High-voltage? What is that supposed to be?

We admit that we started by looking for puns for the headline. “As VOLTed, but not skillfully” was only discarded after some deliberation, but can still serve as a semi-sensible transition: High-voltage is about ability, but even more about being allowed to (we see ourselves as the “VOLTaires of automotive articles”, so to speak…):

The term “high-voltage” is only used explicitly in vehicle technology and refers to electrical systems that work with voltages above 60 volts for direct current (DC) or 30 volts for alternating current (AC). Now the name of the band “AC/DC” probably makes more sense. It also makes sense that we find such systems primarily in the context of electric and hybrid vehicles. Without these high voltages, the systems in electric vehicles would simply not be able to provide the required power. The pros and cons of electric vehicles are not the subject of this article, but the fact is that the electrification of global vehicle fleets can hardly be stopped as things currently stand. In other words, almost every OEM is relying on electric vehicles with high-voltage systems.

In addition to the familiar road traffic licensing regulations, OEMs must also undergo special approval procedures in order to meet the requirements for the high-voltage system. Be it for the safety of users, service personnel or with regard to fire safety. The fire safety of the battery in particular has often been an unjustified topic in the media. Due to the requirements of the following European regulations, fully electric and hybrid vehicles are at least as safe as a conventional vehicle with a purely combustion engine.

• Regulation (EU) 2018/858:
  This regulation governs the type approval of motor vehicles in the EU and also includes requirements for the safety of high-voltage systems. These include regulations on electrical safety and minimizing the risk of electric shock for vehicle occupants and maintenance personnel.
• UN ECE R100 (Regulation No. 100 of the United Nations Economic Commission for Europe – ECE):
  This regulation specifies the safety requirements for electric drive vehicles, including high-voltage safety. It covers aspects such as the insulation of high-voltage components, protective measures against electric shocks and the marking of high-voltage systems.

However, it’s not so easy to just drive to a mechanic when something breaks down, because working with high-voltage systems requires certain prerequisites. Not every mechanic, not even every workshop, is allowed to tinker with electric vehicles “just like that” and certainly not with the battery – even changing the tires is an activity that is only permitted under certain conditions. Europe wouldn’t be Europe if there weren’t regulations on this too:

• DGUV Information 209-093: This specific information of a statutory nature describes the qualification levels required for working on vehicles with high-voltage systems and provides instructions for training.

In order to be able to carry out the relevant work on the vehicle, various high-voltage qualification levels are required depending on the depth of activity, which are essential for car dealers and affiliated workshops in particular. In the next paragraph, we will explain exactly what these training courses involve (and of course we will also give you a good address for high-voltage training courses) before we look at what exactly these networked artifacts of the automotive industry mean for the market launch and sales of international OEMs in the electrified vehicle sector.

Safe handling of high-voltage systems: HV qualification 1S/1E to 3S/3E

At this point, we should open up our focus a little by taking a step back and looking away from individual electric vehicles to workshops and dealers. Towards a network of dealers operating throughout Germany or even Europe who represent, distribute, support, sell, service and repair certain vehicles. There is a whole armada of retailers and wholesalers, a dealer network – to which gaining access is no simple exercise – who are therefore obliged to be certified to handle high-voltage systems in the course of increasing electrification on the roads. Without this, it would simply be impossible to maintain a professional technical approach to electric vehicles at all. This is because only an “expertly instructed person (FuP)”, i.e. a person who has received general instruction in the dangers of high-voltage technology and the safety measures, is allowed to work near high-voltage components on an electric vehicle at all. And even that only under the supervision of an even better qualified person, an FHV, an “expert person for working on high-voltage systems”. This is because there may be an immense danger here: If several faults are present, parts of the high-voltage system may, in the worst case, be live. This makes the specialist knowledge taught in high-voltage training courses all the more important. We spoke to Barbara Huber, head of the training department for high-voltage training at Cognizant Mobility, among others, to find out what is included in such a high-voltage training course (without going into the many different levels of training options). We will go through this using the example of the market entry of an international car manufacturer that is successfully launching electric vehicles on the German market and had to familiarize itself with the European requirements at the beginning. Once a dealer network has been found and established (experts such as Stefan Sauer from Cognizant Mobility can also be helpful here), they need numerous technical training courses to familiarize themselves with the vehicles.

The crux of the matter is that high-voltage training is already required to take part in the technical training courses with practical exercises on hybrid and electric vehicles (e-cars). If the vehicle needs to be certified, the high-voltage 2S training course must already have been completed, as only an FHV is permitted to do this. If training is also carried out on the live battery, the “High-voltage level 3S” training to become a “Qualified person for working on live high-voltage components” must be successfully completed in advance. This training provides comprehensive knowledge about the function and diagnosis of HV vehicles and their components and ensures safe working on HV systems.

This is where the first stumbling blocks in the industry can already be seen: OEMs and dealer networks are aware that training is necessary in order to be able to deal with the quantitative, but also performance-oriented increase in high-voltage systems – the voltage has already risen to 800V in some cases. Nevertheless, the industry sometimes shies away from offering high-voltage training courses with the 3S/3E certification level. This is not least due to a certain scarcity of information and a limited selection of providers for high-voltage courses. The big names such as TÜV and Dekra are usually well known, but the fact that companies such as Cognizant Mobility also offer high-voltage training courses is often unknown. The development background of automotive suppliers offers a considerable advantage in terms of the specialist and technical depth of training courses: Anyone who not only knows what a component is, but also knows how and in what context it was developed and built, can access a higher level of systemic knowledge.

