1. Two-mode Safety and Battery System Service
Safety Overview
PowerPoint Presentation 1

2. Two-mode Safety and Battery System Service
Personal Protective Equipment
Required
Recommended
Precautions
Electrical Safety
Vehicle Safety

3. Personal Protective Equipment (PPE)
Refers to the safety materials and equipment used when working nearby or servicing high voltage systems
Proper guidelines and correct use of PPE should be executed each and every time a high voltage system is serviced
Two types of PPE
Required
Recommended

4. Required Personal Protective Equipment
Required PPE:
Safety glasses with side shields
Class 0 insulation gloves
Class 0 insulation gloves are a protective system consisting of:
Leather outer glove
Rubber inner glove
Rubber inner glove provides insulation against electrical current
Protective leather glove shields the rubber insulation from being altered or destroyed
Class 0 insulation gloves create a barrier between electrical current and user
Danger: Class 0 insulation gloves resist voltage up to 1000 volts.
Class 0 insulation gloves must be worn when servicing high voltage
systems. If they are not used, serious injury or death may occur.

5. Required Personal Protective Equipment
Class 0 insulation glove inspection procedure must be performed prior to servicing high voltage systems:
Remove rubber glove from the outer leather protector
Inflate the glove and pinch the opening tightly to seal the opening and prevent air loss
Press the glove to increase pressure inside the glove, and inspect for pin holes, air leaks, wear, tear, or abrasions
In addition to inspecting gloves, there is also a date stamp on each glove that must be certified up to date
Each glove must be re – certified every six months, in order to ensure proper glove protection
If any of the criteria mentioned are not met, do NOT use the gloves

6. Required Personal Protective Equipment
Safety glasses, which must include side shields, are also a PPE requirement

7. Recommended Personal Protective Equipment
Rubber soled shoes are recommended when working on high voltage systems
These types of shoes are non – conductive, and help isolate the wearer from the earth ground

8. Recommended Personal Protective Equipment
Because electrical shock is almost always associated with burns, it is recommended that non – synthetic clothing be worn when servicing high voltage systems
Any cotton clothing is non – synthetic and suitable to wear when servicing these systems
Wearing synthetic clothing may result in burns to skin, since this type of clothing melts at high temperatures

9. Recommended Precautions
Before Servicing High Voltage Systems:
Remove any jewelry that can conduct electricity and cause shock, such as:
Watches
Rings
Necklaces
Remove metal objects from pockets that may fall and create arc flash hazard, such as:
Mechanical pencils
Tools
Remove or cover metal on clothing
* Arc flash is produced when current suddenly flows due to loss of isolation between electrodes.
Characterized by unexpected dissipation of instantaneous power across conductive path.

10. Recommended Precautions

11. Electrical Safety
There are two factors of electricity on the body, voltage and current.
Voltage - pressure that causes electron flow
Current - flow of electricity through a circuit.
(which could include the human body)
The higher the voltage and current flow, the more severe damage to your body if it becomes part of the circuit.

12. Electrical Safety
Current passing through the body can cause electric shock, resulting in potential injuries such as:
Surface and internal tissue burns
Broken bones and muscle damage resulting from falls
At 16 mA, the muscles clamp on to whatever the person is holding.
Nervous system effects 
Breathing can stop at 30 mA.
Ventricular fibrillation can occur at 75 to 100 mA.

13. Electrical Safety
Ventricular fibrillation means the heart is twitching and there is no blood flow to the body.
The heart can be damaged because it is in the path of most common pathways:
Hand to hand
Hand to foot

14. Electrical Safety Circuits completed through grounding:
Across the Body:
Across the Hand:
To avoid these conditions:
Use category III rated DMM and test leads rated to 1,000 volts
when measuring the high voltage bus
Use PPE

15. Electrical Safety When you become part of the circuit:
Across the Body:
Across the Hand:
Pretty Obvious
To avoid these conditions:
Use category III rated DMM and test leads rated to 1,000 volts
when measuring the high voltage bus
Use PPE

16. Vehicle Safety High Voltage Interlock Circuit (HVIC)
When any service cover is removed, the High Voltage source is interrupted to prevent access to energized electrical circuits
Features:
Manual Disconnect Lever
HV DC cable extension cover
PIM Motor Cable Cover
Transmission Cable Access Cover
Danger: The HVIC system should NOT be relied on to disconnect the high voltage sources to the vehicle, since this interlock circuit will have no effect if the high voltage contactors fail in the closed position. If the contacts were stuck, a cover could therefore be removed, and the system would still be active. Relying on the HVIC system to disable high voltage may cause serious injury or death.

17. Vehicle Safety “Live-Dead-Live”
Live - Check your DMM against a known voltage source (vehicle’s 12 volt battery)
Dead - Check circuits for no voltage present
Live - Check DMM against same known voltage source to assure checks were valid

18. Vehicle Safety When Servicing a Two-mode Hybrid Vehicle Remember To:
Wear PPE
Verify vehicle is off and NOT in Auto Stop
Attach keys and manual disconnect lever
Store in a safe, secure place
Never leave a high voltage system exposed
Use a Category III DMM and test leads rated up to 1000 volts

19. Any Questions?