Hi all, Im looking for some 'qualified' help and advice. I have been asked to risk assess the testing and commissioning of commercial electric vehicles which we manufacture onsite. This is a relatively new venture for us and we are becoming more involved in the development, manufacture, set-up and repair of these EV's. During the testing and commissioning of EV's there is a need to carry out 'live' working on terminals during the setting up of the vehicles throttle response. This cannot be carried out dead. I am concerned about a couple of issues:- 1. The level of training required for individuals working on electric vehicles - the voltages involved are 415 volts. 2. The safety equipment we might require. Obvious ones such as insulated tooling, rescue hooks, signage and defib set spring to mind. This is a new industry and there is a little information available within the UK. As such I have been applying the principles of The Electricity at Work regs, specifically Reg 14: Work on or near live conductors, and Reg 16: Persons to be competent to prevent danger or injury. However, this does raise a few issues with me. Training is a real concern. At the moment, my organisation has employed the use of auto-electricians as they have the understanding of auto-electrics. However, they may not have the experience required to work on 415V, nor of the risks/controls involved. I have now been told we will be assemblying batteries onsite too. This carries with it particular risks involving high voltage and high current. Again, as this is a new industry I can find little information. Can anyone provide help or contacts I could discuss my concerns with - particularly in relation to training and competency?

Yes - well aware electric forklifts have been around, as have electric milk floats and electric pallet trucks. However, the vehicles I am referring to here are more technologically advance than your standard lead-acid battery forklift. Our vehicles are standard diesel-engined commercial vans (from well known suppliers) which we convert from diesel to electric. Quite different from electric powered forklift. I should have explained that earlier.

Safety Smurf As has been highlighted in past threads constructive help, assistance and criticism is always accepted on this forum! No, this is the same electricity we all know and love, just different technology requiring significantly more setup than a forklift which in turn increases the significantly increases risk from electric shock/electrocution. My questions/request for help was quite clear...............and if you dont personnally have any experience in this field can I suggest you leave it for others to answer. Many thanks

Hi Paul Talking about voltages from the battery pack of 280v @ 300A at the terminals into an invertor. The potential for exists for these terminals to be short circuited - during the setting up of the throttle response we need to access a PCB which exposes these terminals. This is just one of the potential hazards I am trying to control. Forgive me - im not an electrical engineer so I am unsure what you mean by the 'vehicles being referenced to true earth'. There is direct contact with earth as the car is resting on its tyres the ground (not raised on a ramp). Other than that, there is not contact with earth via approved/tested earthing conncections - is this something we should consider. Potentially, the risks are even greater when fault-finding/diagnosing system failures as they need the system to be live at various points in the circuit. My concerns lie with the levels of training and competency that our guys should have. I have concerns about some engineers, I dont believe they have sufficient understanding of the risks involved and the safety measures which need to be taken. I would be keen to standardise their training - but I need advice on the type of training I should be looking at. I have suggested at minimum the engineers should be working with single ended insulated tooling and using rubber matting. However, the 'others' suggests this is not necessary!? My knowledge of electrically theory stops at 1st Uni level im afraid - no your limitations is what I say! Hence I am seeking some professional advice. Any help would be appreciated.

I will suggest that you liaise with appropriate experts (i.e electro-mechanics, manufacturer of the vehicle) who need to assess your system then they can help to design (i.e training need analysis) and carry a proper training. As it is a paradigm shift system, it might be appropriate to firstly upgrade the basic level of concerned employee in any appropriate subject(s) prior to start the above mentioned training.