E-mobility in everyday workshop activities: new technology, safety requirements and opportunities for specialised companies

Workshop working on an electric vehicle: high-voltage diagnostics, measuring equipment, insulated gloves and PPE for safe de-energising as part of everyday e-mobility workshop activities.

E-mobility is changing everyday workshop activities: new technologies, high-voltage systems and networked components bring new requirements – and simultaneously open up new opportunities for workshops.
Safety is a top priority: clear-cut guidelines, personal protective equipment and structured processes are crucial to safely work on high-voltage systems.
Different vehicle types – from mild hybrids to BEVs (battery electric vehicles) – require different diagnostics strategies, system expertise and procedures.
Qualification levels define responsibilities: they accurately define who is authorised to carry out which high-voltage activities – from simple tasks to working on live components.
Well-prepared workplace: tested tools, suitable PPE and concise manufacturer specifications form the basis for efficient and professional work on electric vehicles.

Why electromobility is now becoming a key competence for modern workshops

E-mobility has long since been a part of everyday workshop activities: an increasing number of hybrid and all-electric vehicles are on the lifting platform. This means new technologies, new safety requirements and new competences, but also new opportunities for companies. High-voltage systems, networked control units and dedicated thermal management require structured diagnostics processes and trained staff. At the same time, a host of familiar components from the low-voltage electrical system remain in use and are integral to electric and hybrid vehicles.

What e-mobility means for contemporary workshops today – new activities, risks and opportunities

By now e-mobility has become more than just a topic for the future and it is increasingly characterising everyday workshop activities. With the growing number of electrified vehicles throughout all segments, from compact cars to commercial vehicles, the need for qualified specialists able to safely and professionally test and repair electrical systems is increasing.

For workshops, this means that troubleshooting and safely handling high-voltage components are new key elements of vehicle diagnostics. At the same time, familiar procedures, tools and test sequences remain relevant. Many familiar systems, such as the low-voltage electrical system, air-conditioning system, lighting and chassis electronics continue to be pivotal. Nevertheless, it is paramount to note that there is a close link between high-voltage and low-voltage systems in electrified vehicles. A basic understanding of the electrical system's architecture is therefore also necessary for routine work to be able to correctly assess safety-relevant contexts. Workshops that adapt to the changes brought about by electromobility at an early stage secure their competitive edge.

Three factors are crucial in this context:

Safety awareness: working on high-voltage systems requires dedicated procedures, personal protective equipment (PPE) and suitable tools as well as workshop equipment.
Diagnostics expertise: Electrical and electronic systems must be comprehensively considered and understood.
Continuous further training: Training and technical information form the basis for safe and efficient repairs.

Why e-mobility is becoming invaluable – technical developments and environmental factors at a glance

E-mobility is a response to the global challenges of climate change and the limited availability of fossil fuels. The aim is to make mobility more sustainable and reduce the reliance on conventional fuels. Electric vehicles do not generate local emissions during operation and therefore make an important contribution to improving the air quality in cities. In addition, electrifying the drivetrain enables more efficient energy utilisation, as electric motors are significantly more efficient than combustion engines.

E-mobility also promotes technological innovation and strengthens new value creation chains. The development of battery technology, software, charging infrastructure and recycling is creating new production and service sectors. E-mobility is therefore making a significant contribution to the transformation within the vehicle industry and is also at the epicentre of sustainable and future-oriented transport development.

Electric vehicle types at a glance – differences, features and system voltages

Within the automotive sector, electromobility encompasses various vehicle concepts that differ in terms of their design and energy supply. The following overview sums up the most important types.

Vehicle type	System voltage	Main features
Mild Hybrid (MHEV)	42V to 150V	Start/stop function, recuperation, electric boost support, no fully electric driving
Hybrid Electric Vehicle (HEV)	> 100 V	Recuperation, boost, limited electric driving, no external charging function
Plug-in Hybrid Electric Vehicle (PHEV)	> 100 V	Combination of combustion engine and electric motor, recuperation, electric driving, external charging option
Battery electric vehicle (BEV)	200V to 1000V	Fully electric vehicle, recuperation, electric driving, charged by external power source

Voltage range illustration: colour gradient from 0 V to over 240 V with marking of the high-voltage limits at 30 V AC and 60 V DC.

