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Equipping Schools for EV Education: Essential Tools and PPE

 

The demand for skilled EV technicians is rising. Schools with existing automotive programs now have a unique opportunity to expand their offerings by introducing hands-on EV training, preparing students for the fast-evolving industry.

However, safely training students to work with EVs requires specialized personal protective equipment (PPE), tools, and equipment beyond those used for traditional internal combustion engine (ICE) vehicles. This guide breaks down the essential components for setting up an effective EV training program, from PPE to specific tools and equipment.

 

Understanding the Unique Requirements of EV Education

Electric vehicles operate at high voltages, presenting unique electrical hazards compared to conventional vehicles. Instructors and students must prioritize safety and adopt an unwavering commitment to careful handling procedures. An effective EV curriculum should start with a comprehensive introduction to electrical safety, followed by focused training on the PPE, tools, and equipment necessary for working with high-voltage systems.

By investing in the right tools and protective equipment from the start, schools can meet industry standards and give students hands-on experience in a secure learning environment.

 

1. Essential Personal Protective Equipment (PPE) for EV Education

PPE is a non-negotiable in any automotive program, especially for EVs, as they expose technicians to potentially lethal high-voltage currents. Ensuring that both students and instructors are equipped with the right PPE will mitigate risks and promote safe learning.

It is important to note that most HV PPE in particular is only a requirement when working on an energized system. That being said, when in doubt, wear protection.

Key PPE items include:
High-Voltage Gloves and Leather Protectors:

These gloves, typically rated to handle up to 1,000 volts, provide a valuable line of defense when working on live systems. While many classes of gloves are available - offering different levels of protection for different levels of HV electricity - Class 0 gloves, rated for 1000V max are sufficient for most EV work as modern EV systems rarely exceed 800V.

Additionally leather protectors should be worn over the rubber gloves to prevent accidental punctures to the rubber. Regular testing and inspection of gloves for insulation integrity are important and should be done on a routine basis. 

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Face Shields and Safety Goggles: 

When working on battery packs or high-voltage cables, face shields and safety goggles protect against potential arc flashes, debris, and chemicals. Ensure that face shields are arc-rated to withstand high-voltage exposure.

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Insulated Tools for HV Work:


All hand tools used in an EV program to work on live circuits should be insulated to reduce the risk of electrical shock. Look for tools rated up to 1,000 volts and marked with double insulation symbols.

At Legacy EV, we use WIHA insulated tool sets when working on circuits or batteries that can not be energized. 

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High-Voltage Insulated Mats and Blankets:

Insulated mats protect technicians working on EV systems from grounded surfaces, reducing the risk of shock. Insulating blankets can be used to cover live components, creating a safer work area.

 

By instilling PPE habits early, students will develop a solid understanding of electrical safety procedures, making them well-prepared for the industry.

 

2. Tools and Equipment Required for an EV Education Program

The tools and equipment necessary for EV education are different from those used for ICE vehicles. They include diagnostic equipment, high-voltage test tools, and battery handling equipment designed for safe operation on EVs. Here’s what every program needs:

Diagnostic Tools

EVs rely heavily on advanced electronics, making diagnostic tools essential. Here are the core diagnostic tools for an EV-focused curriculum:

 

  • OBD-II Scanner with EV Capabilities: An OBD-II scanner is essential for reading trouble codes and diagnosing issues specific to EVs, like battery health and regenerative braking. Ensure the scanner is compatible with electric drivetrains and can read EV-specific codes.
  • Thermal Camera: Batteries can overheat, and thermal cameras allow students to monitor battery temperatures safely. This tool is also useful for diagnosing overheating in other components.
  • Multimeter with High-Voltage Testing Capability: A multimeter capable of measuring up to 1,000 volts AC/DC is a must. Look for models with CAT III or CAT IV ratings to ensure safe measurement of high-voltage components.
  • Insulation Resistance Tester: This tool checks the insulation of EV wiring to ensure there’s no risk of current leakage. It is often referred to as a megaohmemeter or a “megger”. While they share many of the same functions as a multi-meter they are essential for teaching students how to verify the safety of high-voltage cables and systems as they can measure resistance, isolation, and continuity with much more accuracy.

