High Voltage Vehicle Safety Systems and PPE C1732

High voltage vehicle safety is a primary concern for every technician or engineer involved in developing, diagnosing or repairing hybrid or electric vehicles. Engineers/technicians working in this field should complete safety training before they interface with hybrid, plug-in or electric vehicles. This course provides participants with fundamental technical and safety information on high voltage personal protective equipment (PPE) such as how to test high voltage gloves, when and where to send high voltage gloves for periodic testing, and how to safely use test equipment for measuring high voltage components in live and disabled high voltage systems.

Much of the high voltage vehicle safety systems information covered in this course is based on the FMVSS requirements and SAE Recommended Practices. The vehicle safety systems contain interlock circuits, passive and active bus (capacitor) discharge circuits, and DC and AC isolation detection systems that are monitored by high voltage controllers to maintain the required resistance barrier between the vehicle technician/engineer and the vehicle body/chassis to mitigate the possibility of an electrical shock event.

Learning Objectives

At the conclusion of this course, participants will be able to:

  • Properly care for high voltage electrical gloves
  • Field test high voltage electrical gloves
  • Identify providers that test high voltage gloves required by ASTM requirements
  • Disable a vehicle high voltage system
  • Safely acquire measurements on a high voltage system
  • Describe the operation of automotive AC and DC isolation fault detection systems
  • Apply FMVSS 305 requirements and SAE J1766 Recommended Practice to testing high voltage vehicle safety systems
  • Describe the operation of high voltage interlock circuits and passive and active bus discharge circuits
  • Test the high voltage system for isolation faults, interlock circuit failures and passive and/or active discharge circuits
  • Describe how and when to use high voltage gloves, serial data (Scan Tool), insulation meter, and DVOM to test the high voltage system and components

Who Should Attend

This course will benefit vehicle electrification engineers involved in the design or development of high voltage systems as well as lab and vehicle technicians (beginner to intermediate level) who perform systems diagnostics as well as vehicle proto builds. This course will also benefit automotive technicians with an automotive certificate, A.A.S. or B.S. (experienced auto techs but are beginners in vehicle electrification) who service automotive systems. This course would assist all disciplines and personnel working with automotive high voltage systems found in vehicle electrification in understanding how high voltage vehicle safety systems operate, and how to use safe practices and the necessary equipment to analyze, test, and repair them.

This course applies to every OEM or product with high voltage electrification systems. This type of training may be required by OEMs and Tier 1 and 2 suppliers who are interfacing with high voltage systems. Automotive aftermarket service businesses who have employees servicing products with electrification systems would also benefit from attending.


An electronic/electrical engineering degree is highly recommended, but not required. Experience as an electronic/electrical technician or engineer is recommended. A fundamental knowledge of electrical and electronics background is required. And, a basic knowledge of vehicle electrification high voltage system is recommended but not required.

You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

  • High Voltage Safety & PPE (1.5 hours)
    • Characteristics of AC and DC Electrical Power
    • Ground Circuit Paths
    • Tools & Equipment CAT Ratings
    • Tool & Equipment Usage
    • High Voltage Glove Selection, Field Testing, Testing Requirements, and Storage
    • Insulation Meters and Usage on High Voltage Components
  • High Voltage Vehicle Safety Systems (4.5 hours)
    • High Voltage Cabling
    • High Voltage Cable and Electrical Symbol Identification
    • Service Disconnect Types, Locations, and Removal/Install
    • High Voltage Fuse
    • Interlock Systems and System Types, Location, Circuits, Operation, Failure Modes and Diagnostics
      • Serial Interlock
      • Local (component) Interlock
      • Testing and Diagnosing of Interlock Systems
      • Use of standard and special tools for testing
    • Active and Passive Bus Discharge Systems, Location, Circuits, Operation, Failure Modes and Diagnostics
      • Bus Discharge Active Circuit Operation
      • Bus Discharge Passive Circuit Operation
      • High Voltage Battery Contactor Control with Bus Discharge Systems
      • Testing and Diagnosing Bus Discharge Systems
      • Use of standard and special tools for testing
    • Isolation Fault Detection Systems, Circuits, Operation, and Diagnostics
      • DC Detection System Operation
      • AC Detection System Operation
      • Diagnostics associated with Isolation Fault Systems
      • Use of standard and special tools for testing
  • Mark Quarto

    Dr. Mark Quarto is currently the Chief Technology Officer (CTO) for Quarto Technical Services where he is responsible for the design/development of diagnostic test equipment and software, technical education and training programs, and technology innovations focused on hybrid and electric vehicle propulsion and energy management systems. Dr. Quarto previously worked within the General Motors Company as an Engineer and Engineering Group Manager in Advanced Powertrain Technology Systems / Global Aftermarket Engineering where he was responsible for the management and development of control and diagnostics systems and service solutions for the Chevrolet Spark & Volt, Fuel Cell, Two-Mode Hybrid, Parallel Hybrid Truck (PHT), EV1 Electric Vehicle, S10 Electric Truck, and Alternative Fuel Systems Programs. He also served as the Service Training Development Manager and Resident Service School Instructor. Mark began his automotive career as a technician at both dealership and aftermarket facilities. In addition to his accomplishments and experiences while working at General Motors, Mark has served as a CTO, Senior Consultant, Author, and Subject Matter expert in Hybrid, Electric, and Fuel Cell Technologies. Dr. Quarto has a Bachelor's Degree in Electrical Engineering from LaSalle University specializing in Power Electronics; a Bachelor's Degree in Automotive Technology from Ferris State University; Master's Degree in Technical Education from Ferris State University specializing in electric and hybrid propulsion systems; and a Doctorate in Technical Education from Nova Southeastern University, specializing in designing and developing learning systems for hybrid/electric vehicles and high voltage energy and propulsion systems. He has patents and trade secret designs in vehicle electrification testing, testing equipment, and diagnostic systems.

    Duration: 1 Day
    CEUs: .7

    Format: Classroom

    Event ID: 6845

    Location: Troy, Michigan

    Session Info:

    8:30 a.m. - 4:30 p.m.

    Fees: $599.00

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