ASE XEV1 flashcards
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31 cards. Read the term and the definition here. The deck at the top of this page is optional.
- Rubber insulating glove class 0
- Class 0 gloves are rated for 1,000 V AC or 1,500 V DC maximum use voltage and must receive an electrical retest every six months under ASTM D120.
- Glove air test procedure
- Roll the glove cuff to trap air inside and check for pinholes, cracks, or bulges. Any defect removes the glove from service immediately.
- Leather protectors over gloves
- Leather over-gloves are worn on top of rubber insulating gloves to resist punctures, cuts, and abrasion, and provide no electrical insulation themselves.
- Hazardous voltage threshold
- SAE J1766 and FMVSS 305 treat 60 V DC or 30 V AC as the hazardous threshold; anything at or above this requires full high-voltage safety procedures.
- CAT III meter rating
- A CAT III rated multimeter is tested for transient overvoltage in fixed installations and is the minimum acceptable rating for measuring xEV high-voltage circuits.
- Let-go current threshold
- About 10 mA of body current can cause muscle contraction severe enough that a person cannot release the conductor, and 100 mA can induce ventricular fibrillation.
- One-hand rule
- Keep one hand in a pocket or behind the back while probing circuits so any unintended current path stays out of the chest cavity.
- Insulated tool rating
- High-voltage hand tools should be rated to 1,000 V under IEC 60900 and inspected for cracked or missing insulation before every use.
- Orange cable color code
- SAE J1673 and ISO 6469-3 require high-voltage cables to be marked orange, alerting technicians to circuits that may carry 60 V DC or more.
- HV interlock loop
- A low-voltage loop routed through high-voltage connectors and covers; opening any connector breaks the loop and commands the battery contactors to open.
- Ten-minute discharge wait
- After disabling the high-voltage system, wait at least the OEM-specified time, commonly ten minutes, for inverter capacitors to discharge before probing conductors.
- Three-point voltage verification
- Measure HV+ to HV-, HV+ to chassis ground, and HV- to chassis ground; all three readings must be below 60 V DC to confirm de-energization.
- Meter prove-out
- Verify the voltmeter on a known live source before and after testing the high-voltage system so a failed meter cannot produce a false zero reading.
- Lockout tagout requirement
- OSHA 1910.147 requires the energy-isolating device to be locked and tagged with a personal tag while service work is being performed on the vehicle.
- High-voltage warning label
- ISO 7010 symbol W012, a yellow triangle containing a lightning bolt, marks enclosures, covers, and cables that contain hazardous voltage.
- Battery pack architecture
- Cells are grouped into modules and modules into the pack; a pack typically produces 350-400 V nominal, with some newer designs near 800 V.
- Pre-charge resistor function
- A resistor in series with the main positive contactor limits inrush current while inverter capacitors charge, preventing contactor arcing and welded contacts.
- BMS monitored parameters
- The battery management system monitors individual cell voltages, module temperatures, pack current, and isolation resistance, and commands the state of the contactors.
- Inverter IGBT function
- The inverter switches DC from the battery into three-phase AC using IGBTs or SiC MOSFETs, controlling frequency and voltage to set motor speed and torque.
- Permanent magnet synchronous motor
- PMSM rotors contain permanent magnets; the inverter must know rotor position from a resolver to synchronize current, and spinning the shaft generates voltage.
- Regenerative braking
- During deceleration the motor acts as a generator, converting kinetic energy to DC that the inverter returns to the pack; friction brakes blend in at low speed.
- Isolation resistance test
- A megohmmeter applies a specified DC test voltage between high-voltage conductors and chassis; low resistance indicates insulation breakdown and requires component isolation.
- Battery capacity formula
- Energy in kilowatt-hours equals pack ampere-hours multiplied by nominal pack voltage, divided by 1,000.
- P0Axx DTC family
- Codes in the P0A00-P0AFF range are reserved for hybrid and electric propulsion systems, covering battery, motor, inverter, and contactor faults.
- Bidirectional scan tool control
- Commanding contactors, coolant pumps, or fans through the scan tool confirms circuit function, but the OEM preconditions and safety precautions must be met first.
- Isolation fault diagnostics
- An isolation DTC sets when resistance between high-voltage circuits and chassis falls below the OEM threshold; disconnect sections one at a time and retest to locate it.
- Cell voltage spread PID
- Comparing maximum and minimum cell voltages under load reveals weak modules; a spread exceeding the OEM limit indicates a failing cell or module.
- Lithium-ion thermal runaway
- Overheated or damaged lithium-ion cells vent flammable electrolyte and self-propagate heat; large water volume cools the pack and limits spread to neighboring cells.
- Swollen battery handling
- A swollen or physically damaged pack is a thermal-runaway risk; do not charge it, do not stack it, and move it to a designated outdoor quarantine area.
- High-voltage barrier tape
- Mark the work zone with cones and warning tape at the OEM-recommended distance to keep unprotected personnel outside the arc-flash approach boundary.
- Module programming power supply
- Maintain a stable 12 V power supply on the auxiliary battery during reprogramming; voltage sag can abort the flash and render the control module unusable.