Training and Certification
Level 2 Overview and General Information
Level 2 Training
Outline and Outcomes
Level 2 Training and
Certification Standards
Level 2 Training Event Host Requirements
Level 2 Program
Webinar Presentation
Level 2 Outline and Outcomes Outline and Outcomes
The outcomes of the Pro+ training Level 2 course is designed to provide instructors and service professionals with information and skills that are inclusive of technical metrics governed in core technologies and industry standards of:
- High Voltage Battery and Control Systems
- Diagnostics, Analysis, Service, and More
- When documenting vehicle High Voltage Battery Pack systems information students shall be able to use proper vehicle electrification terminology and acronyms
- When provided physical Battery Packs or pictures/graphics of Battery Packs the students will be able to identify the Battery Pack type, how it is mounted in specific vehicle types, cooling system type, and kW-h rating
- When provided a physical component or graphic diagram of a High Voltage Battery Pack, students will be able to identify each major component and define its function
- Remove and replace an Electric Vehicle, Hybrid Electric, Plug-In Hybrid, or Fuel Cell EV Battery Pack from a vehicle using the prescribed OEM procedures, processes, tools, and equipment
- Determine High Voltage Battery Pack SOH, with the Battery Pack installed in the vehicle, using a Scan Tool and Specialized Testing Tools
- List the major failure modes, and the causes of each, for NiMH and Lithium based battery chemistries
- When provided with Battery Pack module/cell Power Tests and Capacity (Energy) test signatures, the Students will be able to determine module/cells SOH
- Leak test a High Voltage Battery Pack using OEM procedures and specialized tools and equipment, and articulate why leak testing is required
- Disassemble and reassemble High Voltage Battery Pack, using OEM and battery industry service and technical information
- Articulate how the High Voltage Battery Pack SOC% level can effect the electric propulsion, HVAC, and Charging systems
- Perform Isolation Tests on the High Voltage Battery Pack systems using an Insulation Meter
- Describe the difference between a High Voltage Fuses vs. Pyro Fuses
- Articulate how High Voltage Contactors internally quench electrical arcs
- Compare and Contrast battery module/cell connection methods when battery cells are connected in series & parallel during manufacturing
- Explain how the battery pack is used as a structural member of the vehicle body & chassis system
- Define how the High Voltage Battery Pack Contactor and Pre-Charge Contactor system operates by listing its sequencing during a vehicle Power ON cycle
- Articulate how the High Voltage Battery Pack SOC% level can effect the electric propulsion, HVAC, and Charging systems
- Summarize the control and diagnostic system for the High Voltage Battery Contactor system when provided a Contactor software timing diagram
- Explain the operation of the High Voltage Battery Pack Current Sensor during propulsion and regenerative braking, including providing the resolution (scaling) of the sensor
- Summarize the rationale for the use of insulated tools during High Voltage Battery Pack servicing, and cite the requirements standards
Outline of Training
- HEV & BEV Systems
- Battery Pack Power & Physics
- Battery Power & Capacity Specifications: kW vs. kW-h vs. A-h
- Battery Module & Cell Configurations
- Shielded Cable and Connectors
- Manual Service Disconnect (MSD), Fuse, and Pyro Fuse Systems
- Battery Cell and Module Bus Systems (Bus Bar, Ω Weld, Laser Bus Bar, Laser Wire Bond)
- HV Contactor and Pre-Charge Circuits and Controls
- Sensors: Temp, Air, Voltage, and Current
- Battery Module & Cell Ratings
- Nickel-Metal Hydride (NiMH) Technology (HEV only)
- Cylindrical & Prismatic
- Lithium-Ion Battery Cell Technologies (HEV & BEV)
- NCA, NMC, LiFePO4, LTO, LMO, & Solid State
- 18650, 2170, 4680 Cylindrical; Pouch; Prismatic
- Battery Management Systems (BMS): NiMH & Lithium
- NiMH BMS Systems
- Lithium Family BMS Systems
- Major Sub-Topics for NiMH & Lithium
- Voltage Sensing Electronic Circuits & Isolation ICs
- Cell Balancing Systems: Amplifier, Transistor, & Resistor Systems
- Opto-Isolating or DC-DC Converter IC HV to LV Isolation Systems
- Multiplexing, Microcontroller, and Software Controls
- Battery State Estimator (BSE) State-of-Charge (SOC%) Estimation
- Displayed vs. Actual SOC% / Usable SOC% vs. Displayed
- Cell & Module Failure Modes, Aging, Power Fade, and Capacity Fade / Loss
- Cell Material, Geographic, Terrain, Driving Cycle, and Aging Functions
- NiMH and Lithium Specific Failures and Failure Modes
- Battery Testing and Diagnostic Methods: HEV, PHEV, & BEV
- OEM On-Board Diagnostics: Strengths, Weaknesses, and Limitations
- On-Board & Road Testing (Stress Testing Method and Metrics)
- Battery Pack Loading on Stress Test
- Battery PID Data During Testing
- Battery Cell Technology vs. PID Data
- Off-Board Testing: Power & Capacity Testing, IR, & Thermal Testing
- Power Test Standards (HEV, PHEV, BEV)
- Power Test Signatures
- Capacity Testing Standards
- Capacity Test Signatures
- NiMH & Lithium Families (NCA, NMC, LiFePO4, LMO, LTO)
- Thermal Testing/Monitoring: During Power, Capacity, & Off-Board Charging
- Internal Resistance (IR) During Power Testing
- Required Tools & Equipment to perform Servicing & Standardized Testing
- On-Board Diagnostics
- Scan Tool PIDs & DTCs
- Scan Tool Special Functions or Output Controls
- Battery Pack Field Special Service Considerations
- Battery Controller Replacement: Capacity Relearn Function
- HEV & PHEV; EREV & BEV
- Rebuilding & Remanufacturing (Pros; Cons; Process)
- Introduction to High Voltage Battery Pack Heating & Cooling Systems
- Air & Liquid Heating & Cooling
- PTC Heating
- A/C Cooling
- Isolation Fault Testing (On-Board & Off-Board)
- Leak Testing (Pressure/Smoke Testing)
- Equipment
- Ingress Protection – IP67 & 68 Requirements
- Battery Pack Repurposing and Recycling