Entering the market can be especially challenging for new automotive manufacturers and distributors if the necessary structures aren’t already in place. Where established German OEMs have access to extensive training landscapes (always with the advantage of comprehensive broad-based knowledge, but also the risk of massive legacy systems becoming obsolete), international manufacturers, especially manufacturers from non-EU countries in the field of electromobility, are often able to start from the much-cited “greenfield”. Finding suitable partners who have access to experience and development expertise, who have the relevant certifications and who also offer brand-specific training is a real challenge.

But let’s take another look at the high-voltage training courses, which also work outside of our example. A distinction is made here between OEM, i.e. marked “1-3E” before the start of series production, and service/workshop personnel, i.e. marked “1-3S” after the start of series production (customer vehicle).

1st HV qualification level 1S/1E: Competently instructed person – FuP

Target group: People who carry out general work on vehicles with high-voltage systems.

Contents:

• Electrical hazards and protective measures
• Operating vehicles and the associated equipment (e.g. test benches)
• Carrying out general activities that do not require the HV system to be disconnected from the power supply
• Position and labeling of HV components and cables in and on the vehicle
• Carrying out all mechanical work on the vehicle (but: “Hands off orange!”)
• Decommissioning the HV system, actuate service disconnect/emergency stop as an additional safety measure
• Unauthorized work on the vehicle
• Stop work in the event of uncertainties and inform the responsible FHV
• Organizational procedure for work on HV components carried out under the direction and supervision of an FHV

Duration: Level 1S/1E: 2-4UE

2nd qualification level 2S/2E: Qualified person for work on high-voltage systems – FHV

Target group: Automotive mechatronics engineers, technicians, engineers, etc. with basic knowledge of electrical engineering who also have to de-energize HV systems.

Contents:

• Electrical hazards and first aid
• Protective measures against electric shock and electric arcs
• Organization of safety and health when working on HV components
• Specialist and management responsibility
• Qualifications of employees in the field of electrical engineering vs. high-voltage technology
• Use of HV systems in the vehicle
• HV concept and vehicle technology
• General practical procedure
• Structure and mode of operation of vehicle electrical systems

Duration: Level 2S 16 units / Level 2E 48 units

3rd qualification level 3S/3E: Qualified person for work on live HV systems / HV components – AuS

Target group: Personnel who have to work under voltage, e.g. on the HV battery, troubleshooting under voltage.

Contents:

• Safe working procedures for working on live HV systems
• Types, structure, specific properties and potential hazards of HV energy storage systems
• Working on live HV components

Duration: Level 3S/3E: 24UE

One provider of high-voltage training and certification is Cognizant Mobility; you can find the entire range on our website under “Academy“. The following points characterize our high-voltage competence team:

• All high-voltage levels available
• Manufacturer-specific high-voltage training
• Market support and introduction for OEMs: training and coaching of dealers, dealer systems (how a vehicle is handed over, what the systems for recording warranty claims look like, through to branding of the location)
• Extremely high level of experience: 15 years of high-voltage training for Stellantis and direct cooperation with many well-known OEMs (e.g. Volkswagen, Audi, Porsche, MG-Motors, BMW)
• Technical background through own development activities
• Own training environment with own certification plus IHK examination
• 80 trainers, 20 of which are specifically for high voltage
• Onboarding, dealer training
• 360-degree coaching for market launches

From the green high-voltage meadow to 360-degree market launch coaching

Yes, we admit it, the title sounds a bit sensational, but it actually shows that electric mobility cannot simply be divided into independent environments. Anyone who wants to sell electric vehicles in Germany, Europe and, in some cases, globally, cannot avoid specialist knowledge and expertise, if only because of the overflowing regulatory landscape. However, since there are few providers who can offer high-voltage training at all, and even fewer who offer a comprehensive concept that can also offer market launches, dealer coaching and their own development experience, Cognizant Mobility is a special case here, which prompted us to write this article.

Developing a dealer network is complex, but implementing a comprehensive training concept is even more challenging —especially for new players in the global electric vehicle market. There is often a lack of intangible soft facts such as experience, contacts in the industry or even time, but even more often a lack of hard facts such as a (too) small staff (if there is one) and the lack of certifications to be able to realize a training landscape at all. There is no way around established training providers. For international OEMs in particular, the lack of opportunities for practical training is a knock-out criterion, whereas Cognizant Mobility, for example, relies on a high proportion of practical, technology-related training as part of its high-voltage training courses. Even before entering the market, OEMs not only receive the necessary technical expertise, but also coaching on setting up and organizing locations, knowledge of system landscapes, the German legal situation and many other aspects.

Considering that, despite all the prophecies of doom, electromobility is experiencing stable growth and working with increasingly complex and powerful high-voltage systems is becoming ubiquitous, ignoring the necessary training requirements would be fatal. Electric vehicles must be safe and efficient to maintain and repair, dealers must act competently and promptly, and an entire industry must undergo further training.

Cognizant Mobility is your trusted partner in obtaining high-voltage qualifications and offers expert coaching to help you navigate the challenges of market launches, dealer networks, and complex training landscapes. Simply contact us via our website, the contact form, our blog or simply by phone – we look forward to hearing from you, because (pun alert): It remains exciting in the high-voltage scene. Or: Avoid the Volt disaster with our training courses.