HV Training FAQ

DGUV Information 209-093 itself is a technical guidance document issued by the statutory accident insurance bodies – not a direct legal norm. However, the obligation to train arises from several legal sources:

• § 3 ArbSchG: Employers must demonstrably qualify employees who work on hazardous equipment
• DGUV Regulation 3 § 3: Requirement for a qualified electrical specialist for work on electrical installations (including HV vehicles from 60 V DC)
• BetrSichV § 12: Instruction before commencing work and regular repetition thereafter

A workshop working on hybrid or electric vehicles must meet the following requirements:

• At least one FHV (Level 2S) as the responsible electrical specialist on site
• FuP (Level 1S) for all staff carrying out general work on HV vehicles
• VDE-tested tools to EN 60900 (1,000 V protection)
• Insulating gloves Class 0 or 1 to EN 60903, plus further PPE
• CAT-III measuring device for voltage-free verification
• Written hazard assessment per BetrSichV
• Documented qualification records for all HV-active staff

Anyone who works professionally with vehicles or equipment operating at high voltage (60 V DC / 30 V AC or above): automotive technicians, service staff, production workers, test engineers, developers – and also breakdown services, logistics and warehouse staff in HV environments.

The required qualification level depends on the specific tasks. The HV Course Advisor matches your activities to the correct level in minutes.

It depends on the role. Staff who occasionally work near HV vehicles (reception, breakdown, logistics) need at minimum Level S/E (sensitisation). Those with no contact with HV systems and no proximity to them do not require qualification under DGUV 209-093.

In borderline cases the employer determines the requirement within their risk assessment.

Employers are legally required to maintain complete qualification records. If a valid record is missing during a workplace accident or a statutory accident insurer (Berufsgenossenschaft) audit, this can result in civil and criminal liability for the employer.

Staff without adequate qualification must not be deployed on HV systems. More on HV hazard assessment.

DGUV Information 209-093 is a publication by the German Social Accident Insurance (DGUV). It describes the requirements for qualification and protective measures for all persons working professionally on high-voltage systems. Employers are required under DGUV Regulation 1 to qualify their employees according to their specific tasks.

Key contents: qualification levels (FuP / FHV), minimum content and teaching unit requirements, entry paths A–D based on prior qualifications, trainer requirements and documentation obligations.

DGUV Information 209-093 applies from 60 V DC (direct current) and from 30 V AC (alternating current) – this is stricter than the general standard, which only classifies voltages above 120 V DC as dangerously high.

Practical consequence: even 48 V mild-hybrid systems can fall under the training obligation if they are galvanically connected to the main system.

Source: DGUV FAQ Electromobility, October 2025, Ch. 2.5

According to DGUV Information 209-093, voltages above 60 V DC or above 30 V AC are classified as high voltage – up to a maximum of 1,500 V DC or 1,000 V AC. HV systems are found in hybrid, electric and fuel-cell vehicles.

Orange cables are the internationally recognised identifier for HV-carrying conductors in vehicles.

Demand for HV-qualified specialists is growing rapidly:

• By end of 2024, more than 3 million electric vehicles were registered in Germany – with a sharply rising trend
• The EU has mandated the end of combustion engine vehicles from 2035
• Every EV requires HV-qualified technicians throughout its entire service life (15–20 years)
• Beyond passenger cars, commercial vehicles, buses, construction machinery and industrial trucks are also electrifying

The supply of HV-qualified specialists is growing much more slowly than demand. Early qualification secures long-term employability.

It depends on your role. Level S/E (sensitisation) is sufficient for staff without direct HV contact. Level 1S/1E (FuP) covers work near HV systems under supervision. Level 2S/2E (FHV) allows independent de-energisation and work in a voltage-free state. Levels 3S/3E permit live working.

The HV Course Advisor identifies the right level based on your specific activities.