When do we start talking about high voltage?

In the automotive sector, the term high voltage (HV) is used when the rated voltage exceeds 60 V DC (direct voltage) or 30 V AC (alternating voltage). Components that operate at this voltage level are part of the high-voltage system.

Central components of an electric vehicle

An electric vehicle features various linked high-voltage and low-voltage components that ensure the electric drive and power supply.

Opened high-voltage battery of an electric vehicle with modules and orange HV cables in aluminium housing. — High-voltage battery

Power electronics of an electric vehicle with orange high-voltage cables and warning labelling in the motor compartment. — Power electronics (inverter, DC/DC converter)

Electric motor of an electric vehicle in the underbody, with housing ribs for cooling and high-voltage warning labelling. — Electric motor

Charging connection of an electric vehicle with connected charging plug and warning lamps, combined with a detailed view of the on-board charger featuring high-voltage connections. — Charging connection and on-board charger

Orange high-voltage cables of an electric vehicle with insulated plug connections for safe energy transfer in the high-voltage system. — High-voltage cables

Thermal management system – protection and efficiency control for high-voltage components. Regulates the operating temperature of a wide range of high-voltage components, ensuring that they always operate within their optimum temperature range. — Thermal management system

Motor compartment of an electric vehicle with visible high-voltage components and highlighted 12 V battery, supplying the low-voltage vehicle electrical system for control units and comfort functions. — Low-voltage electrical system (e.g. 12 V/24 V)

Overview of basic components

High-voltage battery – energy storage and pivotal system component: stores electrical energy and supplies both the drive and auxiliary units.
Power electronics (inverters, DC/DC converters) – control and energy conversion: converts DC to AC voltage, controls the torque and speed of the electric motor as well as energy recovery.
Electric motor – highly efficient drive: converts electrical energy into mechanical motion and operates as a generator for energy recovery in overrun mode.
Charging connection and on-board charger – connection between vehicle and charging infrastructure: enables charging of the high-voltage battery using alternating or direct current.
High-voltage cables – energy transfer and safety: establish the electrical connection within the high-voltage system and enable safe, low-loss power transfer. These cables feature orange insulation as marking.
Thermal management system – protection and efficiency control for high-voltage components: Regulates the operating temperature of a wide range of high-voltage components, ensuring that they always operate within their optimum temperature range.
Low-voltage electrical system (e.g. 12 V/24 V) – energy source for control and comfort systems: Supplies control units, sensors and comfort functions. If the high-voltage battery fails, it ensures that safety-related systems such as lighting, door control and emergency calls are supplied with power.

Working safely on electric vehicles – qualification, responsibility and specifications at a glance

HELLA Academy high-voltage training area with locked electric vehicle, open motor compartment, diagnostic equipment and personal protective equipment to safely work on the high-voltage system. — HELLA Academy supports workshops with practical training in the high-voltage sector and offers qualifications for levels 1S to 3S.

E-mobility entails new safety and organisational requirements for workshops. It requires trained specialists to work on high-voltage systems. In Germany, DGUV Information 209-093 "Qualification for work on vehicles with high-voltage systems", defines the required qualification levels and protective measures.
In other countries, applicable national regulations, training guidelines and safety regulations must be observed. These are fundamentally based on the same basic technological high-voltage safety principles, even if they are regulated on a country-specific basis.

DGUV Information 209-093 was comprehensively revised in 2021 and adapted to current vehicle technologies and new requirements from everyday workshop activities. It replaces the former DGUV Information 200-005. High-voltage training courses that have been already completed in accordance with the older version remain valid. However, we recommended that you regularly check your own skills level and, if necessary, refresh what you have learnt as per the current requirements of DGUV Information 209-093 to remain in-the-know about the latest safety requirements.

