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⚡ HV Safety Certification — 1 Month — Admissions Open 2026
3 Weeks Online + 1 Week Intensive Offline
High Voltage Safety Training — 4-Wheeler Electric Vehicle
Last updated: February 2026 | Program by DIYguru eMobility Academy in partnership with ev.care | Recognised by NEAT AICTE & ASDC | Offline at Pune & Delhi | Live training on Mahindra e-Verito EV platform
⚡ CRITICAL SAFETY CERTIFICATION: 4-Wheeler EVs operate at 400V–800V — voltages that are instantly lethal without proper training. Every OEM, dealership, service centre, fleet operator, and first responder working on electric cars must be HV-safety certified. DIYguru pioneered India's first-ever Four-Wheeler High Voltage EV Safety Training at ADYPU Pune in September 2025 (covered by Tribune India, The Wire, Devdiscourse). This program brings that groundbreaking training into a structured 1-month certification: 3 weeks online + 1 week intensive offline hands-on at COE labs. Contact admissions at +91-9910918719 or info@diyguru.org.
1. Program Overview
The High Voltage Safety Training — 4-Wheeler EV is DIYguru's focused, safety-first certification designed to make professionals qualified and confident to work on high-voltage 4-wheeler electric vehicles. Unlike 2-wheeler EVs that typically operate at 48V–72V, electric cars from Tata, Mahindra, Hyundai, MG, BYD, and other OEMs operate at 300V–800V DC — voltages classified under Voltage Class B per ISO 6469, where contact with live circuits can cause cardiac arrest, severe burns, or death within milliseconds.
This is not a general EV awareness course. It is a dedicated safety training that covers HV system architecture in 4-wheelers, international and Indian safety standards (ISO 6469, AIS 156, AIS 038, IEC 60479, UN R100), Personal Protective Equipment (PPE) selection and usage, Lockout-Tagout (LOTO) procedures, isolation resistance testing, thermal runaway science and emergency response, CAN bus diagnostics for safety-critical faults, and complete vehicle-level safety walkthroughs — all practised on real 4-wheeler EV platforms during the offline phase.
India's electric car sales crossed 176,500 units in CY2025 (77% YoY growth, Autocar India), and the 4-wheeler EV segment is the fastest-growing category. As the 4W EV fleet scales rapidly, every authorised service centre, multi-brand workshop, fleet maintenance depot, insurance assessor, roadside assistance crew, and emergency responder needs HV-certified personnel. Without HV safety certification, working on any 4-wheeler EV is illegal and potentially fatal.
Phase 1 — Online Theory
3 Weeks
HV system architecture, safety standards (ISO 6469, AIS 156/038, IEC 60479), PPE theory, LOTO procedures, isolation testing, thermal runaway science, CAN diagnostics, 4W EV subsystems. Live demos + recorded modules + assessments.
Phase 2 — Offline Hands-On
1 Week
Intensive 5-day HV safety drills on real 4W EV (Mahindra e-Verito). PPE practice, live LOTO, isolation testing, HV disconnection, thermal runaway simulation, CAN fault reading, full vehicle safety walkthrough.
1
Month Total
400–800V
Voltage Class B
4W
EV Focused
5 Days
Intensive Offline
Why This Training Is Non-Negotiable: At 400V DC, it takes just 30 milliamps through the heart to cause ventricular fibrillation (IEC 60479-1). A 4-wheeler EV battery pack stores enough energy to power a house for days. Without proper training in HV disconnection, PPE usage, isolation testing, and emergency response, any contact with live HV circuits — even through a damaged cable or a compromised connector during routine service — can be fatal. HV safety certification is a legal and moral prerequisite for anyone working on electric cars.
Who Is This For? Automobile service technicians & mechanics working on or transitioning to 4W EVs, OEM dealership service teams (Tata, Mahindra, Hyundai, MG, BYD), fleet maintenance managers (Uber EV, BluSmart, corporate fleets), automobile engineering graduates entering EV service, insurance assessors and accident investigators, roadside assistance and towing operators, fire departments and emergency first responders, and workshop owners adding electric car service capabilities. Essential for anyone who may come into contact with a 4-wheeler EV's HV system.