• Level 1S – Fachkundig unterwiesene Person (FuP): May carry out general work on HV vehicles – but only under supervision of an FHV. No independent switching off. Typical tasks: vehicle movement, tyre changes, bodywork and interior work.
• Level 2S – Fachkundige Person Hochvolt (FHV): Electrical specialist per DGUV Regulation 3. May independently switch off, verify voltage-free status and work on de-energised HV systems. Basic requirement for any HV workshop.
• Level 3S – FHV live work: Highest qualification level. Enables fault-finding and measurements under active HV voltage with appropriate protective equipment.

The xE levels (1E, 2E, 3E) apply accordingly to development and testing before SoP – prototypes, pre-series vehicles and test rigs.

Both qualify candidates as Fachkundige Person Hochvolt (FHV) for work under de-energised conditions. Level 2S (S = Service) is designed for production vehicles and automotive service environments. Level 2E (E = Entwicklung, development) targets R&D, engineering and prototype work.

The practical focus differs; the qualification level is equivalent. Details at Level 2S and Level 2E.

FuP – Fachkundig unterwiesene Person (Level 1S/1E): May carry out general work on HV vehicles, but only under supervision and the responsibility of an FHV. No independent switching off.

FHV – Fachkundige Person Hochvolt (Level 2S / 2E / 3S / 3E): Electrical specialist per DGUV Regulations 3 & 4. May independently work on HV systems, switch off and verify voltage-free status. Full personal responsibility.

No – DGUV 209-093 clearly distinguishes between two areas of deployment:

• xS levels (Series): For vehicles after SoP (Start of Production) – production vehicles in normal operation
• xE levels (Development): For vehicles before SoP – prototypes, pre-series, test rigs

A Level 2S qualification does not authorise work on development vehicles. Development tasks always require the corresponding E qualification.

No. Level 1S/1E and Level 2S/2E are entirely independent qualification pathways under DGUV 209-093 – not a stepped system.

• Level 1S/1E (FuP) is for persons without an electrical background who carry out general work alongside HV vehicles – but do not intervene in HV systems.
• Level 2S/2E (FHV) is for qualified electrical specialists (automotive mechatronics technicians, electricians etc.) who work independently on HV systems.

Yes. Level 3S (and 3E) is a genuine advanced course – a mandatory sequence applies here.

• Level 3S requires fully completed Level 2S (DGUV 209-093, Section 5.1.5)
• Level 3E correspondingly requires Level 2E
• Level 3S/3E authorises fault-finding under active HV voltage – without Level 2S this would not be justifiable from a safety perspective

Summary: between Level 1 and 2 there is no mandatory sequence. Between Level 2 and 3 there is a binding mandatory sequence.

Entry paths define training scope based on prior qualifications:

• Entry Path A (no electrical background): up to 80 teaching units – electrical fundamentals taught from scratch
• Entry Path B (automotive mechatronics from 2013 onwards): significantly shorter thanks to recognised electrical training – approx. 16 teaching units
• Entry Path C (qualified electrical engineering background): only HV-specific modules required

The final certificate is the same – the route to it varies. The HV Course Advisor determines your entry path in 3 steps. Details: Entry Path A, Entry Path B, Entry Path C.

Automotive mechatronics technicians who qualified from 2013 onwards (under the revised training framework) bring electrical engineering foundations that are recognised for Entry Path B at Level 2S – significantly shorter training duration of approx. 16 teaching units instead of up to 80 teaching units for Entry Path A.

For qualifications before 2013, Entry Path A applies – electrical fundamentals must be taught in full.

Source: DGUV FAQ Electromobility, October 2025, Ch. 4.20

No – the DGUV and the statutory accident insurers (Berufsgenossenschaften) do not issue certifications for training providers or individual courses. The only relevant criterion is whether training content aligns with the requirements of DGUV Information 209-093.

Providers who describe themselves as "BG-certified" or "DGUV-certified" are using a misleading term.