DGUV distinguishes between two area:

which will be discussed in more detail below.

The following content is based on applicable safety and qualification guidelines, including DGUV Information 209-093. They serve as a general technical guide and do not replace the full implementation of specifications defined in applicable regulations.

Responsibility at work – what really matters for employers

In addition to staff's professional qualifications, the employer bears the main responsibility for the safe performance of work on high-voltage systems.

Key duties include in particular:

Creating a risk assessment and defining suitable protective measures
Ensuring that only adequately qualified persons work on high-voltage systems
Providing the necessary tools and protective equipment
Providing regular staff instruction and training
Organising clear responsibilities and processes within the company
Making sure that staff are suitable in terms of their health and expertise
Assigning tasks relating to occupational health and safety to reliable and competent persons (FHV) in writing

High-voltage qualification levels overview diagram: Matrix with four qualification levels (S, 1S, 2S, 3S) and their authorisations for working on high-voltage components such as electric motors, air conditioning compressors, batteries, vehicles' high-voltage systems and HV cables. — (1) Level S, (2) Level 1S, (3) Level 2S, (4) Level 3S, (5) High-voltage service connector disconnected

Qualification levels in the high-voltage sector – who is authorised to safely carry out what kind of work?

DGUV has defined several qualification levels for working on high-voltage systems in vehicles. They determine the authorised activities depending on the level of training and qualification.

The table shows which qualification levels are authorised to remove high-voltage components such as electric drive motors, air conditioning compressors, coolant heating elements, traction batteries and high-voltage cables. The activation status of the high-voltage service connector is also taken into account.

HELLA Academy supports workshops with practical training in the high-voltage sector and offers qualifications for levels 1S to 3S. Training content is tailored to the requirements of everyday workshop activities and teaches both theoretical knowledge and practical skills.

Level S – Electric vehicle awareness

Persons trained in electric vehicle awareness may carry out simple activities in the vehicle that do not involve high-voltage components.

This includes:

Operating the vehicle, topping up familiar fluids (e.g. motor oil, coolant or wiper fluid)
Replacing windscreen wipers
Cleaning the interior and exterior as long as all service flaps and hoods remain closed.

These activities are comparable to those of an electric vehicle driver. Before carrying out any activities, persons must be aware of any dangers that may arise from vehicles featuring electric drives. Employers or suitably qualified persons can carry out awareness courses, for example competently instructed persons (FuP).

Level 1S – Competently instructed person (FuP)

High-voltage warning symbols: yellow triangle with lightning bolt, safety instructions with information manual and — Exemplary illustration of high-voltage hazard symbols as they may be attached to high-voltage components.

A competently instructed person (FuP) may carry out general work on the vehicle that does not directly affect the HV system.

This includes:

Replacing oil and changing wheels
Working on the body
Brake system
Steering
Internal combustion engine of hybrid vehicles as well as on axles and chassis components.

Carrying out these kinds of activities, staff may be exposed to an electrical hazard as a result of incorrect handling or in the event of a fault, as they may work around high-voltage components during mechanical activities. They must therefore be instructed regarding electrical hazards, protective measures and rules of conduct by a qualified high-voltage specialist (FHV) before starting work. It is not permitted to change any wheels without this instruction.

The instruction must cover the following contents, among others:

Electrical hazards and protective measures
Safely operating the vehicle and associated equipment
Knowledge of the position and labelling of high-voltage components and cables
Carrying out mechanical work in compliance with the rule stating that high-voltage components, identifiable by orange cables or special warning symbols, such as lightning bolt symbols, must not be touched, opened or manipulated (see image of high-voltage hazard symbols).

Level 2S – Qualified high-voltage specialist (FHV)

After successful qualification, qualified high-voltage specialists (FHV) at level 2S are authorised to work independently and safely on high-voltage systems.

They are authorised to:

De-energise the high-voltage system
Test and put it back into operation after completion of their work
Work on de-energised high-voltage components.

This also includes measuring the insulation and equipotential bonding, provided the high-voltage system is de-energised. In this process, the specifications and safety instructions of the respective vehicle manufacturer must always be complied with.