2. Program Details at a Glance
| Parameter | Details |
|---|---|
| Program Name | High Voltage Safety Training — 4-Wheeler Electric Vehicle |
| Program Category | HV Safety Certification — Intensive, Compliance-Focused |
| Domain | HV System Safety, PPE, LOTO, Isolation Testing, Thermal Runaway Response, CAN Diagnostics — 4W EV |
| Duration | 1 Month Total: 3 Weeks Online + 1 Week Intensive Offline Hands-On |
| Online Phase | 3 Weeks: HV architecture, safety standards, PPE, LOTO theory, isolation testing, thermal runaway science, CAN diagnostics. Live demos + recorded modules + assessments via DIYguru LMS. |
| Offline Phase | 1 Week (5 Days): Intensive hands-on HV safety drills on real 4W EV platform (Mahindra e-Verito). PPE practice, live LOTO execution, isolation resistance measurement, HV battery disconnection, thermal runaway emergency simulation, CAN fault reading, complete vehicle safety walkthrough. |
| Vehicle Platform | Mahindra e-Verito EV & other 4W EV platforms available at COE labs |
| Offline Locations | Pune: DIYguru COE, ADYPU, Lohegaon, Pune — 412105 | Delhi: 374, MG Road, Sultanpur, New Delhi — 110030 |
| Offered By | DIYguru eMobility Academy in partnership with ev.care | Supported by IIT Delhi Tadpole Projects & EVi Technologies |
| Certifications | DIYguru Certified HV Safety Technician — 4-Wheeler EV (recognised by NEAT AICTE & ASDC) |
| Course Fee | ₹15,000 — Includes online modules, offline hands-on, certification, and career guidance |
| Eligibility | ITI/Diploma holders, automobile technicians, B.E./B.Tech graduates, service centre staff, fleet operators, first responders. Basic automobile knowledge required. |
| Contact | Phone: +91-9910918719 | Email: info@diyguru.org |
3. Safety Standards Covered
This program is built around international and Indian safety standards that govern HV work on 4-wheeler electric vehicles. Graduates understand not just the procedures but the science behind the standards — why each rule exists and what happens when it's violated.
ISO 6469
EV Safety — Electrical Safety (Parts 1–4)
AIS 156
India: Vehicle Electrical Safety & REESS
AIS 038 Rev.2
India: EV Safety & Construction
IEC 60479
Effects of Current on Human Body
UN R100
Approval of BEV Safety
ISO 26262
Functional Safety (ASIL Awareness)
4. Fee Structure
₹15,000
Includes: 3 Weeks Online Modules + 1 Week Intensive Offline HV Safety Drills + DIY Safety Assessment Project + HV Safety Certification (NEAT AICTE & ASDC) + Career Guidance Session
- 3 Weeks Online Training: HV theory, standards, PPE, LOTO, isolation, thermal runaway, CAN diagnostics — via DIYguru LMS
- 1 Week Offline Intensive: 5-day HV safety drill program on real 4W EV at COE labs in Pune or Delhi
- HV Safety Certification: DIYguru Certified HV Safety Technician — recognised by NEAT AICTE & ASDC
- All PPE & Equipment Provided: Class 0 insulated gloves, face shields, insulated tools, HV-rated multimeters, thermal imagers, fire safety equipment
- Career Guidance Session: Final-day session covering resume tips, interview readiness, and HV-specific job opportunities
5. Detailed Curriculum
Phase 1 — Online — Week 1, 2 & 3: HV Theory, Standards & Safety Protocols
Week 1
Module 1: 4-Wheeler EV HV System Architecture
Complete layout of a 4W EV: HV battery pack (300–800V), electric drive motor (PMSM/induction), traction inverter, DC-DC converter, on-board charger (OBC), HVAC compressor, HV wiring harness (orange cables). Voltage Class A vs. Class B (B1/B2) per ISO 6469. HV interlock loop — how the vehicle detects disconnected HV connectors. Service disconnect (manual service plug / pyrofuse). Contactors, pre-charge circuit, current sensors. Architecture comparison: Tata Nexon EV, Mahindra XUV400, Hyundai Ioniq 5, MG ZS EV.
Week 1
Module 2: Electrical Hazards & Human Body Effects
Physics of electrical shock — current path through the body, touch voltage, step voltage. IEC 60479-1: body current zones (DC-1 to DC-4, AC-1 to AC-4) — thresholds for perception, let-go, fibrillation, cardiac arrest. Why DC (used in EV batteries) is dangerous differently than AC. Energy hazard: capacitor stored energy >0.2J threshold (ISO 6469-3). Arc flash risk at HV disconnect points. Thermal hazards — battery cell temperatures, coolant loops, HV cable heating. Real-world 4W EV incident case studies and root cause analysis.
