DGUV Information 200-006 - Training for work on vehicles with high voltage systems

1.1 General

Training (topics and duration) is classified in three stages in consideration of the hazard and the work to be performed. The topics of training listed serve only as an example and must be adapted to the specific requirements of the tasks. Training must be concluded by theoretical and practical examination demonstrating the skills and knowledge acquired. The demonstration of this acquisition must be documented.

The following staged model shows the required qualification as a function of the work to be performed:

Stage 1 describes all non-electrical work which is required on a vehicle or installations containing HV systems. The employees must be informed of the possible electrical hazards presented by the HV system and of the intended use of the vehicle.

Stage 2 requires expertise in work on HV systems which are not intrinsically safe. This includes all electrical work performed in the non-live state. This requires decommissioning and recommissioning of the HV system in accordance with application and performance of the first three of the "five safety rules".

A precondition for training to Stage 3 is successful completion of training to Stage 2 and safe performance of the associated practical tasks. Training for live work on the HV system qualifies the employee for all electrical work on the vehicle.

If it is found during the production development process that components are fitted which satisfy the safety standards of series production, they can be assigned to a post-SoP training stage. The corresponding decision must be taken by the responsible skilled electrical person.

The flow charts in Annex 2 and Annex 3 provide support in determining the requisite scope of training.

The scope of training stated includes the teaching of theoretical knowledge and practical skills.

1.2 Qualification for Stage 1: non-electrical work

Instruction is required for all non-electrical work to be performed on the HV vehicle.

This instruction is intended to raise the employees' awareness of the HV systems in order to enable them to work safely on the vehicle. The objective is for employees to be able to operate the HV components safely, to understand their structure and principles of operation, and to be familiar with the markings of the components. The topics covered by instruction must also cover the fact that electrical work on HV components is not permissible. Failure to observe these requirements may lead to dangerous electric shock or arcing.

The topics of this instruction must include:

• Operation of vehicles and the associated equipment (e. g. test rigs),

• Performance of general tasks which do not require isolation of the HV system,

• Performance of all mechanical tasks on the vehicle (but: don't touch orange!),

• Isolation of the HV system, additional safety measure in the form of withdrawal and plugging in of the service disconnect/maintenance plug,

• Appointment of the individual to be consulted in the event of uncertainty,

• Impermissible work on the vehicle,

• Organizational procedure for electrical work that is performed under the control and supervision of a skilled electrical person for HV systems.

Instruction in Stage 1 must last between 2 and 4 teaching periods.

1.3 Qualification for Stage 2: electrical work

Employees must have an electrical qualification for any Stage 2 electrical work to be performed on the HV vehicle.

Training for Stage 2 must take account of the particular electrical knowledge already acquired by the employee.

Stage 2a: persons without prior electrical knowledge but with technical training

Topics covered by training:

• Basic electrical knowledge,

• Electrical hazards and first aid,

• Measures for protection against electric shock and against fault arcs,

• Organization of safety and health for electrical work,

• Specialist and man-management responsibility,

• Employee qualifications in the area of electrical engineering,

• Use of HV systems in the vehicle.

A specification of the topics covered by training can be found in Annex 4.

The training must encompass at least 100 teaching periods.

Stage 2b: persons with prior electrical knowledge in the automotive sector, e. g. auto-electricians, automotive mechatronics technicians, car mechanics

Topics covered by training:

• Electrical hazards and first aid,

• Measures for protection against electric shock and against fault arcs,

• Organization of safety and health for electrical work,

• Specialist and man-management responsibility,

• Employee qualifications in the area of electrical engineering,

• Use of HV systems in the vehicle.

A specification of the topics covered by training can be found in Annex 5.

The training must encompass at least 48 teaching periods.

Stage 2c: skilled electrical persons, e. g. industrial electronics specialists, electrical fitters, electrical engineers

Topics covered by training:

• Specialist and man-management responsibility,

• Employee qualifications in the area of electrical engineering,

• Use of HV systems in the vehicle,

• Design and function of vehicle electrical systems.