As a rule, the prerequisite for qualification as a high-voltage specialist (level 2S) is a completed apprenticeship in the automotive sector or a comparable technical field.
The training course comprises theoretical and practical content and concludes with a recognised examination.
Regular training courses safeguard the level of expertise and guarantee the safe handling of high-voltage systems in the long term.

Making sure staff are in good health is recommended for work on high-voltage systems. The suitability test is carried out within the scope of operational responsibilities and is based on the general occupational health and safety regulations.

The prescribed personal protective equipment (PPE) must be used for any work involving the high-voltage system.

A qualified high-voltage specialist (FHV) can also take on management and supervisory tasks. This includes staff instructions, monitoring safety-relevant measures and providing and checking the necessary safety equipment. The employer must assign these tasks in writing.

Level 3S – Competent person for work on live HV components

This level provides authorisation to work on live high-voltage systems.

These include:

Troubleshootingand measuring if the vehicle cannot be de-energised or it is not possible to determine whether components are still live
Working on live high-voltage battery units
High-voltage tests according to manufacturer specifications.

These kinds of activities can exclusively be carried out by specially trained, specialist staff wearing personal protective equipment (PPE) and a second person responsible for safety. In this process, the specifications of vehicle manufacturers must be observed.

Work on live high-voltage systems includes any activities during which persons may come into contact with high-voltage components or parts with any part of their body or objects such as tools, devices or equipment if the de-energised state cannot be guaranteed, for example in the case of electric vehicles involved in accidents. In such cases, an electrical hazard must always be assumed.

According to DGUV Information 209-093, qualification for level 3S requires a completed training in the automotive or electrical sector and proof of level 2S qualification. In addition, participants must be at least aged 18, provide a valid first aid training certificate including cardiopulmonary resuscitation and be in good health for these activities.
The qualification for working on live high-voltage systems builds on level 2S and delivers in-depth theoretical and practical knowledge to be able to safely master specific hazards. It concludes with a theoretical and practical examination.
Regular training is required to keep expertise up to date and ensure the safe handling of high-voltage systems in the long term.

Maintenance and repair of electric vehicles – safe, structured and according to manufacturer specifications

Working on electric vehicles requires special care, even if, at first glance, it does not involve high-voltage components. The integrated networking of contemporary systems means that even simple modifications to conventional components can have an impact on the high-voltage system. A structured approach that guarantees the safety of everyone involved at all times is therefore crucial.

Risk assessment at work: basis for safe operations

A risk assessment must be carried outbefore starting work. It forms thebasis for all protective measures and must be regularly reviewed as well as adapted in the event of safety-relevant changes. The responsibility for this lies with the competent and responsible person in the company or with the employer.

Preparing workstations – so that every job can start safely

Safe operational processes start with the right preparation:

workstations must be clean, clearly marked and labelled with warning signs.
Uninvolved persons must be kept away from the danger zone.
All required tools and measuring equipment must be insulated, approved and suitable for the intended purpose. Lifting platforms and other equipment must also be suitable for use on electric vehicles.
The prescribed personal protective equipment (PPE) must be provided.
Barrier and safety material must be provided. This includes barrier tapes, safety cones, warning signs and barriers to mark the workstation.

Overview of personal protective equipment and equipment for high-voltage activities: insulated gloves, face shield, safety footwear, diagnostics equipment, insulated tools, padlock, recovery hooks, barriers and warning signs. — (1) Insulating gloves, (2) Face shield, (3) Protective clothing/safety footwear, (4) Voltage tester, (5) Insulated tools, (6) Lock, (7) Recovery hooks, (8) Barriers, (9) Warning signs

Personal protective equipment (PPE) – basic protection for every procedure

Applicable personal protective equipment depends on the work due as well as the manufacturer specifications.