Source: DGUV FAQ Electromobility, October 2025, Ch. 4.12

There is no regulatory approval or BG certification for HV training providers. According to the DGUV, training may be delivered by various organisations:

• OEM training centres of vehicle manufacturers
• Technical inspection organisations (TÜV, DEKRA)
• Vocational education institutions and further training providers
• Independent training providers with appropriately qualified trainers

The only decisive criterion is whether the training content meets the requirements of DGUV Information 209-093.

Source: DGUV FAQ Electromobility, October 2025, Ch. 4.18

Costs depend on level and format. Level S/E from approx. 89 EUR per person, Level 1S/1E from approx. 149 EUR, Level 2S/2E (on-site) from approx. 499 EUR per person, Levels 3S/3E from approx. 899 EUR. On-site training is often more cost-effective for groups of 3 or more.

The HV Course Advisor provides a tailored estimate. Proposals within 24 hours.

On-site training is often more cost-effective than sending individual employees to external courses – particularly from 4 or more participants. The cost per person decreases as the group size increases.

• No travel or accommodation costs for your employees
• Training tailored to your specific vehicles and equipment
• Flexible scheduling – including outside business hours
• Multiple qualification levels can be combined in a single session

We provide a non-binding group quote within 24 hours. More at on-site training.

The training scope depends not only on the qualification level but above all on the prior qualifications of participants:

• Automotive mechatronics technician from 2013: Entry Path B – significantly shorter duration (approx. 16 teaching units) thanks to recognised foundational training
• Qualified electrical engineering background: Entry Path C – only HV-specific content added
• No prior electrical knowledge: Entry Path A – up to 80 teaching units, as electrical fundamentals must be taught from scratch

The certificate at the end is the same – the route to it varies depending on prior qualifications.

Duration varies by level and entry path: Level S/E approx. 1.5 hours, Level 1S/1E half a day, Level 2S 16 to 80 teaching units (2 days to 2 weeks depending on prior qualifications), Level 2E 24 to 100 teaching units, Levels 3S/3E approx. 3 days.

Automotive technicians with electrical engineering foundations can reach Level 2S via Entry Path B in just 2 days. See all course levels.

Yes – for selected levels we offer the theory component as a structured online course via video conference. Particularly suited for:

• Annual refresher training for entire workforces – no travel required
• Level S/E and Level 1S/1E (FuP) – theory content fully deliverable remotely
• Cross-site training for teams at multiple locations

Open courses are bookable directly through the Course Calendar. On-site dates can generally be arranged within 2 to 4 weeks – or sooner for urgent needs. All enquiries are answered within 24 hours.

Yes. All qualification levels are available as on-site training at your premises, anywhere in Germany. The trainer comes to you. The programme is tailored to your specific HV systems and operational requirements. A combination of remote theory and on-site practical sessions is also available.

More at on-site training or submit an enquiry.

Yes. We deliver training in English for companies with international staff, both on-site and in the remote theory phase. Please indicate this when submitting your enquiry.

After successfully passing the learning objective assessment, we issue each participant with a digital qualification certificate in accordance with DGUV Information 209-093. It contains:

• Name, qualification level and completed training content
• Training date and issuing organisation
• Qualification record under DGUV 209-093 – for use in the employer's risk assessment
• Digital delivery – usually on the same day as training

Employers are legally obliged to maintain complete qualification records. If this proof is missing in the event of an incident, it can have significant liability consequences.

The certificate documents qualification in accordance with the requirements of DGUV Information 209-093 – independent of any specific manufacturer or system. Whether it is sufficient for a particular task is determined by the employer as part of their risk assessment.

Individual manufacturers may require additional brand-specific training. That is separate from the DGUV 209-093 qualification.

DGUV Information 209-093 does not set a fixed expiry date. The employer is required to regularly assess the qualification status of their staff. In practice, most employers require annual refresher training and a full requalification every 3 to 5 years – depending on technological developments and operational context.

Yes. DGUV 209-093 requires annual refresher training (approx. 4 teaching units) for all qualified HV personnel. This mandatory training serves as both a knowledge refresher and a documentation requirement. Without annual renewal the qualification effectively lapses.

