Safe Handling of High Voltage Battery Systems
Build the Knowledge to Safely Recognize, Assess, and Manage High-Voltage Battery Risks Throughout the EV Battery Lifecycle.
This updated and enhanced training course delivers a comprehensive and technically robust overview of high-voltage (HV) battery systems used in electric and hybrid vehicles. Participants will explore the latest developments in lithium-ion battery technologies, safety procedures, international standards, and lifecycle handling practices. The course emphasizes hazard identification, risk mitigation, emergency response, and regulatory compliance through interactive exercises and real-world case studies.
By the end of this course, participants will be able to:
- Describe the basic operation and construction of lithium-ion battery systems.
- Differentiate between common battery chemistries and cell formats used in EV applications.
- Explain battery pack architecture, energy calculations, and key battery management functions.
- Identify electrical, thermal, chemical, mechanical, and human-factor-related hazards associated with HV battery systems.
- Apply awareness-level safe handling practices across service, storage, transport, and emergency scenarios.
- Understand major international regulations, standards, and compliance requirements governing HV battery systems.
- Recognize thermal runaway indicators, toxic off-gassing risks, and delayed ignition hazards.
- Understand OEM battery safety features such as BMS functions, HVIL systems, thermal management, and pyrotechnic disconnect devices.
- Conduct basic hazard identification and risk assessment activities using established risk management principles.
- Support incident response planning and decision-making during HV battery emergencies.
Disclaimer: This training is designed to build foundational knowledge and awareness of HV battery systems. It does not qualify participants to perform live work on HV systems. For certification to work directly on energized HV components, please refer to our Live Working EV Training: High-Voltage Vehicle Systems and Battery Safety – Level 3 course.
This course is ideal for:
- Vehicle and battery engineers
- System integration engineers
- Safety and electrical engineers
- Prototype shop staff
- Professionals involved in EV and hybrid vehicle design, testing, and planning
- Automotive technicians, workshop foremen, and car workshop owners seeking foundational training in HV battery systems
This training is especially valuable for professionals in the aftersales and service sector, where demand for high-voltage battery knowledge is rapidly growing. It provides essential understanding of HV battery features, risks, and safe handling practices—making it an excellent entry point for those servicing electric and hybrid vehicles.
- Introduction to HV Battery Systems
- Lithium-Ion Technologies and Chemistries
- Pack Architecture and Energy Calculations
- Hazard Identification and Risk Awareness
- International Standards and Regional Regulations
- Safe Handling Procedures Across the Lifecycle
- Emergency Response and Incident Management
- Risk Assessment and Mitigation Planning
- Case Study: Damaged EV Scenario
- Summary, Q&A, and Final Exam
The Safe Handling of High Voltage Battery Systems training course provides a comprehensive introduction to the technologies, hazards, safety practices, and regulatory requirements associated with high-voltage (HV) battery systems used in electric and hybrid vehicles.
As the automotive industry continues its transition toward electrification, understanding the operation, risks, and safe handling of lithium-ion battery systems has become essential for personnel involved in vehicle engineering, testing, manufacturing, service, transportation, and emergency response activities.
Participants will develop foundational knowledge of lithium-ion battery technologies, battery chemistries, cell formats, charging principles, battery pack architecture, and battery management systems (BMS). The course explores the primary hazards associated with HV battery systems—including electrical, thermal, chemical, mechanical, and human-factor-related risks—and introduces strategies for identifying, assessing, and mitigating these risks throughout the battery lifecycle.
The training also provides an overview of key international regulations and industry standards governing battery design, handling, storage, transport, emergency response, and end-of-life management. Through instructor-led discussions, knowledge checks, practical exercises, and a real-world damaged EV battery case study, participants will gain the awareness needed to support safe decision-making when working around high-voltage battery systems.
This course is designed for awareness and knowledge development only and does not qualify participants to perform live work on energized HV systems.
Participants will gain:
- Increased awareness of high-voltage battery hazards and associated safety controls.
- Understanding of lithium-ion battery technologies, architectures, and charging principles.
- Knowledge of safe handling practices throughout the battery lifecycle, including storage, transport, service, and incident response.