Week 2
Module 3: Safety Standards Deep Dive — ISO 6469, AIS 156/038
ISO 6469-1 (RESS safety), ISO 6469-2 (operational safety), ISO 6469-3 (electrical safety — insulation, barriers, enclosures, isolation resistance requirements: 100 Ω/V for DC, 500 Ω/V for AC), ISO 6469-4 (post-crash electrical safety). AIS 156 Amendment 2: RFID battery tracking, IPX7, thermal propagation testing, BMS requirements (4 temperature sensors, active parallel circuits, earth leakage detection). AIS 038 Rev.2: battery system, subsystem, and vehicle-level testing. UN R100: international type approval for BEV safety. Practical implications for technicians at each standard level.
Week 2
Module 4: PPE, LOTO & Isolation Procedures
PPE selection for HV work: Class 00 (500V) and Class 0 (1000V) insulated gloves per IEC 60903, leather protectors, glove inspection (air test, visual, electrical retest cycle). Insulated tools (IEC 60900 — 1000V rated). HV-rated multimeters (CAT III/IV). Face shields, safety shoes, flame-resistant clothing. Lockout-Tagout (LOTO) procedure: de-energisation sequence, service disconnect removal, voltage verification (live-dead-live test), energy dissipation (capacitor bleed-down wait time), isolation verification. LOTO tag documentation and communication protocols. When to LOTO and when not to — understanding HV interlock limitations.
Week 3
Module 5: Thermal Runaway — Science, Prevention & Emergency Response
Thermal runaway mechanism: internal short circuit → exothermic reactions → cell venting → gas ignition → propagation to adjacent cells. Trigger factors: mechanical damage, overcharge, manufacturing defects, external heating. AIS 156 thermal propagation test requirements — 5-minute warning before fire/explosion. Prevention: BMS thermal monitoring, cell-to-cell spacing, propagation barriers, fire-retardant materials. Emergency response: identifying thermal runaway (smoke, hissing, sweet chemical smell, HV warning lights). Evacuation protocols. Fire suppression: Class D, Lith-X, water immersion (sustained application for re-ignition prevention). First responder guidelines for 4W EV crashes.
Week 3
Module 6: CAN Diagnostics & Safety-Critical Fault Codes
CAN bus in 4-wheeler EVs — how battery, motor, inverter, BMS, VCU, and charger communicate. Reading Diagnostic Trouble Codes (DTCs) related to HV safety: isolation faults, contactor failures, BMS errors, thermal warnings, interlock violations. Using OBD-II and CAN tools to sniff live data. Understanding DTC priorities — which faults require immediate HV shutdown vs. derated operation. Post-crash safety assessment using diagnostic data. Practical workflows: what to check before touching any HV component.
Phase 2 — Offline Hands-On — Week 4: 5-Day Intensive HV Safety Drills (Pune / Delhi)
Five consecutive days of intensive, hands-on HV safety practice on real 4-wheeler EV platforms at DIYguru COE labs. Every session is supervised by certified HV safety trainers. All PPE and equipment provided.
Day 1 — EV System Architecture & HV Component Identification
Walk-around and under-vehicle inspection of 4W EV platform (Mahindra e-Verito). Identify all HV components: battery pack location, orange HV cables, service disconnect, contactors, DC-DC converter, inverter, on-board charger, HVAC compressor. Trace the HV circuit from battery to motor and back. Identify safety labels (ISO 7010–W012 HV warning symbols). Read vehicle-specific HV architecture diagrams. Document all HV access points and connector locations.
Day 2 — PPE Practice & LOTO Execution
PPE donning and doffing drill — Class 0 insulated gloves (air inflation test, visual inspection, leather protector application), face shield, insulated tools, safety shoes. Glove retest awareness. Execute full LOTO procedure on 4W EV: (1) Park vehicle, key off, wait 5 min. (2) Remove service disconnect / manual service plug. (3) Apply LOTO lock and tag. (4) Wait for capacitor bleed-down (5–10 min per OEM spec). (5) Verify zero voltage using HV-rated CAT III multimeter (live-dead-live test across HV terminals). (6) Confirm isolation. Practice multiple LOTO cycles until procedure is instinctive. Document each LOTO execution.
Day 3 — Isolation Resistance Testing & HV Measurement
Isolation resistance measurement on 4W EV: using megohmmeter (insulation tester) to measure resistance between HV circuit and chassis (must exceed 100 Ω/V for DC per ISO 6469-3). Test at battery pack terminals, inverter terminals, and OBC terminals. Interpret results — pass/fail thresholds, identifying degraded insulation. HV voltage measurement practice: safely measuring DC voltage at HV battery terminals, at inverter DC bus, at OBC output. Understanding BMS-reported isolation monitoring data via CAN. Identifying ground faults and isolation failures through diagnostic readings.
