Windrose E700 High-Voltage Course

Who may work on high voltage

• Only trained and qualified people work on high voltage.
• Only qualified workshops do service and repair.
• Do not change the high-voltage system or the body. Risk of fire.
• Drivers without training: do not take apart parts with a high-voltage sign.

On and around the truck

• Do not step on or hit the high-voltage battery.
• After an accident, do not touch orange cables or parts touching them.
• Battery and motor warning lamps stay on? Call after-sales. They read the fault codes.
• Smoke, fire or explosion from the EIC system? Leave the truck. Call the police.
• Truck parked for a long time? Check the high-voltage battery every two weeks. Charge it regularly.

Before and during high-voltage work

• Wear protective gear before you touch a high-voltage part. List: module 7.
• Even after switch-off, do not touch battery pack parts.
• Damaged high-voltage part? Wrap it with insulating tape.
• No watch, ring or metal jewellery.
• No keys, metal pens, phones or coins in your pockets.
• Only tools for the job. Metal tools need insulated handles.
• One person works. One person watches. Never two people working at once.
• Do not touch the person who is working.
• Before switching on: clear debris, send other people away, call it out loudly.

24 volt batteries

• Never touch + and − at the same time, with hands or metal.
• Never connect a 12 volt device to one battery.
• Battery acid burns. In eyes or on skin: rinse with lots of water. See a doctor.
• Do not take a battery apart. Only trained people service it.
• 24 volt battery on fire? Leave the truck fast. Breathed smoke? Go outside. See a doctor.
• Damaged cables, plugs or data lines? Stop. Cut the power. Call Windrose service.
• Overheating, smoke or sparks? Stop. Cut the power. Call Windrose service.
• Battery pack cracked or leaking? Stop. Cut the power. Call Windrose service.

• High-voltage parts: battery packs, orange cables, drive motors, charging ports.
• PDU (power distribution box): on the frame centre line, just behind the cab, in front of the middle axle.
• Contactors (electric switches) sit in the PDU. Circuits after them go dead at switch-off.
• MSD (low-voltage service plug): pull it and the contactors open.

1. 1 Middle e-axle, drive motor built in 2400100
2. 2 Rear e-axle, drive motor built in 2400200
3. 3 Motor power cables from the PDU 2105210–2105240

1. 1 Charging port, left 5614010, 5614012
2. 2 Charging cable 2107101

1. 1 Charging port, right (CCS2) 5614020–5614022
2. 2 Charging cable 2107102

1. 1 Zone A: battery packs, always live 2101100–2101400
2. 2 PDU with the contactors 2104100
3. 3 Zone B: cables after the contactors 2105210–2105240, 2105310, 2105320, 2105410, 2105510–2105530, 2107101, 2107102

• LFP version: 4 packs, 238 cells each. 766.4 volts nominal (595 to 868.7 volts).
• NCM version: 204 cells per pack. 754.8 volts nominal (571.2 to 887.4 volts).
• Each pack has an HV+ plug, an HV− plug and a small low-voltage plug.
• Each pack has its own + cable and − cable to the PDU. No switch on this cable.

• Safe limit: below 60 volts DC.
• Switching off only opens contactors. A welded (stuck) contactor stays closed.
• Capacitors (charge stores) stay charged after switch-off. Wait at least 10 minutes.
• Active discharge empties them. If it fails, resistors drain them slowly. The 10-minute wait covers this.
• Use a CAT III 1000 volt meter. DC range at least 1000 volts. Shrouded probes.

Take three readings

1. Measure HV+ to HV−.
2. Measure HV+ to chassis.
3. Measure HV− to chassis.

• Why three: the system floats (IT system: no pole is tied to the chassis).
• With bad insulation, one pole can be live to chassis. HV+ to HV− can still read 0 volts.

Live–dead–live: test the meter twice

1. Test the meter on the 24 volt battery. Expect 24 to 28 volts.
2. Take the three readings.
3. Test the meter on the 24 volt battery again.
4. Second test fails? Earlier zero readings do not count. Use another meter.

Readings that mean danger

• One pole steady at several hundred volts to chassis: insulation fault. Any metal may be live. Close the area. Call a specialist.
• Pack HV+ to HV− reads 595 to 868.7 volts (LFP) or 571.2 to 887.4 volts (NCM). That is normal: the pack is always live.
• Pack pole to chassis near 0 volts or drifting: normal. Steady near pack voltage: insulation fault.

