Training for Work on Vehicles with High Voltage Systems : DGUV 209-093

As electric and hybrid vehicles become more prevalent, the need for specialized training to handle their high voltage systems safely is paramount. The DGUV 209-093 standard provides a comprehensive framework for training personnel working on vehicles equipped with high voltage systems, ensuring safety and competence across various roles.

Relevance of DGUV 209-093

The DGUV 209-093 standard is crucial for employers and employees alike, offering guidelines to mitigate electrical hazards associated with high voltage systems in vehicles. It outlines qualification levels required for different stages of vehicle development, production, and service, ensuring that only adequately trained personnel handle these systems.

Introduction to HV Safety Lineages in DGUV 209-093

In the realm of high voltage (HV) safety, the DGUV 209-093 standard outlines two distinct pathways, or lineages, to address the unique challenges and risks associated with HV systems in vehicles: one before production and one after production. This bifurcation is essential to ensure that safety protocols are tailored to the specific environments and tasks associated with each phase of a vehicle's lifecycle.

Qualification Levels Before Production

1. Level E: Sensibilisierte Person
2. Level 1E: Fachkundig unterwiesene Person (FuP)
3. Level 2E: Fachkundige Person (FHV)
4. Level 3E: Fachkundige Person für Arbeiten an unter Spannung stehenden HV-Systemen

Qualification Levels After Production (Service)

1. Level S: Sensibilisierte Person
2. Level 1S: Fachkundig unterwiesene Person (FuP)
3. Level 2S: Fachkundige Person (FHV)
4. Level 3S: Fachkundige Person für Arbeiten an unter Spannung stehenden HV-Systemen

By addressing these two distinct phases, the DGUV 209-093 standard ensures a comprehensive approach to HV safety, providing clear guidelines and qualifications to protect personnel throughout the entire lifecycle of high voltage systems in vehicles.

Qualification Levels Before Production

The pre-production phase encompasses research, development, and manufacturing, where the focus is on creating and integrating HV systems into new vehicle designs. This lineage is critical because it involves handling prototype systems and components that may not yet have the safety features present in final production models. The qualification levels here are designed to ensure that personnel can safely work on systems that are still under development, where risks might be less predictable and safety measures are still being refined.

Level E: Sensibilisierte Person

• Translation: Sensitized Person
• Explanation: This level is for employees who need to be familiar with the basic operation and handling of high voltage (HV) vehicles. It includes understanding how to charge the vehicle, perform simple maintenance tasks like replacing windscreen wiper blades, and preparing vehicles for test drives.
• Knowledge Required: Basic awareness of HV vehicle operation, charging procedures, and safety precautions.
• Objective: Ensure that employees can safely operate and handle HV vehicles without performing tasks that involve direct interaction with HV components.

Level 1E: Fachkundig unterwiesene Person (FuP)

• Translation: Person Instructed with Expertise
• Explanation: This level is intended for personnel who perform general, non-electrical work on HV vehicles, such as changing wheels or oil. They must be aware of the electrical hazards and protective measures but do not need to isolate the HV system for their tasks.
• Knowledge Required: Understanding of electrical hazards, protective measures, and the ability to perform tasks without isolating the HV system.
• Objective: Enable employees to safely perform general tasks while being aware of the risks associated with HV systems.

Level 2E: Fachkundige Person (FHV)

• Translation: Person with Expertise
• Explanation: This level is for technicians and engineers who work on non-live HV systems. They need to be able to decommission and recommission HV systems safely, following the "Five Safety Rules" and manufacturer's specifications.
• Knowledge Required: In-depth electrical knowledge, ability to ensure the non-live state of HV systems, and application of safety protocols.
• Objective: Perform technical work on HV systems in a non-live state, ensuring safety through proper isolation procedures.

Level 3E: Fachkundige Person für Arbeiten an unter Spannung stehenden HV-Systemen

• Translation: Person with Expertise for Work on Live HV Systems
• Explanation: This is the highest qualification level, intended for highly skilled technicians and engineers who work on live HV systems. They must be capable of troubleshooting and handling live components where de-energizing is not possible.
• Knowledge Required: Advanced training for work on live HV systems, including safety protocols and emergency procedures.
• Objective: Safely execute tasks on live HV systems with enhanced safety protocols, ensuring the protection of personnel and equipment.

Qualification Levels After Production (Service)

The post-production phase, or service lineage, deals with vehicles that are already in use, focusing on maintenance, repair, and accident recovery. This environment presents its own set of challenges, as technicians must work on systems that are part of operational vehicles, potentially under live conditions. The qualification levels here emphasize the ability to handle both routine servicing and emergency situations, ensuring that technicians can safely manage HV systems in real-world scenarios, including accident recovery and troubleshooting live systems.

Level S: Sensibilisierte Person

• Translation: Sensitized Person
• Explanation: Similar to Level E, this level is for service personnel and drivers who need to be familiar with the operation of HV vehicles and basic safety precautions.
• Knowledge Required: Basic understanding of HV vehicle operation, charging procedures, and safety measures.
• Objective: Ensure safe operation and minor servicing tasks without direct interaction with HV systems.

Level 1S: Fachkundig unterwiesene Person (FuP)

• Translation: Person Instructed with Expertise
• Explanation: This level is for mechanics performing general vehicle maintenance who need to be aware of the locations of HV components and basic protective measures.
• Knowledge Required: Awareness of HV system locations, protective measures, and the ability to perform tasks without direct intervention with HV components.
• Objective: Safely perform mechanical tasks near HV components without direct interaction.

Level 2S: Fachkundige Person (FHV)

• Translation: Person with Expertise
• Explanation: This level is for service technicians who work on non-live HV systems. They must be able to isolate HV systems and perform repairs or maintenance in a non-live state.
• Knowledge Required: Ability to isolate HV systems and perform repairs or maintenance in a non-live state, following strict safety protocols.
• Objective: Ensure safe servicing and repair of HV systems by adhering to safety protocols.

Level 3S: Fachkundige Person für Arbeiten an unter Spannung stehenden HV-Systemen

• Translation: Person with Expertise for Work on Live HV Systems
• Explanation: This level is for specialist technicians who handle live HV systems. They must be capable of managing live components during troubleshooting or repairs where de-energizing is not feasible.
• Knowledge Required: Advanced skills for working on live systems, including emergency procedures and safety protocols.
• Objective: Safely manage live HV components during troubleshooting or repairs, ensuring the protection of personnel and equipment.

Conclusion

The DGUV 209-093 standard is essential for ensuring the safety and competence of personnel working on vehicles equipped with high voltage systems. By outlining clear qualification levels and tailored training for both pre-production and post-production phases, this standard addresses the unique challenges and risks associated with high voltage systems in vehicles. As electric and hybrid vehicles become more prevalent, adherence to DGUV 209-093 is paramount in maintaining safety and mitigating electrical hazards.

The comprehensive framework provided by this standard not only safeguards employees but also enhances the overall reliability and performance of high voltage systems in the automotive industry. Employers and employees alike must prioritize this training to stay compliant and protect themselves from potential dangers.

By embracing the DGUV 209-093 standard, the automotive industry can continue to innovate while ensuring the well-being of those who work on high voltage systems, ultimately contributing to a safer and more sustainable future.

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