Choosing The Right Company To Carry Out Your Electric Hybrid Battery and High Voltage System Repairs.

IMI TechSafe Certified

Some of the following information is taken from the IMI members website

IMI TechSafe is so much more than just professional recognition. It's also a:

• Platform that encourages you to stay up to date, ensuring you're always at the forefront of vehicle technologies through your commitment to mandatory CPD requirements

• Tool that helps you ensure compliance with international government regulations and insurance company requirements

• Way to instil confidence in your customers, colleagues, or employers in your ability to work safely with these emerging technologies.

• Testament to your commitment to safety and professionalism in the automotive industry.

• Badge of honour that you can display with pride.

Be proud of your achievements, be professional, and be IMI TechSafe

At present there’s no legislation in place to stop unqualified persons from working on high voltage batteries and associated systems but that doesn't mean that any insurance will be valid if not qualified to do so and while appreciating that people are generally pre-disposed to want to save money where possible, it should be said, that a person wouldn't think repairs on household electrical system was a good idea unless qualified, so why would it seem a good idea to take the same risk while working on vehicle high-voltage systems?

The following guidelines are set out by the Institute of the Motor Industry

Persons Permitted to Carry Out Work On Vehicle High Voltage

Systems

L1 Award in Electric/Hybrid Vehicle Awareness

L1 is designed for trainers and employers to promote awareness of the

dangers surrounding and the precautions required to avoid potential

injury while near hybrid electric vehicles.

This course can be delivered online and is aimed at non-technical

persons.

L2 award in electric/hybrid vehicle routine maintenance

Working safely around Hybrid Electric vehicles while carrying out routine

maintenance this level of qualification does not allow working on the high

voltage systems.

L3 award in electric/hybrid system repair and replacement

Designed for maintenance and repair technicians. This is the minimum

level award allowing for repair and replacement of components within

the high voltage system.

L4 award in diagnosis, testing and repair of hybrid electric vehicles

For technicians, this qualification is designed to ensure the safety of

technicians testing and working on or near live high-voltage systems.

It is the responsibility of managers and technicians to manage work on

and around high-voltage vehicle systems to ensure this is done in the safest

possible way, following operating procedures, minimising risks, adhering

to safety standards and using correct PPE (personal protective

equipment) and carrying out risk assessments.

Batteries operate with DC or direct current and 99% of adults will not be able to let go with a current greater than 22 mA

With other factors needing consideration like current path, burns and arc flash which can reach extremely high temperatures in milliseconds turning some metals to vapour or molten metal in an instant, suitable P.P.E and understanding of high voltage systems is a must

Current in mA	Effects on the Human Body
0.2-2mA	Electrical Sensation
1-2+mA	Painful Shock
3-5mA	Let go threshold for children
6-10mA	Minimum let-go threshold for adults
10-20mA	Tetany - contact area
22mA	99% of adults cannot let go
20-50mA	Tetany – respiratory muscles
50-100mA	Ventricular fibrillation

1 milliamp = 0.001 of an amp - As an example, a Toyota Prius high-voltage battery will discharge at 50 amps to provide instant power

The Picture above is of a Toyota battery module which has cracked open during use, causing an isolation fault with an electrolyte leak

Knowing how to keep yourself and customer vehicles safe is of the utmost importance

Although electric/hybrid vehicle systems are generally safe and are designed with safety as a paramount concern and every effort is made to keep anyone who comes into contact with the high voltage system safe, some system faults could be encountered which pose a significantly higher risk of causing injury or death, such as a voltage leak to the chassis of the vehicle where the isolation between the high voltage system and the chassis has become compromised and the voltage can find itself in areas where it is not meant to be found, the outer metal case of a battery as an example, which could be caused by component failure or by water ingress exposing anyone working on batteries to much greater risk if proper safety procedure is not adhered to.

There are other risks which could be encountered and should be considered before work begins on any high-voltage system, especially while testing while the system is live. A full risk assessment should completed prior to any work being carried out, including a full system diagnostic, carried out to search for fault codes that could help identify the level of risk the high voltage fault presents. An example of an additional risk is leaking caustic electrolytes such as potassium hydroxide (KOH) which has the potential to cause harm if correct personal protective equipment (PPE) is not used.

Using the correct service information as supplied by the manufacturer - guesswork is not an option

Without the proper service information, it makes it very difficult to do the job properly, this will include diagnostic fault code information, testing procedures, and detailed schematics including components, current direction flow and required torque settings.

The Picture above is of a Generation 2 Toyota Prius where a build-up of corrosion on the pins of the High Voltage battery ECU voltage sensor connector to the frame wire, there has been increased resistance, resulting in a battery system failure.

Necessary Insurances

There are multiple insurances which should be in place before work can be carried out on your vehicle high high-voltage system these include a mobile works policy if you operate as a mobile service, goods in transit to carry commercial goods including batteries, Public liability and a fully comprehensive motor insurance for when the need to test drive a vehicle arises.

HYBRID REPAIR SERVICE LTD has Level 4 and Level 3 Institute of the Motor Industry TechSafe certificated engineers and technicians and has all relevant insurances in place.

Final Note - Having your electric/hybrid battery and associated system faults repaired by a professional is the best advice,