← Back to TEC AcademyLevelIntermediate Duration3 days FormatIn person AreaEV technology
IntermediateIn person
EV technology · EV 4HV battery diagnostics and condition assessment
Advanced level — 3 days / 24 hours. Battery construction, BMS, SOC/SOH/SOP, cell voltages, temperature deviations, insulation, capacity assessment, Battery Health Report and service decision.
Training objective
Assess battery condition in detail, identify a problematic cell or module, and select the correct next service step.
Who it is for
- Technicians who completed EV 1–EV 3
- HV battery diagnosticians
- Service technicians for EV systems
- SmartSafe partner trainers
Prerequisites
Completed EV 1, EV 2 and EV 3.
Course facts
Theory30%
Practice70%
Learning objectives and outcomes
- Understand pack construction and BMS/CMU
- Analyze cell voltages, temperatures and insulation
- Assess SOC/SOH/SOP and real capacity
- Identify a suspicious cell or module
- Make a technically and commercially justified service decision
Program by day
Day 1 — Battery-pack design and management
Cell types, BMS, CMU and state parameters.
Theory90 min
Instructor demonstration105 min
Hands-on work150 min
Case analysis and review60 min
Theory — Pack design and BMS
- Lithium and NiMH battery types
- Series/parallel cell connections and pack construction
- BMS and Cell Monitoring Units
- Current and temperature sensors
- Contactors and pre-charge circuit
- SOC, SOH, SOP, estimated capacity and degradation mechanisms
Practical work
- Inspect pack construction and cell connections
- Identify BMS and Cell Monitoring Units
- Read SOC, SOH and SOP with P03
Day 2 — Battery-pack diagnostics
Cell voltages, temperatures, insulation and BMS faults.
Theory90 min
Instructor demonstration105 min
Hands-on work150 min
Case analysis and review60 min
Theory — Pack diagnostics
- Pack voltage, individual cell voltages and voltage delta
- Temperature deviations and internal resistance
- Positive and negative insulation resistance
- Contactors, pre-charge process and BMS faults
- OBD battery test and direct pack connection when supported
Practical work
- Use P03 for battery diagnostics
- Check insulation with RT100 / IRT01
- Record voltage, temperature and BMS data
- Identify a suspicious cell or module
Day 3 — SOH assessment and repair decision
Real capacity, criteria and Battery Health Report.
Theory90 min
Instructor demonstration105 min
Hands-on work150 min
Case analysis and review60 min
Theory — SOH and decision
- BMS-estimated versus real capacity
- Historical/current-data analysis and load testing
- Recognition of voltage sag and temperature deviation
- Criteria for reuse, balancing, capacity test, module replacement or pack replacement
- Battery Health Report and customer explanation
Practical work
- Final case: diagnose a prepared battery fault and create a complete condition report
Practical exercises
- Inspect pack construction and identify BMS/CMU
- Read SOC/SOH/SOP and cell voltages with P03
- Check insulation with RT100/IRT01
- Identify a suspicious cell or module
- Final case: complete battery condition report
Training equipment
- P03 — battery diagnostics, cell voltages, BMS data and topology
- RT100 / IRT01 — insulation-resistance measurement and safe-HV-state confirmation
- Multimeter and current clamps — pack-voltage and current checks
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
SmartSafe certificate
TitleSmartSafe EV Diagnostic Technician
Topics
- Issued after EV 3 and EV 4, with the Foundation level (EV 1 + EV 2) completed
- Covers advanced diagnostics and HV-battery condition assessment
- Legal authorization depends on national regulations
Final training outcome
TextThe participant can analyze an HV battery, identify the probable source of the problem and recommend a technically and commercially justified procedure.
Key points
- Certificate: SmartSafe EV Diagnostic Technician (EV 1–EV 4)
- Next step: EV 5 — Battery module service, balancing and capacity testing
Key messageA clear battery condition assessment — before opening the pack.
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.