- Familiarity with major international standards and regulatory requirements impacting HV battery systems.
- Practical experience through exercises involving energy calculations, hazard identification, risk assessment, and emergency response scenarios.
- Enhanced understanding of human factors, communication, and behavioral safety practices that contribute to safe HV battery operations.
- Confidence in recognizing potential battery safety risks and implementing appropriate mitigation measures.
The outcome from this course should help minimize:
- Personal injury
- Equipment damage
- Operational disruptions
- Environmental incidents
- Costly mistakes involving prototype and production battery systems
- Reputational risk for organizations and customers
Students can participate in a real-world battery-handling case study scenario to identify solutions for potential risk situations.
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The course content and structure are designed by the domain experts from TÜV SÜD. With immense experience and knowledge in the relevant standards, our team of product specialists and technical experts at TÜV SÜD, developed the course content based on current business landscape and market requirements.
By performing exercises and group discussions, attendees will develop a hands-on understanding that will facilitate the uncovering of true root causes of problems and the implementation of meaningful corrective actions to help the organization improve the procedure of examining and resolving nonconformities discovered during audits.
At the end of the training, participants will complete a multiple-choice exam designed to reinforce key concepts and ensure understanding.
Assessment Details:
- Format: 15 multiple-choice questions
- Type: Open book (This is not a certified training, so participants may refer to course materials during the exam)
- Passing Criteria: A minimum score of 70% is required to meet the learning objectives
- Retakes: Participants who do not achieve a passing score may retake the exam up to 3 times
- Certification: Regardless of exam outcome, participants will receive a Certificate of Attendance by TÜV SÜD Academy.
Important Note: Completion of this course does not authorize participants to perform direct work on high-voltage battery systems. Hands-on work with live HV systems requires certification through our Live Working EV Training: High-Voltage Vehicle Systems and Battery Safety – Level 3 course.
No prior high-voltage certification is required.
Participants should:
- Have a basic understanding of automotive systems or electrical fundamentals.
- Be familiar with general workplace safety concepts.
- Possess an interest in electric vehicles, hybrid vehicles, battery systems, or vehicle safety.
Recommended but not mandatory:
- Experience in automotive engineering, testing, manufacturing, maintenance, service, logistics, safety, emergency response, or workshop operations.
Is this course suitable for beginners?
Yes. The training is designed as an awareness-level course and assumes little or no prior experience with high-voltage battery systems.
Does this course certify me to work on live high-voltage systems?
No. This course provides awareness and foundational knowledge only. It does not authorize participants to perform work on energized high-voltage systems.
What battery technologies are covered?
The course covers lithium-ion battery technologies commonly used in electric and hybrid vehicles, including:
- LFP
- NMC
- NCA
- LMO
Are EV battery safety hazards covered?
Yes. Participants learn about:
- Electrical shock hazards
- Arc flash risks
- Thermal runaway
- Fires
- Toxic gas release
- Electrolyte exposure
- Mechanical damage risks
Will battery regulations and standards be discussed?
Yes. The course reviews major international standards and regulations affecting EV battery safety, transportation, storage, maintenance, and emergency response.
Does the course include practical exercises?
Yes. Participants complete interactive exercises, knowledge checks, calculation activities, risk assessment discussions, and a real-world case study.
Are emergency response procedures included?
Yes. The course discusses thermal events, battery fires, incident response procedures, quarantine practices, monitoring requirements, and coordination with emergency services.
Does the course cover transportation and storage requirements?
Yes. The course introduces transportation and storage requirements, including UN 38.3, dangerous goods considerations, damaged battery handling, and storage best practices.
Will OEM differences be discussed?
Yes. Participants are introduced to examples of OEM differences in battery architecture, thermal management systems, and high-voltage disablement procedures.
What is the course format?
This is a live instructor-led virtual classroom course that includes presentations, discussions, exercises, knowledge checks, case studies, and a final assessment.
Is there an exam?
Yes. Participants complete a 15-question multiple-choice assessment at the end of the course.
What certificate will I receive?
Participants receive a TÜV SÜD Academy Certificate of Attendance upon completion of the training.
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