Battery Service Tools

Working on EV battery packs presents specific challenges due to their weight, complexity, and safety requirements. Schools should invest in these tools to facilitate safe battery handling:

  • Battery Lift Table: EV batteries are often large and heavy. A lift table makes it easier and safer to remove and install batteries for testing or repairs.
  • Battery Cell Balancer and Analyzer: Students need to understand how to evaluate battery cell health. A battery balancer and analyzer will allow them to test cell voltages, resistance, and capacity, giving them a firsthand look at maintaining battery packs.
  • Battery Terminal Torque Wrench: High-voltage batteries have specific torque requirements to ensure proper connections. An insulated torque wrench allows students to securely fasten battery terminals without risking short circuits.

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Safety Equipment for High-Voltage Systems

In addition to diagnostic and battery service tools, high-voltage safety equipment is critical for handling EV components safely.

Every EV workbench should have a Lockout/Tagout (LOTO) kit to secure power sources during maintenance. This equipment prevents accidental energizing of circuits, ensuring a safer learning environment.

This tool detects the presence of high voltage from a distance, allowing students to confirm a system is de-energized before working on it.

In case of accidental high-voltage contact, a rescue hook allows instructors to safely pull someone away from the source without risking their own safety. It’s an important item to have on hand, especially in educational settings where students are learning new safety protocols.

Clear signage around high-voltage areas reminds students of the risks and reinforces the importance of caution. Additionally, physical barriers around high-voltage work areas provide an added layer of security.

 

3. Setting Up a Safe and Effective EV Workstation

An organized, safety-oriented workstation is essential for teaching EV skills. Schools should consider these key elements:

  • High-Voltage Work Zone

    Dedicate an area of the workshop to high-voltage work, clearly marked with warning signs. Install insulated mats in this area, and consider adding barriers to prevent unauthorized access.

  • Battery Storage Area

    Battery packs should be stored in a designated, temperature-controlled space to prevent overheating and chemical leaks. Ideally, the storage area is fireproof and has spill containment measures in place.

  • Charging Station for EV Batteries

    As students learn to work with battery packs, a charging station is vital for teaching battery management. Be sure to include safety protocols for charging in your curriculum, such as monitoring charge levels and temperature.

  • First Aid Station with Eye Wash

    Due to the increased risks involved in working with high-voltage systems, ensure a well-stocked first aid station and an eye wash station are nearby. 

  • Fire Suppression System

    A fire suppression system designed to handle electrical fires (such as CO2 or dry chemical extinguishers) is recommended. If this is not possible Class D fire extinguishers should be kept on site and clearly marked. 

 

4. Training and Curriculum Development

Equipping students with the knowledge to work safely on EVs is just as important as providing the right tools and equipment. Consider these tips to build a comprehensive EV curriculum:

  • Start with Electrical Safety Basics

    Before students work hands-on with high-voltage systems, they should be well-versed in electrical safety fundamentals, including PPE, high-voltage terminology, and emergency response protocols.

  • Emphasize Hands-On Learning

    Give students ample opportunities to practice with real EV components, such as batteries, inverters, and electric motors. Encourage them to apply what they learn through supervised projects.

  • Incorporate Troubleshooting and Diagnostics

    Understanding diagnostics is key to EV maintenance. Teach students how to use OBD-II scanners, multimeters, and insulation testers on EV systems to diagnose and troubleshoot.

  • Simulate Real-World Scenarios

    Introduce students to real-world EV service scenarios, such as battery replacements, inverter diagnostics, and charging station repairs. These scenarios will help them build confidence in their skills.

  • Provide Ongoing Safety Refreshers

    High-voltage safety isn’t a one-time lesson. Conduct regular safety refreshers to reinforce best practices and keep safety top of mind.

EVFoundationsCurriculumIf you are ready to get started teaching EV education quickly - consider taking advantage of Legacy EVs turnkey curriculum packages such as EV TECH or EV BUILD. The courses include:

  • Industry-backed EV Technician Standards
  • Turnkey Lesson Plans with Lecture Materials, Handouts, and Labs
  • Extensions and Differentiation
  • Hands-on, Project-based, & Asynchronous Learning
  • Student Diagrams & Installation Guides
  • Practical Lab Applications
  • Pre-made Exams for Industry Certifications

Conclusion

Setting up a hands-on EV education program in an established automotive school requires careful planning and investment in the right PPE, tools, and equipment. By providing students with a safe, well-equipped environment, schools can ensure that the next generation of technicians is prepared to work on the EVs of today and tomorrow.

Ensuring that students master both safety and technical skills is essential to their future success and the credibility of the program. As the automotive industry evolves, so too must our educational programs.

The investment today in EV-focused training will pay dividends by equipping students to confidently and safely enter the electric vehicle workforce.