A specification of the topics covered by training can be found in Annex 6. The topics must be adapted to the participants' current level of knowledge.

The training must encompass at least 20 teaching periods.

1.4 Qualification for Stage 3: live electrical work

Successful completion of training to Stage 2 is a prerequisite. Training for live working on HV systems requires sound knowledge of electrical theory and usable practical electrical skills; proof of adequate health, particularly in the form of an occupational medical examination in accordance with DGUV Principle G 25 governing driving, control and monitoring tasks; a minimum age of 18 years; and training in first aid (including cardiopulmonary resuscitation).

Stage 3a: employees who are qualified to Stages 2b and Stage 2c

Employees who are qualified to Stages 2b and 2c already satisfy the conditions for training to Stage 3.

These employees require additional training for live work on HV systems.

Topics covered by training:

• Definition of the scope,

• Conditions for live work on HV systems:

  • Competence of the employees,

  • Organization of the work,

  • Protective and other equipment to be used,

• Practical exercises.

The training must encompass at least 8 teaching periods.

Stage 3b: employees who are qualified to Stage 2a

Employees qualified to Stage 2a do not necessarily possess the sound theoretical and practical electrical knowledge and skills required for live work on HV systems. The employees' existing knowledge must therefore be reviewed in order for the additional knowledge and skills required as conditions for training to Stage 3 to be determined.

(1) Prior training: engineering or scientific study

Employees who for example have completed an engineering or scientific degree possess theoretical electrical knowledge by which they can evaluate the work to Stage 3. Such employees must be equipped with practical skills as a condition for live work on HV systems.

Equipping with practical skills may focus upon the following aspects:

• Electrical instrumentation,

• Performance of measurements in accordance with the electrical standards

  (e. g. VDE provisions),

• Circuit engineering,

• Use of tools in electrical fitting work,

• Laying and securing of wiring,

• Creation and wiring of circuits according to circuit documentation (parts list, terminal assignment plan, assembly plan and circuit diagram),

• Sensor technology in control engineering,

• Connection and operation of peripheral equipment,

• Function testing on digital switching devices and circuits,

• Fault analysis, systematic troubleshooting, use of vehicle or system diagnostics equipment,

• Elimination of faults.

These employees also require training in live work on the HV system in accordance with Stage 3a.

Topics covered by training:

• Definition of the scope,

• Conditions for live work on HV systems:

  • Competence of the employees,

  • Organization of the work,

  • Protective and other equipment to be used,

• Practical exercises.

The training must encompass at least 48 teaching periods.

(2) Prior training: non-electrical training or apprenticeship in a skilled trade

Employees who have (only) completed training or an apprenticeship in a non-electrical skilled trade possess neither the necessary basic electrical knowledge nor the practical skills by means of which they can evaluate the work to Stage 3. Such employees require further theoretical and practical training as a condition for the performance of live work on HV systems.

Equipping with theoretical and practical skills may focus upon the following aspects:

• Electrical instrumentation,

• Performance of measurements,

• Circuit engineering,

• Use of tools in electrical fitting work,

• Laying and securing of wiring,

• Creation and wiring of circuits according to circuit documentation (parts list, terminal assignment plan, assembly plan and circuit diagram),

• Sensor technology in control engineering,

• Connection and operation of peripheral equipment,

• Function testing on digital switching devices and circuits,

• Fault analysis, systematic troubleshooting, use of vehicle or system diagnostics equipment,

• Elimination of faults.

These employees also require training in live work on the HV system in accordance with Stage 3a.

Topics covered by training:

• Definition of the scope,

• Conditions for live work on HV systems:

  • Competence of the employees,

  • Organization of the work,

  • Protective and other equipment to be used,

• Practical exercises.

The training must encompass at least 100 teaching periods.