Read the dashboard

• Dashboard dark: truck OFF. Doors work. You cannot drive.
• Dashboard lit, “Vehicle ready” off: ON, not ready. You cannot select a gear.
• “Vehicle ready” and “High-voltage connected” lit: READY. You can drive.

Switch ON

1. Swipe the card on the middle of the door handle. The truck unlocks.
2. Get in.
3. Hold the card on the NFC spot on the right dash. Take it away at once.
4. Wait. The screens light up and “NFC Card valid” shows.
5. Wait for “Vehicle ready”. Then select a gear and drive.

“Vehicle ready” stays off? Do not swipe again: that switches the truck off. Read the dashboard message. Fault shown? Call a Windrose service centre.

Switch OFF

1. Stop the truck completely.
2. Select N. Never D or R.
3. Apply the EPB (electric parking brake). On a slope, also chock the wheels.
4. Tap Control Centre → Setting → Power OFF on the screen. The parking brake applies itself.
5. Check: “Vehicle ready” goes out, then the screens go dark.
6. Get out. Swipe the card on the door handle to lock. The lights flash twice.

• Card instead of screen: apply the EPB by hand first. Then hold the card on the NFC spot.
• A brake noise at switch-off is normal. It is a self-test.
• The sliding door switches still work after switch-off.

Towing mode

1. Press and hold the EPB switch.
2. Tap Power OFF on the screen. Do not use the card.
3. Release the EPB switch after more than 5 seconds. The brake stays released.

Good to know

• The 230 volt power outlet works only with high voltage on. Truck off: only 12 and 24 volts.
• High-voltage battery below 20 percent: alarm. Below 5 percent: less power, lower speed. Charge soon.
• Card care: do not bend, twist or cut it. Keep it away from heat, damp and strong vibration.
• Keep the card off wireless chargers and out of phone cases. Do not swipe it with other cards.
• Lost the card? Call the Windrose service hotline.

• Two 12 volt batteries in series make 24 volts. They sit in the front compartment.
• IBS (battery sensor) sits on the − post. A link cable joins the two batteries.
• With high voltage on, the truck's 24 volt DC/DC (DCDC1, 6 kW) recharges the batteries.

Check

1. Swipe the card on the dash. Screens dark and battery lamp on? Probably flat.
2. Switch the truck off. With high voltage on, the reading is too high.
3. Set the meter to DC volts.
4. Measure the pair at the two outer posts.
5. Measure each 12 volt battery.
6. Compare with the table.

• Charge the pair as 24 volts. Or switch high voltage on and let the DC/DC charge it.
• Workshop battery test: service manual 7.4.4 (good, charge, or replace).

Jump-start (24 volts only)

1. Get a 24 volt source: another Windrose truck, or a 24 volt pack or charger.
2. Switch both trucks off.
3. Leave every cable on. Do not touch the link cable.
4. Red clamp on the free + post. It is the one without the link cable.
5. Other red clamp on the donor's 24 volt +.
6. Black clamp on the donor's 24 volt − first.
7. Other black clamp on clean chassis metal, away from the batteries. Or on the free − post with the IBS.
8. Run the donor for a few minutes.
9. Swipe the card on the dash. With high voltage on, DCDC1 recharges the pair.
10. Remove in reverse: black from this truck, black from donor, red from donor, red from this truck.
11. Keep the clamp jaws apart.

Hard reset of the 24 volt system: high voltage off first, then open the − post.

Open the 3D battery guide

Touching + and − together: see the 24 volt rules in module 1.

1. Switch on the hazard lights.
2. Try to start the truck again.
3. It works? Pull over. Get it inspected before you drive on.
4. It does not work? Roll to the side of the road.
5. Place warning signs around the truck.
6. Call the Windrose service hotline.

• Prevent it: service the truck regularly at a Windrose centre.
• Warning lamps that stay on: see module 1.

For qualified high-voltage mechanics only. Follow your national rules too.

Gear you need

Steps

1. Park. Apply the EPB.
2. Unplug any charging cable.
3. Connect the diagnostic tool. Read the PDU fault codes.
4. “Contactor welded” code? Stop. See “If something is wrong”.
5. Pull the MSD. One place is enough. High voltage switches off by itself.

