Mandatory HV PPE – Complete Overview
The following equipment is required by DGUV 209-093 and the underlying standards EN 60903 and EN 60900. The exact requirements differ depending on whether the work is voltage-free or live HV work.
EN 60903
Insulating Gloves Class 0
Rated to 1,000 V AC. Required for standard de-energisation and voltage-free work on production HV vehicles (Level 2S/2E).
EN 60903
Insulating Gloves Class 1
Rated to 7,500 V AC. Required for live HV work (Level 3S/3E). Must be used with outer protective leather gloves.
CAT III / IV
Digital Multimeter
CAT III minimum for vehicle HV systems (up to 600 V at distribution level). CAT IV for some high-energy applications. Must be in calibration.
EN 60900
Insulated Tools
All hand tools must be rated 1,000 V to EN 60900 when used near active or recently de-energised HV components.
Inspection and Testing Requirements
PPE that is damaged, past its test date or of unknown origin must never be used on HV work. The employer must maintain records of all PPE inspections:
- Insulating gloves: visual pre-use inspection (inflation test); periodic electrical retest every 6 months per EN 60903
- Multimeter: annual calibration check; probe cables and fuses must be checked before use
- Insulated tools: visual inspection before each use; replace any tool with cracked, split or missing insulation immediately
- Face shield / visor: inspect for cracks, scratches impeding vision or damaged retaining straps; replace annually or when damaged
Employer Obligations
Under §4 and §5 of the German Occupational Safety Act (ArbSchG) and the PSA-Benutzungsverordnung, employers must:
- Carry out a PPE risk assessment and select appropriate equipment for each task
- Provide PPE free of charge to all employees who require it
- Train employees in the correct use, care and storage of PPE
- Maintain an inspection log with testing dates and results
- Replace PPE that is damaged, worn or has exceeded its service life
Is a face shield always mandatory for HV work?
A face shield is mandatory for
live HV working (Level 3S/3E). For voltage-free work, the need for a face shield depends on the task-specific risk assessment – for de-energisation procedures with CAT III meter, many workshops require it as standard practice. When in doubt, wear one.
Do HV PPE requirements apply to hybrid vehicles too?
Yes. DGUV 209-093 and the associated PPE requirements apply to all vehicles with a nominal voltage above 60 V DC, which includes all plug-in hybrid (PHEV), full hybrid (HEV) and battery electric (BEV) vehicles. Mild hybrids with 48 V systems are generally exempt, but always verify the actual system voltage before working.