Insulated gloves of protection class 0
Full face protection (helmet with integrated visor)
Flame-retardant, conductive protective clothing
Insulated safety footwear

PPE must be checked for damage before each use. Do not use faulty equipment.

an insulated rescue hook and a complete first aid kit must be readily available and in the immediate vicinity of the workstation. This equipment is used for quick and safe recovery in the event of an electrical accident and must be checked regularly for completeness and functionality.

Tool requirements – why exclusively tested HV tools must be used

Exclusively authorised and tested tools must be used for work on high-voltage systems. Tools must comply with the applicable standards, be insulated and have a dielectric strength of at least 1000 V. Visual inspections are mandatory before each use. Exclusively fully tested and undamaged tools guarantee the required levels of safety.

Drawer with insulated high-voltage tool set, including sockets, screwdrivers and special tools, approved and designed for working on live HV systems. — Insulated HV tools, approved and designed for ≥ 1000 V

De-energising – safety-relevant decisions before every repair

Always check whether the vehicle must be de-energised before starting any maintenance or repair work.Manufacturer specifications must also be observed. Play it safe if you are unsure. The vehicle must be de-energised in accordance with the manufacturer specifications. The safety of anyone involved is the top priority.

The five safety rules – an indispensable basis for all HV activities

Regarding work on high-voltage systems, the recognised five safety rules of electrical engineering apply in an adapted form:

De-energise
Secure against reconnection
Determine systems are no longer live
Earth and short-circuit
Cover or prevent access to adjacent live parts.

The first three safety rules must always be implemented when working on high-voltage systems. Whether rules four and five are also applicable depends on individual circumstances. Manufacturer specifications must always be observed.

Voltage isolation in practice – what manufacturers differentiate and what workshops must consider

The process of working on electric vehicles differs depending on the vehicle manufacturer. Consequently, the respective manufacturer specifications must always be observed for all activities, including the replacement of 12 V components. Some manufacturers stipulate that the high-voltage system must be de-energised before any intervention in the 12V vehicle electrical system, for example when replacing the intelligent battery sensor. Non-compliance with this specification may cause high-voltage contactors to open under load and be damaged as a result.

The de-energising procedure itself may also differ between the individual manufacturers. While, in one vehicle, de-energising the high-voltage system must be verified and recorded using a suitable measuring device, this condition is confirmed by a display or message in the instrument cluster in another, provided the high-voltage system is not affected by any faults.

The vehicle manufacturer's de-energising and testing instructions must be strictly observed for all work on electric vehicles. This is the only way to guarantee that there is no unwanted voltage and that high-voltage contactors or control units do not suffer consequential damage.

Diagram of 12 V and high-voltage topology of an electric vehicle with BMS, pyrotechnical battery isolation, HV contactors and the HV connections for positive and negative terminals. — Example illustration: The BMS is supplied by the 12 V vehicle electrical system battery. If the 12 V supply is interrupted, the high-voltage contactors open. (1) 12 V battery, (2) Pyrotechnical battery isolation, (3) BMS (Battery Management System), (4) High-voltage battery (HV battery), (5) High-voltage contactor (+), (6) High-voltage contactor (-), (7) High-voltage connection (+), (8) High-voltage terminals (-)

Conclusion and outlook

Electromobility is fundamentally changing everyday workshop activities. In addition to new components and diagnostics procedures, the focus is primarily on safety. Working on the high-voltage system must exclusively be carried out by qualified specialist personnel with verified high-voltage training. Workshop staff that familiarises itself with the technical principles, qualification levels and safety requirements at an early stage gain a decisive, skill-based advantage and position themselves as competent partners for contemporary vehicle technology.

With the further expansion of e-mobility, the need for specialised technicians able to safely and professionally test high-voltage systems and carry out repairs according to manufacturer specifications is also increasing. At the same time, a large proportion of the familiar systems will continue to be used. The combination of proven expertise in the low-voltage sector and targeted qualification in the high-voltage segment forms the basis for the safe handling of electrified vehicles.

Ongoing training, reliable technical information and an active safety culture are crucial to ensure that workshops can continue to operate successfully in the age of electromobility. The transition is already underway and it is being actively shaped with expertise and responsibility.