Day 4 — Thermal Runaway Emergency Simulation & Fire Response
Thermal runaway identification drill: recognising early warning signs (smoke, hiss, temperature spike on BMS, HV warning lights). Evacuation protocol practice — safe distance (minimum 15m), upwind positioning, bystander management. Fire suppression training: Lith-X extinguisher usage, sustained water application technique for fully involved battery fire, sand containment. Post-fire assessment: vehicle approach protocol, re-ignition risk monitoring (up to 24 hours). First responder coordination briefing. Real-world 4W EV incident case study analysis with root cause walkthroughs.
Day 5 — Complete Vehicle Safety Walkthrough, CAN Diagnostics & Certification Assessment
Full vehicle-level safety walkthrough: participants perform a complete pre-service HV safety check on the 4W EV from start to finish — visual inspection, PPE donning, LOTO execution, voltage verification, isolation measurement, BMS data review, CAN DTC scan, HV component inspection, and safe re-energisation. CAN diagnostic practice: reading live HV data, interpreting safety-critical DTCs, making go/no-go service decisions. Final practical assessment and certification exam. Certificate distribution, career guidance session, participant feedback, and Q&A wrap-up.
6. Offline Training Locations
DIYguru Headquarters
Delhi NCR
374, MG Road, Sultanpur, South Delhi, New Delhi — 110030
Primary HV safety training facility with 4W EV platforms, HV safety training zone, complete PPE inventory, isolation testing equipment, and fire safety apparatus.
Pune COE — ADYPU Campus
Pune
DIYguru COE, Ajeenkya DY Patil University, Charoli Bk. via Lohegaon, Pune — 412105
Site of India's first-ever 4W HV EV Safety Training (September 2025). Full COE lab with Mahindra EV platforms, industry-grade HV diagnostic tools, and dedicated safety training infrastructure.
7. Certification & Accreditation
| # | Certification | Description |
|---|---|---|
| 1 | DIYguru eMobility Academy | Certified HV Safety Technician — 4-Wheeler EV. Specialised safety certification verifiable online. Recognised by OEMs and authorised service networks. |
| 2 | NEAT AICTE | Recognised by National Educational Alliance for Technology, Ministry of Education, Government of India. |
| 3 | ASDC | Recognised by Automotive Skills Development Council (under NSDC, Ministry of Skill Development). |
8. Career Outcomes
HV safety certification is a mandatory prerequisite for any technician or engineer working on 4-wheeler EVs. Without it, OEM dealerships, authorised service centres, and fleet operators will not allow you to touch an electric car. This certification opens doors across the entire 4W EV service ecosystem.
| Job Role | Experience | Salary Range |
|---|---|---|
| 4W EV Service Technician (HV Certified) | 0–2 years | ₹20,000–35,000/month |
| HV Safety Inspector / Auditor | 2–5 years | ₹30,000–50,000/month |
| EV Dealership Service Advisor (HV Certified) | 1–3 years | ₹25,000–40,000/month |
| Fleet EV Maintenance Supervisor | 2–5 years | ₹35,000–60,000/month |
| Insurance / Accident Assessor (EV Specialist) | 2–5 years | ₹30,000–50,000/month |
| EV First Responder / Fire Safety Officer | Any | Variable (govt. + private sector) |
| HV Safety Trainer / Consultant | 3+ years | ₹40,000–80,000/month |
HV-certified technicians command a 15–25% salary premium over non-certified technicians at the same experience level. As India's 4W EV fleet scales (176,500 electric cars sold in 2025, 77% YoY growth), demand for HV-certified service personnel is growing exponentially. Key employers: Tata Motors, Mahindra, Hyundai, MG Motor, BYD, Mercedes-Benz India, BMW India, BluSmart, Uber EV fleets, insurance companies (New India Assurance, ICICI Lombard), fire departments.
9. Faculty & HV Safety Trainers
| Name | Role | Specialisation |
|---|---|---|
| Rahul Kumar | Program Lead — EV Engineering | EV Powertrain & HV Systems Integration |
| Ashutosh Dehury | Program Delivery — Battery & Safety | Battery Pack Design, BMS & HV Safety Protocols |
| Saurabh Kumar | Program Delivery — EV Automotive | AUTOSAR, CAN Diagnostics & Functional Safety |
| Ankit Khatri | Program Delivery — Automotive Testing | Automotive Testing & Safety Standards | Ex-ICAT |
| Divyvani Metla | Program Lead — Technical Operations | Engineering Operations & Safety Compliance |
| Vasheel | Program Delivery — Technical Admin | HV Diagnostics & Drive Systems |
Training Partners: This program is delivered in partnership with ev.care (DIYguru's EV service knowledge hub), supported by IIT Delhi Tadpole Projects and EVi Technologies — providing industry-grade EV hardware, embedded systems, and diagnostic tools for immersive, hands-on training.
