Formula Hybrid 2011 Preliminary Electrical Inspection

Transcription

1 Formula Hybrid 2011 Preliminary Electrical Inspection Before beginning inspection Identify Rules and Safety officer, who must explain to us plans for work on HV, avoiding fire hazards, safe work practices, emergency response. Name of RSO: 4.10 High voltage schematic with wire size/rating, fuse rating, enclosures, isolation Electrical Safety Report contains: a. FMEA for HV system and unintended accel. b. Master switch 4.10 operation, c. Accumulator monitoring and d. fusing Note: check off here is only contents, not approving design and implementation. Preliminary Electrical Inspection: must be completed before mechanical inspection or any work on car 4.2 No exposed HV (even with body panels, etc. off); no HV in cockpit 4.6 System for de energizing HV outside accumulator container 4.7 No conductive penetrations of accumulator container. 4.3 No ungrounded metal or conductive body panels etc., that could become energized Accumulator fusing rated for voltage (detailed check of fuse rating to be done later) 4.4 Any low voltage battery must be fused. Note: Issue preliminary electrical sticker on completion of all of the above, including documentation.

2 Formula Hybrid 2011 On Site Inspection Upon arrival, check for safety violations safety glasses in use, etc. and complete Paddock report if any. Y / N Any violations found? (circle one; report violations separately) Safety equipment. Any team member must be able to locate at any time and explain use. Fire extinguishers: min 2, 5 lb. dry chem ABC; others if required. Chem spill absorbent Insulated cable cutters: Bahco 2520s, Knipex , Knipex , Willi Hahn Corp (Wiha) , Willi Hahn Corp (Wiha) are only acceptable choices Insulated gloves with protective overgloves. Check date and condition. Safety glasses MSDS for accumulator, and any additional equipment called for based on MSDS Any team member must be able to identify rules and safety officer. Name: Charger inspection: must be completed before use of charger 4.9 Charging equipment: HV stickers, UL or advance waiver, 4.9 Grounded or insulated enclosures, strain relief, fusing 4.9 Describe charging procedure Note: issue sticker for charger upon approval.

3 Formula Hybrid 2011 Electrical Inspection Needed for Inspection 4.10 High voltage schematic with wire size/rating, fuse rating, enclosures, isolation Electrical Safety Report contains: a. FMEA for HV system and unintended accel. b. Master switch 4.10 operation, c. Accumulator monitoring and d. fusing Note: even though this was checked of previously, it is needed for the full inspection process. Any pending items from preliminary inspection Initial if no remaining issues from preliminary inspection or all are resolved. On site inspection completed successfully High Voltage System (some items are repeats, but checked more carefully now) 4.2 No exposed HV (even w/o body panels) 4.2 No HV in cockpit or behind control panels 4.2 Mechanical linkages to high voltage controls isolated and/or grounded. 4.1 HV/LV segregation: not in same conduit 4.1 HV/LV segregation: in enclosures, adequately spaced and secured or 150 C barrier. 4.1 HV/LV segregation: spacing on PCBs Brake overtravel switch All three master switches tested Strobe: on when HV on, off when HV off HV disable with lockout/tagout capability. Must also disable strobe GFD: review design for latch off, accessible or indicator, no reset from driver's seat GFD test: test multiple points. 4.3 Wire insulation: Marked w/ voltage, temp, gauge. Visible in car or on sample. 4.3 Other insulation materials: rated for temp, at least 60 C 4.3 Test, or approve without test any insulation materials that might get hot. 4.3 Wiring to professional standards, bolted connections locked, conduit routed safely 4.3 HV wiring outside enclosures in LFNC A or B orange conduit, including low power HV. Are there any HV conductors inside frame members? (If so needs further review) 4.3 Conduit anchored at both ends with proper fittings; hold 200 N/45 lbf. 4.3 Exposed conductive objects near HV and conductive body panels grounded. 4.5 Maximum voltage: (must not exceed 300 V) Fuse current ratings match wire sizes Fuses carry adequate voltage rating Parallel cells or strings individually fused Accumulator monitoring sense wires protected Fusible links require lower current series fuse, AMS detectable, current rating

4 Accumulator Type: Manufacturer: Quanity: Part number: Official FH capacity rating: Total capacity: Battery chemistry: Does it contain metallic Li? AMS: must monitor temp, v as specified, latching shut down, no driver reset 4.6 Contactor current rating >= fuse rating, voltage rating 4.6 At least one contactor per container, at least one at most + and most end 4.6 Voltage decay: under 30 V in 60 seconds; label if > 5 seconds. 4.6 Energization indicator: LED for ultracaps; "always energized" label for batteries 4.7 Accumulator enclosure and mounting good for 20g XY, 8g Z 4.7 Fireproof and insulation OK; one face transparent 4.7 No conductive penetrations (grounding is not adequate) 4.7 High voltage label 4.7 Ventilation if needed Cockpit barrier: inside and top, 0.62 inch (1.6 mm) Al + nomex or equivalent, grounded. Low Voltage Systems 4.8 Grounded to frame 4.9 Fused System Design Methodology to ensure fail safe throttle actuation for ICE and elec. mot. Rain certification (optional) Visual inspection Spray test

5 Paddock Safety Steward Report Steward: Student name(s): Observed violations Anyone working on the car or within 10 feet of a car being worked on w/o safety glasses. Unsafe welding, grinding, etc.; note any nearby flammalbe materials: batteries/ultracaps Wheels not off the ground (at least 4") when energized (strobe on, unless otherwise disabled) or with engine running. Charging with a charger without a FH approval sticker Charging without a team member familiar with charging operation present Charging while other work (electrical or mechanical) is going on on the car. Energized electrical work without prior approval of inspectors and access control Failure to maintain an orderly and safe working environment Spot checks: Each team member must be familiar with the location and proper use of: Fire extinguishers: min 2, 5 lb. dry chem ABC; others if required. Chem spill absorbent Insulated cable cutters Insulated gloves with protective overgloves Safety glasses MSDS for accumulator, and any additional equipment called for based on MSDS. Each team must have a designated rules and safety officer (RSO) Any team member must be able to tell you who the RSO is