Fault Diagnosis and Testing in High Voltage Vehicle Systems

Understand the structure, component layout and functions of electrical and electro-mechanical systems

Layout of electric motors (single, twin, series hybrid, parallel hybrid, dual hybrid). Technical specifications and OEMs instructions (high and low voltage systems, fluid systems, operational voltage, electrical and wiring diagrams). Charge cables, plugs and charging modes. Safe operation and charging procedures.

Recognise faults and types of damage in electrical systems

In high voltage electrical and mechanical components and in high voltage battery packs (thermal runaway, overheating, damage and accidents, water damage, chemical leaks). In low voltage systems and network systems. Fluid and cooling systems. Faults in sensors and measurement units.

Understand how to diagnose and rectify faults within high and low voltage systems

Knowledge and practical utilisation of diagnostic testing methods (multimeter, oscilloscope, insulation tester). Performing appropriate set of diagnostics and correct use of the equipment. Data analysis and their uncertainty. State of health and state of charge of batteries, loading tests, insulations tests. Battery cell balancing procedures.

Knowledge and practical skills of installation and replacement of components and sub-components,

Typical battery chemistries, components (transistors, diodes, capacitors, fuses, relays), control units, isolators, convertors, BMS, drive trains and ancillary components.

This qualification has been developed in close liaison with industry specialists, electric vehicle manufacturers, training providers, the health and safety executive and the IMI Sector Skills Council. This is the first qualification of its kind to address working on live electric/hybrid vehicle high voltage vehicle systems and components. The qualification is essential to ensure the health and safety of individuals working on electric/hybrid vehicles. On completion of this qualification technicians will be able to practically demonstrate that they have the skills required for repairing high voltage vehicle systems and components.

This qualification is designed for technicians who maintain and repair electric/hybrid high voltage vehicle systems and components. It contains the knowledge and skills required to work on live high voltage vehicle electrical components and associated systems.

On completion, technicians will be able to practically demonstrate that they have the skills required to repair high voltage vehicle electrical components and systems.

610/0975/1

This qualification is designed for people looking to develop their knowledge and skills to allow them to safely diagnose and rectify high voltage system faults, test, remove and replace high voltage battery packs and battery modules and to safely store high voltage battery packs.

This qualification covers the competence and knowledge needed to safely diagnose and rectify high voltage system faults in an electric vehicle. The qualification also covers competence and knowledge on testing and storing high voltage batteries, as well as removing and replacing high voltage battery modules/packs and re-fitting high voltage battery packs in electric vehicles.

610/0082/1

Discover the advanced principles of hybrid & EV technology: battery design, chemistry and thermal management, regenerative braking systems, and Live high-voltage component repair/replacement

Safely remove a battery from an Electric Vehicle using correct lifting equipment and tooling

Remove, test and replace a battery cell • Understand the safety implications of live working with high-voltage electric and hybrid vehicle systems and perform safe working practices

Understand the battery cell balancing process in detail

Understand the legal and regulatory requirements for working on hybrid and electric vehicles

Be able to carry out advanced maintenance procedures on hybrid and electric vehicles, including servicing, lubrication, and fluid changes