Training to be an EV service technician is complex and different from the training received by traditional auto mechanics. For example, most of the training for conventional auto mechanics focuses on the drive train, which typically includes over 1,000 moving parts. The drive train in an average EV has fewer than 100 moving parts. EV technician training strongly focuses on the battery pack and safety when working on HV systems. But it’s not a ‘one-size-fits-all’ situation.
This FAQ looks at the various levels of training for technicians working with EVs, reviews the need for special personal protective equipment (PPE) to protect technicians from HV hazards, and closes with a review of performance standards and recertification requirements for insulating gloves that serve as the front-line protection from shock hazards.
There are three general levels of technician involvement and training for EV repair and service establishments (Figure 1):
- Upon arrival in the shop, EVs must be identified and segregated into special service bays set up to work on high-voltage systems. This requires minimal special training.
- Next, the EV systems, especially the battery, must be safely shut down in preparation for servicing. This requires a higher level of training. In addition, these technicians need to use PPE to work on EVs.
- The third level requires the most advanced training. These technicians are qualified to perform battery classification, repair, and recycling. They require the most complete understanding and use of PPE.
Figure 1. There are three levels of training for EV service technicians. (Image: Tech Design Forum)
What is PPE?
PPE includes a range of garments:
- Gloves
- Insulated rubber gloves must be worn near all high-voltage components — not just the battery pack.
- Cotton under gloves are worn when working in hot or humid conditions. They facilitate the activities and enhance the comfort of technicians.
- Leather-over gloves can also be worn on top of the insulating gloves when the technician may be exposed to additional mechanical hazards.
- Face shield protects the eyes, covers the forehead, and provides a 180° field of view.
- Dielectric over boots are worn over standard shoes used in the shop to provide an additional layer of insulation and protection from high voltage shocks.
- Insulating rubber aprons are made using 1 mm thick neoprene with nylon mesh reinforcement and rated for up to 1 kV to protect any cables or other HV components the technician may inadvertently contact. In some cases, technicians wear coveralls instead of using an insulating rubber apron.
Changing needs for gloves
Insulating gloves are a key part of PPE since hands are often in contact with potentially high voltages. ASTM International, formerly known as the American Society for Testing and Materials, has developed the D120 specification that covers the manufacturing and testing of rubber-insulating gloves to protect workers from electrical shock. In Europe, the corresponding standard is EN 60903. The standards include AC and DC insulation requirements and require that protective (leather) gloves be worn over the insulating gloves.
For EVs, the correct gloves have traditionally been class 00, tested at 10 kVdc and have a maximum working voltage of 750 Vdc. However, this is changing as EV battery pack voltages move up to 800 Vdc and higher. For higher voltage EVs, the correct gloves for technicians are class 0, with a maximum working voltage of 1.5 kVdc.
Recertification of gloves
In the Unites States, the Occupational Safety and Health Administration (OSHA) requires that technicians use gloves retested to the ASTM F496 specification for recertification every six months. Historically, the testing and recertification have been done using AC voltages since the most common HV hazards are in the electric utility distribution system. However, for EV technicians, the retesting should be implemented using DC voltages (Figure 2).
Figure 2. Insulating gloves are required to meet the ASTM D120 specification and be recertified every six months. (Image: Automotive Training Center)
Summary
Training for EV service technicians is strongly focused on the battery pack and other HV system components. Compared with the training received by traditional auto mechanics, EV service technician training emphasizes safety and the proper use of PPE.
References
- Does Your Automotive Program Include EV Training? If Not, You’re Falling Behind, Toolkit Technologies
- PPE for Servicing Electric Vehicles, Saf-T-Gard International
- Safety Clothing For Working On EHVs, Enitac
- Safety Equipment to Use After Hybrid and Electrical Mechanic Training, Automotive Training Center
- Servicing and repairing electric cars requires new skills, The Economist
- The challenge of electric and autonomous vehicle service and maintenance, Tech Design Forum
- Types of Training and Certification Required For Servicing EV Batteries, Midtronics
- Why Technician Training for Electric Cars is Different, Project Shift
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