The Institute of the Motor Industry

  • The ESA Electric and Hybrid Training program is accredited by the IMI (the Institute of the Motor Industry) and the only IMI Tech Center in the United States.At the ESA students can get certified under the following International Qualifications which are recognized by global vehicle manufacturers:

IMI Level 3 High Voltage Certification Training

 

This combined Automotive High Voltage IMI Level 1, 2 and 3 Qualification is developed for 12 students and has the following timetable and learning objectives which will be taught in a blended learning strategy between online and in-person training.

 

Day 1:  8AM – 4PM Basic Electrical Engineering 

  • Understand parallel and series electrical circuits
  • Understand the function of resistors, diodes, and capacitors in HV systems
  • Explain Ohm’s law
  • Describe the operation of transformers and rectifiers
  • Describe High Voltage Battery Circuits and Contactors
  • Explain AC voltage and frequence in Hertz
  • Describe electrical synchronous Motors
  • Explain the function of relays and transistors
  • Understand electrical principles, to include:
    • Electrical symbols and terminology
    • Explain the relevant electrical terminology
    • Relationship between voltage, current and resistance
    • Alternating Current (AC)
    • Direct Current (DC)
    • Three Phase Current
    • Construction and operation of electrical components such as;
      • Coils
      • Capacitors
      • Motors
      • Contactors
      • Diodes
      • Transformers
      • Generators
      • Relays
      • Cabling
      • Circuit protection
    • Wait time on capacitors for deactivating high voltage systems
    • Sources of power within the vehicle, including Storage (high voltage battery, low voltage battery, fuel cell, capacitors) External (12V battery charger, AC charging equipment)
    • Generation (E-machine, towing/pushing vehicles, rolling roads,
    • dynamometers, DC/DC converters)
    • Batteries (internal resistance, ageing, SOH, SOC, high voltage battery construction)
    • Basics of regeneration/recuperation of kinetic energy and the associated risks of towing/pushing vehicles
    • Analogue and digital test and measuring instruments
    • Measurement of current, voltage and resistance
    • Reading circuit diagrams to establish current paths

 

Day 2:  8AM – 4PM High Voltage Safety and Disconnecting Procedures

 

  • Understand the use of Personal Protection Equipment (PPE)
  • Electrical hazards and first aid, to include:
  • Hazards associated with a high voltage such as;
    • Electric shock
    • Burns
    • Fire
    • Explosion
    • Chemicals
    • Gases/fumes
  • The levels of current and voltage that may present a hazard include:
    • Contact time
    • AC/DC current and voltage levels
    • Factors affecting resistance to current flow
    • Resistance of human body
    • IEC 60479
    • IEC 479-2
    • Stimulus thresholds
    • Let-go threshold
    • Injuries associated with high voltage electrical systems such as:
      • ventricular fibrillation
      • Neurological effects
      • Secondary injuries
      • First aid in the event of injury caused by electric current or voltage
      • Reporting procedures for injuries at work
      • Actions to be taken in the event of a fire
    • Health and safety requirements for electrical work, to include:
      • Legislation and regulations to include:
      • OSHA 29 CFR 1910.303(g)(2)(i) ii.
      • HSE Guidelines
      • European legislation
      • ECE R100
      • Motor vehicle safety standards
      • Codes of practice
      • Vehicle safety instructions
      • Warning signs
      • Risk Assessment and Vehicle Intake process
      • Describe the High Voltage system and operation
      • Explain the High Voltage Interlock system
      • Understand the function of High Voltage system components such as Inverter, Electric Motor, Charger, DC/DC Converter and all auxiliary systems
      • Electric/hybrid vehicle charging systems include:
    • Mode 1, 2 and 3 (the use of dedicated charging equipment)
    • AC, DC, three-phase and inductive charging technologies
      • Safety concepts within high voltage systems in vehicles, to include:
    • Active/passive discharge
    • Touch protection
    • Labels
    • Anti-tamper connections
    • High voltage interlock system
    • Potential equalization
    • Isolation detection
    • Understand all steps to safely disconnect a high Voltage system
    • Explain the verification of zero potential
    • Explain passive and active discharge
    • Describe the Manufacturer disconnect process and understand High Voltage Battery or Low Voltage service disconnect

