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EV High-Voltage Safety Trainer

EV-400
The EV-400 EV High-Voltage Safety Trainer represents a fully functional battery electric vehicle (BEV) in a compact classroom sized package. It provides an intuitive, hands-on experience for high-voltage testing, Personal Protective Equipment (PPE) use including gloves and insulated tools, high voltage isolation testing with a mega-ohmmeter, high voltage interlock circuits, first responders’ loops, three phase motor control, high voltage power distribution, and much more. The product has a fault box and a faulty component, allowing diagnostic practice. The system reacts as a real BEV, demonstrating functions of various scenarios and components. All in a completely safe, controlled, classroom environment.

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DESCRIPTION

The ConsuLab EV-400 High-Voltage Safety Trainer includes student assignments and practical exercises that (when combined with the required prerequisites) prepare a technician or instructor to successfully complete the CSA Group Automotive Electric Vehicle Technician Certification.This innovative product is perfect for: Technical training programs: automotive, electrical engineering, emergency response. Educational institutions: motive power trades, vocational schools, community colleges, and high schools. EV manufacturers and repair shops: upskilling technicians and ensuring safety protocols.

The EV-400 is available as a single unit, or as a classroom set with mobile, locking storage cabinet.

EDUCATIONAL ADVANTAGES

  • Students experience the full power of EV systems with real-world voltage, completely safeguarded for student interaction.
  • Comprehensive Simulation: From start to drive motor, the EV-400 replicates the full functionality of an EV, providing an immersive learning experience.
  • Understanding & Usage of Personal Protection Equipment (PPE)
  • Identification of High-Voltage Components
  • High-Voltage Measurements Verification
  • Circuit Insulation & Isolation Testing
  • Lockout/Tagout Demonstrations with Faraday Cage
  • 3 Phase Motor Functionality via Oscilloscope

FEATURES

  • Fault box with 10 faults + 1 faulty component. Hone your diagnostic skills with a built-in fault box simulating common EV issues.
  • Measurable 400V DC and 3 phase motor signals. Experience the full power of EV systems with real-world voltage, completely safeguarded for student interaction.
  • Comprehensive Simulation: From start to drive motor, the EV-400 replicates the full functionality of an EV, providing an immersive learning experience.
  • Includes a printed paper copy of operation manual with schematics, and access to PDF files for student activities and instructors guide.
  • Live loss of isolation (LOI) detection
  • 4 different fault indicator lights (12v, high voltage, isolation, interlock.)
  • Compact & Portable: Thie unit easily stores and transports, making learning accessible anywhere.
  • Available as a single unit, or as a classroom set with mobile, locking storage cabinet.
  • Includes High Voltage gloves and PICO Insulation Tester

APPLICATION

  • A generic electric vehicle, with a common system configuration based on numerous popular manufacturers and models.

Topics, laboratory exercises, and tests performed on this training system are as follows:

Overview of Electric Vehicles (EVs)

  • Importance of High Voltage Systems
  • Safety systems and vehicle construction
  • What is high voltage?
  • Effects of high voltage on your body

Safety and operations

  • Starting and driving an EV
  • Operational modes of electric vehicles
  • Emergency Procedures for first responders
  • Power: what carry’s and stores high voltage

Basic Electric Vehicle Concepts

  • Electric Vehicle Architecture
  • High Voltage Components and Systems
  • Battery Technology and Management Systems

High Voltage System Components

  • Electric Drive System
  • Battery Pack and Management
  • Power Electronics
  • Charging Systems

Equipment Overview

  • Equipment Description
  • Testing equipment with high voltage systems
  • Components
  • Setup and Installation Instructions

Hands-On Training Modules

  • Module 1: High Voltage System Introduction
  • Module 2: Battery Pack testing and Safety
  • Module 3: Service disconnect
  • Module 4: Live dead live testing
  • Module 5: Electric Drive System Operation
  • Module 6: Power Electronics Demonstration
  • Module 7: Testing interlock circuits
  • Module 8: Testing for high voltage leak test
  • Module 9: Components and function (DC/DC)
  • Module 10 Ground testing
  • Module 11: Contactor testing including pre-charge circuits

Troubleshooting and Maintenance

  • Common High Voltage System Issues
  • Diagnostic Procedures
  • Preventive Maintenance Guidelines

Case Studies and Real-World Examples

  • Analysis of Electric Vehicle Incidents
  • High Voltage System Maintenance

Certification testing

  • Overview of Applicable Regulations
  • Testing

Glossary of Terms

  • Key High Voltage System Terminology

EV-400 transcends the limitations of traditional trainers. It’s not just about demonstration; it’s about active engagement, hands-on learning, and real-world application. This innovative tool is perfect for:

  • Technical training programs: automotive, electrical engineering, emergency response.
  • Educational institutions: universities, vocational schools, community colleges.
  • EV manufacturers and repair shops: upskilling technicians and ensuring safety protocols.

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