15.Check the following voltages with the VCT 4 equipotential bonding points Inverter AC connector Inspection lid aluminium frame emotor housing Gearbox housing 2 sides of the snatch-free DC connector Tub Steering wheel & Inverter casing

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38 SAFETY CHECK 16.Check the equipotential-bonding of the following parts with an Ohmmeter Low voltage panel RESS conductive parts Inverter AC connector emotor housing Gearbox housing 2 sides of the snatch-free DC connector DC connector ground connection & Inverter casing

39 SAFETY CHECK 17.Inspect the mechanical state of DC connectors, RESS casing, emotor casing, inverter casing. 18.Inspect the mechanical state of the DC and AC cables (if existing)

40 SAFETY CHECK 19.Inspect the mechanical state of DC connectors, RESS housing, e-motor housing, inverter housing. Connect the DC connector first 20.Then connect the DC HVIL connector 21.Connect the LV RESS connectors

41 22.Put DMS in P2 (Down) SAFETY CHECK 1. Check condition light is on continuous 2. Check RESS Safety light is green and no error message on the steering wheel 23.Check again with the VCT all the voltages as per point 15.

42 SAFETY CHECK 24.Put DMS in P1 and check that the condition light switches OFF 25.Disconnect the inverter cover HVIL connector (if existing) 26.Go to P2 and check condition light blinks 0.5Hz 27.Go to P0 and connect the inverter cover HVIL connector

43 SAFETY CHECK 28.Disconnect the DC HVIL connector 29.Go to P2 and check condition light blinks 0.5Hz Go to P0 and connect the DC HVIL connector

44 SAFETY CHECK 30.Go to P2 Check condition light is switched ON 31.Open the NS (released up) - Check condition light switches OFF 32.Close the NS (pushed down) - Check condition light blinks 0.5Hz 33.Go to P0, wait 15s, then P1, wait 30s, go to P2 Check condition light is switched ON 34.Switch to OFF (up) the Driver ESS - Check condition light switches OFF - Go to P0 (up)

45 SAFETY CHECK 35.Switch ON the Driver ESS (down) - Go to P1 (middle) - Remove barrier and signs All safety devices have been tested and work properly: DMS ESS NS HVIL EQUIBONDING INSULATION MONITORING

46 GREEN LIGHT BOARD As per the sporting regulations, the RESS safety light must be ON at all times when the car is in the garage. When working on the car, teams must apply the GREEN LIGHT board on the chassis The RESS safety light has to be visible at all times

47 POST EVENT 1. Go to P1 (middle) Checks condition light switches OFF 2. Check that no error messages are displayed on the steering wheel 3. Go to P0 (up) Check that the RESS status light stays green 4. Open the NS (released up) and switch OFF the Driver ESS (up) 5. Remove the service plug and put it in a safe place

48 POST EVENT 6. Disconnect the snatch free DC connector HVIL connector first 7. Then disconnect the snatch free DC connector 8. Disconnect the 2 RESS low voltage connectors (red and blue)

49 Safety is priority #1 CONCLUSION

50 HV SAFETY CHECKLIST

51 HV GENERAL SAFETY

52 HV POST EVENT SAFETY