   In the cab

   1. Open the cover at the lower left of the dash.
   2. Pull the MSD.

   

   Outside

   1. Open the door.
   2. Pull the hood release twice.
   3. Pull the MSD in the front compartment.

   

6. Keep the MSD and the key on you. Hang a “Do not switch on” sign.
7. Disconnect the 24 volt battery −.
8. Wait at least 10 minutes.
9. Put on insulating gloves and a face shield. Second person ready.
10. Measure at the part: three readings, live–dead–live (module 3).
11. All three below 60 volts? Start work.

If something is wrong

• Still above 60 volts after 10 minutes? Wait 10 more. Measure again. No drop: treat it as a welded contactor.
• Welded contactor, or steady pack voltage? The circuit is still live. Do not unplug: it arcs. Call a high-voltage specialist.
• Meter test fails? Change the meter. Start again.
• Battery pack hit, flooded, smoking, smelling or hot? No checks. Move the truck outside. Keep away. Watch the temperature. Stop charging.
• Damaged high-voltage cable? Wrap it with insulating tape. Then measure.
• Insulation fault: see module 3.

1. Plug in every high-voltage connector until it clicks.
2. Tug each connector once.
3. Clear debris around the high-voltage parts.
4. Send other people away.
5. Refit the MSD.
6. Reconnect the 24 volt battery −.
7. Call out loudly: “Switching on!”
8. Switch on (module 4).
9. Read the fault codes. No insulation or interlock (safety loop) fault? Done.

Cut-off from outside

1. Park. Apply the EPB.
2. Pull the hood release twice.
3. Pull the MSD in the engine compartment.

Cut-off from inside

1. Park. Apply the EPB.
2. Open the cover at the lower left of the dash.
3. Pull the MSD.

• High voltage then switches off by itself.
• Emergency: you may cut the orange wire on the MSD. Then it cannot switch back on.

Rescuers

• Wear impact-rated goggles, Class 0 gloves (1,000 volts) and insulated tools.
• Have insulated rescue hooks and a lithium battery extinguisher ready.
• One works, one watches, no touching, no metal jewellery: see module 1.

Fire

• Everyone out. Call 112.
• Tell them: battery electric truck with a high-voltage battery. Risk of shock, chemicals and thermal runaway.
• Small fire: dry powder, CO₂ or dry sand.
• High-voltage parts burning: a lithium battery extinguisher.
• Big fire, or a crushed or bent battery: lots of water, non-stop.
• Move burnable things away from the truck.
• Trapped people and doors will not open: rescuers may break a window at its edge.
• Battery fire after a crash: pull over. Everyone out, away from traffic.
• Battery fire: below 20 km/h the sliding door unlocks. Below 6 km/h it opens.
• Battery fire and no braking within 4 minutes? The truck slows and stops itself.
• Smoke, fire or explosion from the EIC system: leave the truck and call the police.

Water

• A truck from floodwater can look fine and still leak current.
• Wear protective gear before you touch high-voltage parts in water.
• Let the truck dry completely before any work.

Windrose does not yet publish a step-by-step procedure for fault finding with high voltage on. Live work only by people with the national live-work qualification. Follow your employer's procedure.

What switch-off does

• Power domain controller (VDC): switches high voltage on and off.
• Normal switch-off: the VDC stops the motors. It opens the main positive contactor.
• Each pack has a main negative contactor. It stays closed for 10 minutes after a normal switch-off.
• Severe (level 3) fault: the VDC switches off without the 10-minute delay.
• Charging gun plugged in: the main negative contactors stay closed.

Insulation monitor

• The PDU has a built-in insulation monitor. It reports to the VDC.
• Released service manual values:

Fault codes and first checks

• Always first: read the code. Clear it. Restart. Read again. Code gone? Look for an intermittent fault.
• Insulation fault (VDC: P109E30, P109D30, P109C30): check the insulation resistance of the high-voltage parts.
• Interlock fault (VDC: P10A930): check the high-voltage harness and the interlock harness of each part. Interlock (HVIL) = a safety loop through the high-voltage plugs.
• Pack interlock fault (battery controller CMU, for example P163700): check the same two harnesses.
• Contactor or precharge fault (PDU, codes P26…): confirm the code. Inspect. Reload the software. Still there? Replace the PDU.
• 24 volt charging fault (DCDC1): check the 24 volt batteries. Then check the PDU charging circuit.

Measuring

• Before high-voltage work, the released manual asks for a 10-minute wait for the capacitors.
• The released manual gives no probe points for measuring with high voltage on.