We offer the annual refresher as a standalone module – also available via video conference for entire workforces.

HV components are all electrical parts connected to the HV system voltage:

• Traction battery (high-voltage storage, Li-ion)
• Electric motor / generator (E-machines)
• Inverter / power electronics (DC/AC conversion)
• DC/DC converter (HV to 12 V vehicle electrical system)
• On-board charger (OBC) and charging sockets (AC/DC)
• HV cables (orange-sheathed) and HV distribution units

Identification features: orange colour, warning labels (lightning bolt symbol), large cable diameter.

HV systems are considerably more hazardous than conventional 12 V vehicle electrical systems. Main hazards:

• Electric shock: cardiac arrhythmia, deep burns, death (life-threatening from 50 mA)
• Arc flash: temperatures up to 10,000 °C, irreversible burns
• Residual energy after HV switch-off (charged capacitors)
• Thermal runaway in Li-ion batteries

HV systems are life-threatening when handled incorrectly. From as little as 50 mA, fatal cardiac arrhythmia can occur. Typical accident scenarios:

• Electric shock through direct contact with live parts → cardiac arrest, internal burns, death
• Arc flash from faulty contact or incorrect tools → temperatures up to 10,000 °C, severe burns
• Thermal runaway of the traction battery → uncontrollable fire, toxic gases (HF, CO)
• Poisoning from escaping battery electrolyte or fire gases
• Delayed harm from residual energy after switching off

The 5 safety rules under DGUV Regulation 3 also apply to HV vehicles:

• Switch off (pull service disconnect, deactivate HV system)
• Secure against reconnection (remove ignition key, secure)
• Verify voltage-free status (using a CAT-III measuring device)
• Earth and short-circuit – CAUTION: do NOT short-circuit energy storage!
• Cover / cordon off adjacent live parts

Minimum standard for HV vehicles: ignition key and service disconnect stored separately, physical barrier using pylons and barrier tape with a warning sign (ISO 7010 W012). For stationary installations: isolator locked out (LOTO). For live working, also cover adjacent live parts with insulating blankets or caps (safety rule 5). Specific clearances and means are defined by the employer in the risk assessment; a clearance of 0.5–1.0 m around the HV object is widely used in practice.

→ Full explanation: HV Work Area Barriers

An FHV (Level 2S/2E or above) may enter the exclusion zone at any time. An FuP (Level 1S/1E) may only enter and work under the direct supervision and responsibility of an FHV – never independently. All other persons – colleagues, managers, customers – may enter only with explicit authorisation and under the personal control of the FHV.

No. A warning sign only prevents accidental entry – it does not prevent accidental re-energisation of the installation. The critical measure is active lockout: secure the ignition key and service disconnect separately (vehicles) or lock out the isolator (stationary systems). Barrier tape, pylons and signs are important supplements – not a substitute for lockout. The most common error in practice: the barrier is in place, but the key is still in the ignition.

The following PPE is required for work on HV systems:

• Insulating gloves Class 0 (up to 1,000 V) or Class 1 (up to 7,500 V), tested to EN 60903
• Protective helmet with face shield / visor against arc flash
• Arc flash protection clothing to EN ISO 11612 (for live working)
• VDE-tested tools to EN 60900 (1,000 V protection)
• CAT-III measuring device for voltage-free verification

Although the 4th safety rule requires earthing and short-circuiting, there is an explicit exception for energy storage units. Short-circuiting causes thermal runaway, fire and explosion hazard, and is life-threatening.

Batteries are deactivated correctly via the service disconnect; voltage-free status must then be verified using a measuring device.

No – insulating footwear (e.g. rubber boots) is not a suitable protective measure for HV vehicle work. The DGUV makes this explicitly clear in its official FAQ on electromobility.

The relevant PPE is determined by the vehicle manufacturer's specifications and the operational risk assessment. Mandatory PPE includes insulating gloves, VDE-tested tools and a CAT-III measuring device.

Source: DGUV FAQ Electromobility, October 2025, Ch. 3.2