DGUV 209-093 – HV Qualification

HV Training for Battery Production

Level 2E qualification for all staff working directly on HV battery systems – from cell formation (up to 1,000 V DC) to module assembly, pack integration and testing. Inhouse at your production facility, including thermal runaway module.

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2E
Level 2E
Mandatory for all staff with direct HV contact in production
1kV
400–1,000 V DC
Operating voltages in battery cell production
TR
Thermal Runaway
Li-Ion specific hazard module included
24 h
Quote after your enquiry
HV Qualification

Why Battery Production Requires Level 2E Training

Battery cell manufacturing operates at voltages between 400 V and 1,000 V DC – far above the 60 V DC threshold defined in DGUV 209-093. All staff with direct HV contact (cell formation, cycler maintenance, module interconnection, pack integration, HV test benches, charger maintenance) require at minimum Level 2E (FHV Development & Production). Staff present in the production area without direct HV contact need at minimum Level S/E (Sensibilisierte Person). We create a complete qualification matrix for your team.

Battery production adds specific hazards not found in standard vehicle work: thermal runaway in Li-ion cells, formation cycling equipment, high-current interconnections and electrolyte exposure. Our Level 2E training includes dedicated modules on Li-Ion electrochemistry hazards, thermal runaway recognition and response, safe handling of formation equipment, module and pack connector systems and CAT-III verification procedures. Reference facilities: BMW Cell Manufacturing Centre Munich, VW PowerCo Salzgitter, CATL Erfurt, Northvolt Heide, Samsung SDI Hungary.

Cell Formation & Cycling
Direct HV exposure up to 1,000 V DC → Level 2E required
Module Assembly
HV interconnections → Level 2E or 1E
Pack Integration & BMS
System voltages up to 1,000 V DC
HV Test Benches & Labs
Level 2E / 3E depending on test scope
Battery Recycling & Second Life
Residual energy → Level 2E required
DGUV 209-093 Qualification Levels

Available Courses

Level S/E
Sensibilisierte Person
HV awareness for all staff near HV vehicles. Safe behaviour around damaged or intact HV systems.
€89per person
Level 1S / 1E
Fachkundig unterwiesene Person (FuP)
General work on HV vehicles under FHV supervision. For service technicians and production staff.
€149per person
Level 2S
FHV Series Vehicles
Independent switching off, voltage-free verification and work on de-energised HV systems. Legal minimum for workshops.
from €699per person
Level 2E
FHV Development & Production
Full qualification for pre-SoP vehicles, prototypes, test rigs and battery production.
from €999per person
Level 3S / 3E
FHV Live HV Work
Highest qualification level – fault-finding and measurements under active HV voltage.
€1,099per person
Questions & Answers

FAQ

Level 2E (FHV Development & Production). Formation cycling operates at voltages up to 1,000 V DC. All staff with direct contact to formation cyclers and HV interconnections require Level 2E. Logistics and support staff without direct HV contact require Level S/E minimum.
Yes. We coordinate shift-by-shift rollouts so production continues uninterrupted. For large facilities, we create a multi-week training calendar covering all shifts and departments. Minimum group size: 5 participants per session.
Yes – our Level 2E battery production module explicitly covers Li-Ion electrochemistry hazards, thermal runaway triggers and early warning signs, correct emergency response procedures and first aid for HV accidents. This is a mandatory module for all battery production training.
It depends on prior qualifications. Electricians with relevant certification (Entry C): approx. 2 days theory + 1 day practical. Staff without electrotechnical background (Entry A): up to 10 training days. We assess your team's entry level in a brief pre-training consultation.
Quote & Booking

Request HV Training for Your Battery Plant

We come to your facility – across Germany and internationally. Describe your production environment and team size, and we will send a tailored qualification plan and quote within 24 hours.

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