 

 

Day 3:  8AM – 12PM High Voltage Service and Diagnostics

  • Explain Potential Equalization verification under ECE-R 100
  • Describe how to perform a four-wire measurement method
  • Describe how to perform an Insulation test
  • Understand diagnostic methods on an electrical vehicle
  • Explain the use of a manufacturer diagnostic tool
  • Describe the manufacturer disconnecting procedure and verify zero potential at an Electrical Vehicle
  • Perform a theoretical Exam (Multiple-Choice)

Day 3: 1PM – 5PM High Voltage Practical Exam

 

  • One-hour practical exam demonstrating the following tasks:
    • Perform a certified disconnecting procedure
    • Diagnosing the High Voltage system
    • Bonding and insulation faults must be found

 

IMI Level 4 High Voltage Certification Training 

This Level 4 Training is the highest international High Voltage Technology education certified by the IMI. Students must have achieved prior to participating in this course the IMI Level 3 Certificate. The course focuses on High Voltage Battery repair and working in live circuits. Newest Battery technology and test equipment will be used to give students the best learning experience.

Day 1- 2:  8AM – 4PM High Voltage Level 4 Certification Training – Working under Live condition:

  • Explain how to disconnect a live vehicle and bring it to a safe state.
  • Explain the safe High Voltage Battery removal process.
  • Explain how to personal protection when working under live conditions.
  • Describe the process how to remove and replace Battery modules.
  • Explain how to perform insulation resistant testing in open Batteries.
  • Explain how to use a two-pole voltage tester at Battery modules.
  • Perform Battery enclosure and coolant testing.
  • Explain diagnostic methods on live electric vehicles.
  • Perform the replacement of High voltage Battery contactors.
  • Explain how to balance high Voltage Battery cells.
  • Describe a safe diagnostic strategy when the system is in live condition.
  • Work safely when carrying out maintenance work on live HV systems on vehicles, to include:
    • individuals authorized to work on a live high voltage vehicle system which must satisfy the following as a minimum:
      • The work cannot be done under isolated conditions
      • Relevant rules and regulations
      • Manufacturer’s guidelines
      • Related training, experience and qualifications
      • Organizational procedures
    • Difference between being authorized to work on high voltage systems on vehicles and being able to work on high voltage systems under live voltage
    • 5 steps to conduct a risk assessment
    • Ensure the surrounding area and environment are safe to carry out live high voltage vehicle system tests and repairs
    • Visual inspection to assess the condition of the high voltage systems including:
      • New high voltage components prior to installation
      • Damaged high voltage components (safe to transport, safe to carry out further repairs)
      • Guidance on assessing/transporting a severely damaged vehicle with high voltage components
    • Procedures for isolating high voltage systems
    • Specialist diagnostic/measurement equipment such as:
      • Isolation testing (100 – 500 volts DC)
      • Di-electric testing (2000 – 5000 volts DC)
      • PE measurements (potential equalization resistance calculations)
      • Cell/module balancing
      • Ingress Protection (IP) testing
    • High voltage battery charging when the battery is not installed in the vehicle
    • Removal and replacement of high voltage components
    • High voltage battery repair at module level
    • Fault diagnosis on high voltage systems, to include:
      • Cell imbalance
      • Over temperature
      • Earth leakage
      • High voltage interlock loop failure
      • Contactors
      • Fuses
      • Isolation faults
      • Insulation faults
      • Potential equalization
      • State of charge/health faults
      • Capacitor faults
      • Current faults
      • Invertor input/output
      • Electromagnetic interference
      • Component failure

 

Day 2:  8AM – 4PM High Voltage Theoretical and Practical Assessment for Level 4

  • Procedure for reinstating the vehicle systems
  • Procedure to confirm repairs were successfully carried out could include:
  • On vehicle functional testing
  • Explain how to retrieve BMS data from a Battery not connected to a Vehicle
  • Checking fault codes
  • Voltage/current checks
  • Perform a Battery Enclosure Test
  • Explain the different methods of coolant leak testing:
    • Pressure, Vacuum and Smoke
  • practical assessment demonstrating the following:
    • Reducing Voltage potential in the Battery safely
    • explain how to work in live circuits.
    • explain Battery module repair.