High Voltage Vehicle Safety Systems and PPE

High voltage vehicle safety is a primary concern for every technician or engineer involved in developing, diagnosing or repairing hybrid or electric vehicles. Engineers/technicians working in this field should complete safety training before they interface with hybrid, plug-in or electric vehicles. This course provides participants with fundamental technical and safety information on high voltage personal protective equipment (PPE) such as how to test high voltage gloves, when and where to send high voltage gloves for periodic testing, and how to safely use test equipment for measuring high voltage components in live and disabled high voltage systems.

Much of the high voltage vehicle safety systems information covered in this course is based on the FMVSS requirements and SAE Recommended Practices. The vehicle safety systems contain interlock circuits, passive and active bus (capacitor) discharge circuits, and DC and AC isolation detection systems that are monitored by high voltage controllers to maintain the required resistance barrier between the vehicle technician/engineer and the vehicle body/chassis to mitigate the possibility of an electrical shock event.

What Will You Learn

At the conclusion of this course, participants will be able to:
  • Properly care for high voltage electrical gloves
  • Field test high voltage electrical gloves
  • Identify providers that test high voltage gloves required by ASTM requirements
  • Disable a vehicle high voltage system
  • Safely acquire measurements on a high voltage system
  • Describe the operation of automotive AC and DC isolation fault detection systems
  • Apply FMVSS 305 requirements and SAE J1766 Recommended Practice to testing high voltage vehicle safety systems
  • Describe the operation of high voltage interlock circuits and passive and active bus discharge circuits
  • Test the high voltage system for isolation faults, interlock circuit failures and passive and/or active discharge circuits
  • Describe how and when to use high voltage gloves, serial data (Scan Tool), insulation meter, and DVOM to test the high voltage system and components

Is This Course For You

This course will benefit vehicle electrification engineers involved in the design or development of high voltage systems as well as lab and vehicle technicians (beginner to intermediate level) who perform systems diagnostics as well as vehicle proto builds. This course will also benefit automotive technicians with an automotive certificate, A.A.S. or B.S. (experienced auto techs but are beginners in vehicle electrification) who service automotive systems. This course would assist all disciplines and personnel working with automotive high voltage systems found in vehicle electrification in understanding how high voltage vehicle safety systems operate, and how to use safe practices and the necessary equipment to analyze, test, and repair them.

This course applies to every OEM or product with high voltage electrification systems. This type of training may be required by OEMs and Tier 1 and 2 suppliers who are interfacing with high voltage systems. Automotive aftermarket service businesses who have employees servicing products with electrification systems would also benefit from attending.

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time

Topics

  • High Voltage Safety & PPE (1.5 hours)
    • Characteristics of AC and DC Electrical Power
    • Ground Circuit Paths
    • Tools & Equipment CAT Ratings
    • Tool & Equipment Usage
    • High Voltage Glove Selection, Field Testing, Testing Requirements, and Storage
    • Insulation Meters and Usage on High Voltage Components
  • High Voltage Vehicle Safety Systems (4.5 hours)
    • High Voltage Cabling
    • High Voltage Cable and Electrical Symbol Identification
    • Service Disconnect Types, Locations, and Removal/Install
    • High Voltage Fuse
    • Interlock Systems and System Types, Location, Circuits, Operation, Failure Modes and Diagnostics
      • Serial Interlock
      • Local (component) Interlock
      • Testing and Diagnosing of Interlock Systems
      • Use of standard and special tools for testing
    • Active and Passive Bus Discharge Systems, Location, Circuits, Operation, Failure Modes and Diagnostics
      • Bus Discharge Active Circuit Operation
      • Bus Discharge Passive Circuit Operation
      • High Voltage Battery Contactor Control with Bus Discharge Systems
      • Testing and Diagnosing Bus Discharge Systems
      • Use of standard and special tools for testing
    • Isolation Fault Detection Systems, Circuits, Operation, and Diagnostics
      • DC Detection System Operation
      • AC Detection System Operation
      • Diagnostics associated with Isolation Fault Systems
      • Use of standard and special tools for testing