New Flyer Xcelsor 2019

Need help?

Do you have a question about the New Flyer Xcelsor 2019 and is the answer not in the manual?

Summary

Lockout; Tagout Procedure for Battery Electric Vehicles

Locking and Tagging Out

Procedure for physically securing switches with locks and tags to prevent operation.

Removing Locks and Tags

Guidelines for safely removing locks and tags, involving installer or supervisor.

De-Energizing & Energizing Procedures for Vehicles with Manual Service Disconnects (MSD)

De-Energizing Procedure (MSD)

Steps to de-energize high voltage systems on vehicles equipped with MSDs.

Energizing Procedure (MSD)

Steps to re-energize high voltage systems on vehicles equipped with MSDs.

De-Energizing & Energizing Procedures for Vehicles without Manual Service Disconnects (MSD)

De-Energizing Procedure (No MSD)

Steps to de-energize high voltage systems on vehicles without MSDs.

Energizing Procedure (No MSD)

Steps to re-energize high voltage systems on vehicles without MSDs.

This document, Service Manual Bulletin SMB-189, outlines the lockout/tagout and de-energizing/energizing procedures for New Flyer battery electric vehicles, with specific instructions for vehicles both with and without Manual Service Disconnects (MSDs). The primary function of these procedures is to ensure the safety of personnel working on or near high voltage components by completely de-energizing the vehicle's electrical systems.

Function Description:

The bulletin details a comprehensive safety protocol for servicing battery electric vehicles, focusing on the critical steps to isolate and verify the absence of electrical energy before maintenance or repair work begins. This includes:

Lockout/Tagout Procedure: This initial step involves physically securing and tagging the Master Run switch, the 12/24 volt Battery switch, and the High Voltage Interlock switch in their "OFF" or "STOP-SYSTEM" positions. This prevents accidental re-energization of the vehicle's systems. The procedure emphasizes the use of commercially available lockout equipment and tags, adhering to local laws and workplace procedures. Key retention is also a critical part of this step, ensuring that only the authorized person can re-energize the system.
De-Energizing Procedures: These procedures are divided into two main categories based on the vehicle's configuration:
- Vehicles with Manual Service Disconnects (MSDs): This involves preparing the work area, ensuring DC high voltage charging cables are disconnected, and then performing the lockout/tagout. Crucially, it requires wearing High Voltage Personal Protection Equipment (PPE) and verifying the absence of voltage on both the 12/24 VDC battery bus bars and the High Voltage System. The bulletin provides detailed instructions for measuring voltage in the main fusebox and the roof-mounted high voltage fuse box, using a multimeter. A critical step for MSD-equipped vehicles is the removal of all ESS Manual Service Disconnect plugs, which reduces the ESS voltage but still leaves individual batteries at a high voltage hazard (88 volts). Insulating covers must be installed in the receptacle locations, and removed MSDs must be stowed in a locked location. Finally, high voltage cables at the HV Junction Box on the side of the ESS are disconnected.
- Vehicles without Manual Service Disconnects (MSDs): Similar to MSD-equipped vehicles, this procedure starts with work area preparation, disconnecting charging cables, and lockout/tagout. PPE is mandatory, and voltage verification on both 12/24 VDC battery bus bars and the High Voltage System (main fusebox and roof-mounted high voltage fuse box) is required using a multimeter. A key distinction here is the disconnection of the mid-string cable within the ESS enclosure. This action reduces the high voltage risk by approximately half, but the individual batteries still pose a significant 88V hazard. The procedure then outlines how to remove specific cable connectors (tabs #1 and #2) and cover them with locking covers to prevent re-installation until service is complete. The most positive and negative cables in the battery string(s) are also disconnected.
Energizing Procedures: These procedures are the reverse of the de-energizing steps, ensuring that the vehicle is safely brought back online after service. They involve visual checks of HV compartments, reconnecting high voltage cables (using insulated tools and a phase rotation meter for correct cable sequences for devices like the Air Compressor, ESS Heat Exchanger, and HVAC Unit), reinstalling junction box covers, installing ESS Manual Service Disconnect plugs (if applicable), closing all HV access panels, and removing lockout/tagout devices from the 12/24 volt Battery Disconnect switch and High Voltage Interlock switch. The Master Run switch is then set to DAY-RUN or NIGHT-RUN, and "Safety Barricade" and "Danger High Voltage" signs are removed.