10. Frequently Asked Questions
Q1. Is this only for people working on 4-wheeler EVs?
The curriculum is designed specifically for 4-wheeler (electric car) HV systems operating at 300V–800V DC. While the fundamental HV safety principles apply universally, the standards coverage (ISO 6469, AIS 156), vehicle architecture, LOTO procedures, and practical sessions are all 4W-specific. If you work on electric 2-wheelers or 3-wheelers (typically 48V–72V), those are Voltage Class A and do not require the same level of HV certification — though the safety knowledge is still valuable.
Q2. I'm already an automobile technician. Do I still need this?
Yes — emphatically. ICE vehicle experience does not prepare you for HV EV work. The electrical systems in a petrol/diesel car operate at 12V–48V. A 4-wheeler EV operates at 400V+ DC. The diagnostic procedures, safety protocols, tools, and emergency responses are completely different. OEM dealerships will not allow any technician to work on EV HV systems without formal HV safety certification. This program bridges that gap in 1 month.
Q3. What vehicle will I train on during the offline week?
The offline training uses the Mahindra e-Verito EV platform and other 4W EV platforms available at the COE labs. You will perform real LOTO procedures, voltage measurements, isolation testing, CAN diagnostics, and safety walkthroughs on actual production vehicles — not demonstration models.
Q4. Is all PPE and equipment provided?
Yes — all PPE and test equipment is provided at the COE labs: Class 0 insulated gloves with leather protectors, face shields, insulated tool sets, HV-rated CAT III multimeters, megohmmeters (insulation testers), CAN diagnostic interfaces, thermal imaging cameras, and fire safety equipment (Lith-X extinguishers). You only need to bring yourself.
Q5. How does this differ from the CEVT or Battery Technician programs?
The CEVT covers general EV service (motors, controllers, charging, retrofitting, batteries). The Battery Technician program goes deep into battery-specific skills. This HV Safety Training is a focused safety certification — it doesn't cover motor servicing or battery assembly, but it makes you legally and practically qualified to work safely on any high-voltage 4-wheeler EV. Many professionals take this as an add-on certification alongside CEVT or Battery Technician programs.
Q6. Is this certification recognised by OEMs?
The certification is recognised by NEAT AICTE and ASDC — the two government bodies that validate automotive and EV skills in India. DIYguru's training programs are used by professionals working at Bosch, Hyundai, Maruti Suzuki, and other major automotive companies. DIYguru pioneered India's first-ever 4W HV EV Safety Training at ADYPU Pune in September 2025, covered by national media (Tribune India, The Wire, Devdiscourse).
Q7. Can fire department / emergency first responders take this?
Yes — and they should. The program covers thermal runaway emergency response, EV crash assessment protocols, fire suppression techniques specific to lithium-ion battery fires, re-ignition monitoring, and safe approach procedures for damaged EVs. As 4W EVs become common on Indian roads, first responders need to understand HV hazards, stranded energy risks, and safe extrication procedures. The offline thermal runaway simulation drill on Day 4 is specifically designed for this.
Q8. Can I take the offline training in both Pune and Delhi?
You choose one location for your offline week during enrolment: either Delhi NCR (374, MG Road) or Pune (ADYPU Campus). Both locations have the same 4W EV platforms, PPE inventory, and testing equipment. Pune has the distinction of being the site of India's first HV EV Safety Training (September 2025).
11. How to Apply
⚡ Apply for High Voltage Safety Training — 4-Wheeler EV
Applications open for 2026. India's pioneering HV safety certification for electric cars. 3 weeks online + 1 week intensive offline at COE labs in Pune & Delhi. Live training on Mahindra e-Verito. NEAT AICTE & ASDC certified. ₹15,000.
Enrol Now → Check Your Eligibility →
Enrolment Process: (1) Submit your application via the website or call +91-9910918719. (2) Complete the admission assessment (evaluates basic automobile knowledge and safety aptitude). (3) Receive selection confirmation and complete fee payment (₹15,000). (4) Begin Phase 1 (Online) immediately via DIYguru LMS — 3 weeks of HV theory, standards, and safety protocols. (5) Attend Phase 2 (Offline) — 5-day intensive HV safety drill at your chosen COE location (Pune or Delhi). (6) Pass the practical assessment, attend career guidance session, and earn your Certified HV Safety Technician — 4-Wheeler EV certification.
© 2026 DIYguru Educational Research Pvt. Ltd. All rights reserved. NEAT AICTE & ASDC recognised. CIN: U80902DL2017PTC323930. India's first 4W HV EV Safety Training pioneered at ADYPU Pune, September 2025.
