High Voltage Work on Electric and Hybrid Vehicles

Servicing, repair, maintenance and recovery of Electric & Hybrid Vehicles will put unprepared and untrained technicians at risk of electric shock resulting in serious injury or death.

Background

Voltages present in electric and hybrid vehicles (EHVs) are significantly higher (currently up to 800 Volts DC) than those present in ICE vehicles (12/24 Volts DC). Contact with parts that are live at voltages above 60 volts DC has the potential to stop a human heart. For EHVs, DC voltages between 60 and 1500 Volts are referred to as ‘high voltage’ with all EHVs running in excess of 250VDC. These numbers will only grow in the future as advances in battery technology and strive towards greater performance and range increases the voltage demands.

Our Expertise

Electric and Hybrid Vehicle safety was the primary reason EINTAC was founded. Since 2016 EINTAC have been serving and supporting this market. In that time, we have dealt with a wide range of businesses and ensured that they can operate on and around EHVs safely. This has included everything from OEMs such as Mazda UK and Subaru Europe to race teams like Wayne Taylor Racing and colleges and universities including Oxford Brookes and University of Warwick.

Our knowledge of EHV safety is unrivalled in the industry and as one of the first companies to push for increased safety, we have amassed a great deal of experience and expertise over the years. Our team is happy to provide you with detailed and in-depth information to ensure you can work safely on EHVs. This includes not only the supply of tools and safety equipment but also training courses certified by the IMI and TÜV Rheinland as well as Health and Safety documentation and policies. We are happy to offer no obligation, impartial advice on any subject related to safety working on EHVs and if we can’t answer your question immediately, we will consult with our partner network to get your answers quickly.

EHV Risks

EHVs introduce hazards into the workplace in addition to those normally associated with the repair and maintenance of ICE vehicles. For example, roadside recovery, first responders and other vehicle related activities including seemingly non-hazardous activities, such as valeting. These risks include:

• The presence of high voltage components and cabling capable of delivering a fatal electric shock.
• The storage of electrical energy with the potential to cause explosion or fire.
• Components that may retain a dangerous voltage even when a vehicle is switched off and/or ‘discharged.’
• Manual handling risks associated with heavy battery pack removal, replacement or disposal.
• The potential for the release of explosive gases and harmful liquids if batteries are damaged or incorrectly handled.
• The possibility of people being unaware of vehicle movements as EHVs are far quieter in operation.
• The potential for the electrical systems on the vehicle to affect medical devices such as pacemakers.
• The increased risk of fire present when a battery pack is being worked on or removed.

How To Reduce Risks

EINTAC offer a wide range of products to help mitigate these risks. Our range includes insulated tools and PPE required to ensure workers are safe to engage with Electric and Hybrid Vehicles. It is vital that the correct equipment is used and that EHVs are never worked on using modified or improvised equipment.

To reduce risks, we recommend the following:

• Attend one of our safety training courses to develop skills and knowledge.
• Warn others about the current state of the vehicle being worked on, using barriers, appropriate signage and lockout devices.
• Only use insulated tools when carrying out repair or maintenance work on the vehicles.
• Be overprotective when it comes to safety clothing.
• Use safety signs to assist in ensuring that correct procedures are being adhered to.
• Ensure items such as safety rescue hooks and first aid posters are located in prominent positions and that staff are aware of the safety procedures.
• Isolate and lock off before working on electric and hybrid vehicles.

Additional skills and training will be necessary for anyone who will work with EHVs. The levels of competency required will vary greatly and are dependent on the type of work that people are expected to do. EINTAC offer a wide range of Training Courses from Basic Awareness courses all the way to IMI and TÜV Rheinland Level 4.

For more information on safe working on Electric and Hybrid Vehicles, please contact or to benefit from our assistance and expertise please contact us on +44 (0)1376 525606 or sales@eintac.com.