Safe Handling of High Voltage Battery Systems
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:
- Identify and classify HV battery hazards (electrical, thermal, chemical, mechanical, human factors)
- Apply OEM-specific disablement and emergency procedures
- Conduct risk assessments and implement mitigation strategies
- Navigate regional regulatory differences and compliance requirements
- Engage in interactive exercises including calculations, hazard mapping, and case study analysis
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, risks, and safety procedures associated with high-voltage (HV) battery systems used in electric and hybrid vehicles. As the automotive industry rapidly transitions toward electrification, understanding the behavior and handling of lithium-ion batteries has become essential for professionals across engineering, service, and workshop environments. This course is designed to build foundational knowledge and awareness, enabling participants to recognize hazards, apply safe work practices, and understand the regulatory landscape surrounding HV battery systems.
Participants will explore the latest developments in battery chemistries, cell formats, pack architecture, and thermal management systems. The course covers key safety concepts including hazard identification, risk mitigation, emergency response, and lifecycle handling procedures—from workshop service and pack removal to transport and storage. Real-world case studies and interactive exercises are integrated throughout the training to reinforce learning and simulate practical scenarios.
Participants will be equipped to:
- Safely handle HV battery systems across service, transport, and emergency scenarios.
- Apply international standards including ISO 6469-3, UNECE R100, NFPA 70E, OSHA 1910.333, DGUV 209-093, UN 38.3, and IATA DGR.
- Recognize and respond to hazards such as thermal runaway, toxic off-gassing, electrical shock, and delayed ignition.
- Implement manufacturer best practices and safety technologies such as BMS, HVIL, and pyrotechnic disconnects.
The outcome from this course should be to minimize:
- Personal injury
- Embarrassment to the company and customers
- Waste of time and expensive prototypes
Students can participate in a real-world battery-handling case study scenario to identify solutions for potential risk situations.
Read how our courses supported Robert Bosch train their employees worldwide. [PDF file size: 1 Mb]
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.