Legacy EV Level 2 High Voltage Safety Certification Training 

This first module establishes the core principles every technician needs before approaching high voltage systems. You’ll learn how to identify risks prior to beginning work, recognize common hazards in EV repair, and locate high voltage “hot spots.” The module covers bus discharge systems, isolation monitoring, and service disconnects, with a detailed look at Tesla’s Model Y Emergency Response Guide as a real-world case study. It concludes with a video introduction to EV safety systems, reviewing HV components, BMS wiring, precharge and discharge circuits, interlocks, and grounding methods to build a strong foundation for safe EV service.

This module introduces the process of establishing an Electrically Safe Work Condition to prevent electrical injuries in high voltage environments. It covers the procedures for shutting down HV systems, disconnecting low- and high-voltage circuits, performing Zero Voltage Verification (ZVV), and applying OSHA-compliant safe work practices. Learners will also explore proper use of PPE, EV-specific maintenance tools, and lockout/tagout (LOTO) protocols, as well as methods for confirming the absence of voltage. The module concludes with guidance on auditing your own workplace to ensure the right safety protocols, equipment, and practices are in place.

This module guides learners through the essential safety and diagnostic procedures required to return an electric vehicle to service after high voltage repairs. It introduces the EV Initialization Maintenance Flow with demonstrations using a milliohm meter and a megohmmeter to perform key safety checks, including bonding tests, Hioki measurements, and insulation resistance tests. Learners will compare multimeters and milliohm meters to evaluate conductor resistance and its impact on heat generation, diagnose joint integrity in high voltage contactor boxes, and interpret stator winding resistance data to assess motor health. The module also covers grounding and electrical isolation checks aligned with FMVSS 305 and ECE-R-100 standards, ensuring vehicles are safely initialized and ready for operation.

This culminating assessment provides an opportunity for participants to demonstrate their proficiency in creating an electrically safe work condition when shutting down a high voltage system. Attendees will demonstrate their ability to disconnect low and high voltage circuits, perform zero voltage verification (ZVV), and apply safe work practices in compliance with OSHA regulations. Key skills to be demonstrated include appropriate PPE and tool selection, proper disconnection of high voltage battery systems, and methods for verifying the absence of voltage. Proficiency in these skills is required to earn certification.