National EV Specialist Safety (NESS)

Electrical safety is paramount in handling hybrid and electric vehicles. Besides meeting the requirements of the National EV Specialist Safety (NESS) Certification, Workplace Safety and Health for Electrical Safety at Proficiency Level 1, this module focuses on electrical fundamentals that lay the foundation for understanding subsequent EV and HEV topics. The participants will be equipped with the knowledge and hands-on practice on DC & AC power, electrical circuits, the relationship between electricity and magnetism, the functions and operations of some basic electronic components such as diodes and transistors, and their applications in an electric vehicle, and the sizing and troubleshooting of electrical wires, fuses & relays.

Participants will learn how to work safely with high voltage systems to minimise risks and hazards and meet the requirements of Workplace Safety and Health (WSH) policies and procedures.

The following will be introduced and demonstrated:

• The effects of alternating and direct current on humans;
• Basic hazards associated with high voltage;
• Potential hazards that may arise from an EV that has been damaged by fire, impact or overcharging; types of suitable personal protective equipment (PPE) for EV and HEV;
• Methods that car manufacturers use to provide protection from high voltage components;
• Types of measuring equipment and tools for HEV and EV;
• EV and HEV high voltage wiring and components;
• Proper precautions and steps to isolate and reconnect high voltage components;
• Risks in the event of electrical incidents;
• Common causes of electrical accidents at the workplace.

Electric vehicles are exposed to high risk during charging. This module will introduce:

• the different types of EV chargers, their fundamentals, operations, charging modes, charging characteristics and the EV charging process. Coverage includes the Original Equipment Manufacturer (OEM) manual on EV and/or HEV charging and types of personal protective equipment (PPE) for operating in a high-voltage (HV) work environment.

Participants will also learn the functions and operations of EV motor/generator and on-vehicle control system, including the on-board charging system and regenerative braking system, i.e. the full spectrum of EV powertrain structure, configuration and operation.

The battery is a key component system of the electric and hybrid vehicle. Its importance in the safe operation & maintenance of EV & HEV cannot be over-emphasized. With the guideline from the National EV Specialist Safety (NESS) Certification on Electric Vehicle and Hybrid Electric Vehicle Battery Management, the module will cover the following:

• Types of electric vehicle (EV) and hybrid electric vehicle (HEV) battery design and configuration;
• EV and/or HEV battery characteristics and charging capacity;
• Fundamentals of EV and HEV battery charging principles;
• Functions and operations of the battery management system;
• Types of tools and equipment to perform EV and HEV battery measurement;
• Safety procedures and methods on electrical isolation on EV and HEV battery;
• Methods to conduct EV and HEV battery inspection;
• Methods to conduct EV and HEV battery evaluation;
• Methods to store and transport EV and/or HEV batteries;
• Organisational standards operating procedures (SOPs) on EV and HEV battery management;
• Original Equipment Manufacturer (OEM) manual on EV and HEV battery management
• Types of personal protective equipment (PPE) for operating in a high-voltage (HV) work environment.

Vehicle maintenance plays a key role in vehicle roadworthiness as proper maintenance can prolong the vehicle’s lifespan and reduce vehicle maintenance costs. Following the guideline of NESS TSC on Electric Vehicle and Hybrid Electric Vehicle Maintenance Management, this module covers the fundamental knowledge of EV and HEV routine servicing of non-high voltage automotive components.

Topics include:

• Differences between the electric vehicle (EV) and hybrid electric vehicle (HEV);
• Types and functions of EV and HEV systems, components and operational principles;
• Types of tools and equipment to perform routine EV and/or HEV servicing;
• EV and HEV service and maintenance plan coverage;
• Safety procedures and methods on electrical isolation on EV and HEV;
• Original Equipment Manufacturer (OEM) manual;
• Types of personal protective equipment (PPE) for operating in a high-voltage (HV) work environment.

The major systems to be covered for the maintenance will include:

• Air-conditioning system
• Brake system
• HEV engine
• Power steering
• Tire and suspension system
• Lighting and wiper systems