← Back to TEC AcademyLevelAdvanced Duration3 days FormatIn person AreaEV technology
AdvancedIn person
EV technology · EV 5Battery module service, balancing and capacity testing
Professional level — 3 days / 24 hours. Safe battery opening, module inspection, EB240/EB480, balancing, EP401, charge/discharge and reuse-or-replace decision.
Training objective
Perform controlled work on an opened battery pack and service individual modules in a de-energized, safe working environment.
Who it is for
- Technicians who completed EV 1–EV 4 with confirmed safe-isolation ability
- Service technicians for battery packs
- SmartSafe partner trainers and EV specialists
Prerequisites
Completed EV 1–EV 4 and confirmed ability to isolate the HV system safely.
Course facts
Theory30%
Practice70%
Learning objectives and outcomes
- Safely open a battery pack and prepare the work zone
- Inspect modules, connectors, busbars and fuses
- Perform cell balancing with EB240/EB480
- Test capacity by charge/discharge with EP401
- Decide on module reuse or replacement
Program by day
Day 1 — Opening the pack and module inspection
Work-zone preparation, safe removal and module inspection.
Theory90 min
Instructor demonstration105 min
Hands-on work150 min
Case analysis and review60 min
Theory — Opening and inspection
- Prepare a dedicated work zone and risk assessment
- Safe battery removal and transport
- Inspect mechanical damage, water ingress and corrosion
- Check connectors, busbars and fuses
- Measure residual voltage; mark and number modules
- Measure cell voltages and inspect temperature sensors
- Safe disassembly and assembly
Practical work
- Prepare work zone and risk assessment
- Safe battery removal and transport
- Inspect modules, connectors and busbars
- Measure residual voltage and cell voltages
- Mark, number and safely disassemble modules
Day 2 — Cell and module balancing
Passive vs active balancing and controlled process.
Theory90 min
Instructor demonstration105 min
Hands-on work150 min
Case analysis and review60 min
Theory — Balancing
- Passive versus active balancing
- When balancing is justified and when it masks a fault
- Target voltage and permitted deviation
- Temperature control and recording of initial/final state
Practical work
- Use EB240 or EB480
- Connect channels and select automatic/manual mode
- Monitor the process in real time
- Export and analyze results
Day 3 — Charging, discharging and capacity testing
Controlled charge/discharge and capacity assessment.
Theory90 min
Instructor demonstration105 min
Hands-on work150 min
Case analysis and review60 min
Theory — Charging and capacity
- Prepare the module and set current/voltage limits
- Controlled charging and discharging
- Measure real capacity and analyze curves
- Identify weak or unstable modules
- Match a replacement module and perform final balancing
- Document all results
Practical work
- Use EP401
- Perform module capacity testing
- Compare two or more modules
- Decide on reuse or replacement
Practical exercises
- Safely open the pack and inspect modules
- Measure residual voltage and cell voltages
- Balance with EB240/EB480 and analyze results
- Capacity test with EP401
- Compare modules and decide on reuse/replacement
Training equipment
- P03 — check module condition and BMS data before and after service
- EB240 / EB480 — controlled balancing of cells and battery modules
- EP401 — controlled charging, discharging and real-capacity testing of modules
- RT100 / IRT01 — insulation check before working on an opened pack
Assessment and certification
Theory
- Theory test — 20% of the total score
- Covers EV architecture, HV safety, measurements, diagnostics and the course equipment
Practical exercises
- Practical exercises — 50% of the total score
- Final practical task — 30% of the total score
Completion criteria
- At least 75% of the total score
- All safety-critical procedures must be performed correctly
- A critical safety error automatically terminates the practical exam
- Maximum eight participants; hands-on work in pairs
- At least one equipment set for every two participants
- At least two vehicles, or one EV and one PHEV of different architecture
Final training outcome
TextThe participant can inspect and service battery modules, perform balancing and capacity testing, and document the results correctly.
Key points
- Professional level — fifth of six courses
- Next step: EV 6 — SmartSafe EV Professional, complex faults and final qualification
Key messageControlled module service — safe, measurable, documented.
Register your team
Ready to prepare your team for this training?
Send an enquiry and we will arrange training tailored to your team, equipment and schedule — live at the SmartSafe Europe TEC Centre in Croatia.
