Fundamentals of High Voltage xEV, Safety, and PPE

Do you know what personal protective equipment (PPE), tools, and instruments are needed to keep you safe around high voltage (HV) vehicles? Are you aware of how to protect yourself or your employees when working around high voltage systems and platforms?

Safety is paramount when working around any type of high voltage. As electric vehicles (EV) and EV fleets become more prevalent, the critical need for OEMs, suppliers, companies, and organizations to provide comprehensive safety training for teams working with or around xEV systems and platforms increases. Engineers, technologists, and technicians involved in the design, development, testing, and/or servicing of high voltage EV systems must learn to protect themselves using safe procedures and practices.

This one-day course explains EV safety fundamentals, including personal protective equipment (PPE) and how to develop and establish common safety procedures for working around high voltage vehicles. You’ll learn how to safely connect and disable a high voltage system for testing and diagnostic purposes - and during disaster and crash events. You’ll be introduced to various types of EV, their characteristics, architecture, and components, including how to determine critical connection and disconnection procedures. The course explains the tools, PPE, safety procedures, and practices that should be in place, as well as methods to establish new procedures and test PPE. It also discusses how to develop and comply with FMVSS 305 requirements and OSHA PPE guidelines.

What Will You Learn

By participating in this course, you'll be able to:
  • Describe the various xEV’s subsystems and components
  • Identify, select, test, care for high voltage (HV) electrical gloves per ASTM requirements
  • Recite the steps to disable a HV EV
  • Utilize appropriate processes and PPE tools when disabling/connecting EV
  • Safely measure HV vehicle platforms
  • Explain the EV grounding mechanism
  • Explain OSHA PPE & FMVSS 305 requirements
  • Describe interlock system types, operational mechanism, strategic location, testing, schematic circuits, failure modes, diagnostics, and standardization
  • Determine how to deal with HV vehicle subsystems during vehicle crash
  • Examine the EV HV system for faults, failures, and discharge circuits

Is This Course For You

This course would benefit OEM, Tier I, II and III suppliers, and aftermarket companies’ vehicle electrification engineers, engineering technologists, and related professionals involved in the design, development, testing, support, and service of high voltage EV components and systems. Technicians involved in testing, diagnosing, disabling, and servicing high voltage EV may also benefit from this course.

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time


Module 1: What & Why Electrification?
  • xEV categories and architectures
  • Series, parallel, and combined market
Module 2: The Effects of Electricity on the Body
  • Effects of electricity - current & voltage levels
  • Electrical shock
  • Ground circuit
Module 3: Grounding Mechanisms for Internal Combustion Engines and EV
  • Distinguish grounding mechanisms
  • High voltage isolation fault system
  • Isolation fault detection
Module 4: High Voltage xEV PPE, Tools, and Equipment
  • Required PPE equipment – selection, use and care
  • Measurement categories - Category I, II, III & IV
  • Multimeters and their capabilities
  • Most common electrical safety mistakes
Module 5: High Voltage EV Labeling

Module 6: BEV High Voltage Connection and Disconnection
  • High voltage cable and electrical symbol identification
  • Existing service disconnect types, corresponding locations, and methods of removing and installing them
  • High voltage fuses and their uses
Module 7: EV Motor and Power Electronics High Voltage Connection and Disconnection
  • Interlock systems and their control strategies
  • Interlock system types, operational mechanism, strategic location, testing, schematic circuits, and failure modes
  • Diagnostics and standardization
  • Active and passive bus discharge systems, location, circuits, and operation
Module 8: High Voltage Vehicles and Subsystems During Disaster and Crash Events

Module 9: High Voltage Vehicle Subsystem Tear Down and Assembly Process

Module 10: Factors That Can Affect xEV High Voltage Performance
  • Clearance and creepage distances between conductive parts
  • Pollution degree and altitude
  • Corona discharge, arcing, and dielectric breakdown
  • Oxidation and galvanic corrosion
Module 11: Summary - Safety Procedures with High Voltage xEV