Important Technical Specifications:

Voltage Hazard: Even after removing Manual Service Disconnects or mid-string cables, individual batteries within the ESS remain a high voltage hazard at 88 volts. This is a critical safety specification.
Multimeter Requirements: The bulletin repeatedly references the need for a specific type of multimeter for voltage verification, as detailed in the New Flyer Service Manual's "Equipment Requirements" section. While not explicitly stated in the bulletin, this implies a multimeter capable of safely measuring high DC voltages (e.g., up to 1000V DC) and potentially insulation resistance. The figures show a "1587 MULTIMETER" with "INSULATION TEST" capabilities.
Cable Disconnection: The procedure for vehicles without MSDs involves disconnecting a "mid-string cable" that reduces the voltage by approximately half. This highlights a specific design feature of these vehicles' battery systems.
Safety Equipment: The consistent emphasis on High Voltage Personal Protection Equipment (PPE) underscores the inherent dangers of working with these systems.

Usage Features:

Clear Step-by-Step Instructions: The bulletin provides highly detailed, numbered steps for each procedure, making it easy to follow.
Visual Aids: Numerous figures (e.g., "Fig. 1: Locking / Tagging Out," "Fig. 2: Low Voltage Verification," "Fig. 3: High Voltage Verification - 1," "Fig. 6: Manual Service Disconnect - 1," "Fig. 13: Mid-String Cable," "Fig. 16: Locking Cable Cover") illustrate critical steps and component locations, enhancing clarity and reducing ambiguity.
Safety Warnings (DANGER/NOTE): Prominent "DANGER" warnings highlight critical risks, such as attempting to connect/disconnect components with current flowing or touching cable terminations before voltage verification. "NOTE" sections provide additional important information, such as multimeter requirements or specific device considerations during energization.
Vehicle Specificity: The bulletin clearly differentiates procedures for vehicles with and without Manual Service Disconnects, ensuring that the correct protocol is followed for each vehicle type.
Personnel Responsibility: The lockout/tagout removal procedure clearly defines who can remove locks/tags (the installer or their supervisor) and outlines the steps for supervisor removal if the installer is unavailable, emphasizing accountability.

Maintenance Features:

Preventive Safety: The entire bulletin serves as a critical maintenance feature by providing the necessary safety protocols to prevent electrical shock, burns, fire, and other hazards during vehicle servicing.
Standardized Procedures: By outlining standardized de-energizing and energizing procedures, the bulletin ensures consistency and reduces the risk of errors across different maintenance personnel and facilities.
Component Identification: The instructions implicitly guide technicians in identifying key electrical components like the Master Run switch, 12/24 volt Battery switch, High Voltage Interlock switch, main fusebox, roof-mounted high voltage fuse box, ESS Manual Service Disconnect plugs, HV Junction Box, and mid-string cables.
Tool Requirements: The mention of "insulated tools" for reconnecting high voltage cables and a "phase rotation meter" for specific devices during energization highlights essential tools for safe and effective maintenance.
Documentation: The bulletin itself is a vital piece of maintenance documentation, ensuring that safety procedures are formally recorded and accessible to technicians. It also refers to the broader New Flyer Service Manual for additional information on "Service Preparation," "PPE Requirements," and "Equipment Requirements," indicating a comprehensive documentation ecosystem.
Verification Steps: The repeated emphasis on verifying the absence of voltage using a multimeter is a crucial maintenance step, ensuring that the de-energization process has been successful before work commences.