Charg-Ed: Raising Global Standards in EV Safety and High-Voltage Training

 As the electric vehicle (EV) revolution continues to gain momentum, the automotive and emergency response sectors are facing a pressing question: Are your technicians truly prepared to work safely and effectively with high-voltage systems?

The rapid transition to electrification brings not only environmental and economic benefits but also new, often underestimated challenges. Chief among them are safety risks and skills gaps that threaten lives, disrupt operations, and undermine regulatory compliance.

High-voltage components are no longer confined to specialist garages—they’re becoming standard in every workshop, salvage yard, and first-responder scenario. Yet, many technicians lack the comprehensive, consistent training needed to safely manage these powerful systems. One mistake—just one—can have catastrophic consequences, from severe injury to fatal accidents.

This is where Charg-Ed steps in.

Charg-Ed exists to close the training gap and raise global standards in high-voltage EV safety. Backed by TÜV Rheinland accreditation, Charg-Ed’s training programme isn’t just another course—it’s a robust, internationally recognised certification designed to equip automotive professionals, first responders, and technical educators with the tools they need to work safely and confidently in an electrified world.

What makes Charg-Ed different is its emphasis on consistency, practicality, and adaptability. Training is delivered hands-on, with real EV components, and tailored to the specific needs of your workforce—whether you operate in a busy metropolitan garage, a rural emergency service, or an OEM facility halfway across the world.

Charg-Ed’s trainers bring more than knowledge; they bring experience. Developed by EV veterans from Salvage Wire, the programme draws on over a decade of frontline industry insight to ensure every session reflects the real-world challenges faced in today’s automotive and emergency sectors.

Charg-Ed’s reach is truly global. With over 200 technicians trained across 8 countries, the programme has supported professionals in environments as diverse as OEM assembly lines, independent garages, fire departments, and vocational schools.

Language differences? Not an obstacle. Charg-Ed is designed to accommodate multilingual learners. Remote locations? No issue—we bring the training to you. The goal is simple: to make high-quality, consistent EV training accessible wherever it’s needed.

The industries served are equally broad:

• EV manufacturers, who demand the highest standards from their production teams.
• Vehicle technicians, who face the daily challenge of diagnosing and repairing high-voltage systems.
• Emergency services, who need to respond quickly and safely at accident scenes involving EVs.
• Government agencies and educational institutions, who are responsible for shaping the EV workforce of tomorrow.

What unites them is a shared need for skilled, safety-conscious professionals who can operate around high-voltage systems without hesitation or risk.

So, why do top EV operators, public agencies, and training institutions choose Charg-Ed?

Because Charg-Ed doesn’t just train—it transforms. It transforms the way teams think about high-voltage systems, how they approach risk, and how they deliver results.

Here’s what sets Charg-Ed apart:

• ✔️ TÜV Rheinland accredited, ensuring globally recognised standards.
• ✔️ Customised delivery, adapted to your sector and operating environment.
• ✔️ Multilingual support, empowering all learners regardless of language barriers.
• ✔️ Proven international success, with deployments in both developed and emerging markets.

Charg-Ed is committed to three core outcomes:

• 👉 Safer people—so everyone goes home at the end of the day.
• 👉 Stronger standards—so businesses operate with confidence.
• 👉 A cleaner, smarter future—so the EV transition benefits everyone.

Electric vehicles are the future, but only if we train today’s workforce to handle them with the respect and expertise they demand. Safety isn’t optional. Neither is competence.

If you’re responsible for technicians, first responders, or students who interact with high-voltage vehicles, now is the time to act. Join a growing global network of organisations who are choosing to lead the EV revolution—not follow it.

Charg-Ed is ready to help you raise the bar.

📩 Get in touch to book a training session or learn more: https://www.charg-ed.com/contact

High Voltage Risk Management

Developing a comprehensive risk management document for high-voltage vehicle work is an essential part of any business owner or leader’s responsibility; the approach to risk management can indeed have dual interpretations—either seen as bureaucratic, or as a constructive framework to enhance knowledge and safety. 

 

Here’s a structured outline for a risk assessment based on the context of Salvage Wire’s level 3 electric and hybrid vehicle training:

 

1. Identifying Risks

Begin by listing all potential hazards, such as:

• High Voltage Energy: e.g. Risk of electric shock or arc flash.
• Component Weight: Potential for muscular or skeletal injuries.
• Movement of Components or Vehicles: Risks related to shifting, lifting, or manoeuvring large, heavy objects.
• Others: Any environmental hazards, such as fire or chemical exposure.

 

2. Who Could Be Harmed

Consider all personnel who could be impacted, for example:

• Technicians: Risk from handling components or electrical shock.
• Other employees: who may be in the vicinity of these vehicles.
• Visitors/Contractors: Exposure to ongoing operations.
• Public: Potential exposure if incidents occur outside controlled areas.

 

3. Current Mitigations

Document the current safety protocols in place, which could be:

• Training and Certification: Ensure that employees have level 3 HV vehicle training and are certification.
• Tools and PPE: Availability and proper use of insulated tools, gloves, visors, and other required PPE.
  
• Standard Operating Procedures (SOPs): Follow either manufacturer SOPs or company-developed guidelines for handling or working on HV components and vehicles.

 

4. Risk Matrix: Likelihood vs. Consequence

Use a grid to assess the:

• Likelihood of Occurrence: From unlikely to highly probable.
• Consequence of Incident: Ranges from minor to catastrophic.

Example:

• Risk: Working on HV vehicle without training or PPE.
• Likelihood = High
• Consequence = Catastrophic
• Overall Risk = Unacceptable

 

5. Action Plan for Improvement

After identifying unacceptable risks, list steps to mitigate them which may include:

• Action: Train employees, enforce SOPs, provide necessary PPE.
• Responsible Person: Assign a team member or manager to oversee implementation.
• Deadline: Set a clear date for completion.

Then go back to the risk matrix and determine the overall risk – is it acceptable?

 

6. Review and Update Process

The document is dynamic and should be revisited periodically:

• Incident-based Review: Following any accidents or near misses.
• Scheduled Review: Quarterly, bi-annually, or annually depending on the nature of the risks.
• Component Changes: Reassess when new technology or components are introduced.

 

7. Document Archive

Retain older versions for reference to track progress and changes:

• File Versions: Save previous and current versions to maintain a clear historical record.

 

This framework allows organisations to proactively manage risks while fostering a positive culture of continuous learning and safety. 

 

For more details about certified High Voltage training from Salvage Wire  then please check out the training pages on the Salvage Wire website - https://www.salvagewire.com/training-courses and if you would like help to complete risk assessment documents then arrange your free 1 hour consultation at https://www.salvageinsight.co.uk

 

 

 

Electric Landmines

Landmines are designed to injure or kill, they are placed to trap the unaware and could be detonated by presence, proximity or direct contact.

 

Electric vehicles may not have landmines fitted, but they can harm if you are in the presence or proximity of the vehicle or by direct contact.

 

There are four main risks to take account of:

Chemical

Electrical

Fire 

Electromagnetic

 

All batteries are chemical devices that include an electrolyte, this electrolyte can cause serious personal damage if it leaks from the battery, the battery module or battery cell. 

A Lead Acid (12v) battery will lose all of its electrolyte if damaged, the risk of this acid is well known by vehicle technicians as we have been working with these for well over 120 years.

High voltage batteries have an alkaline electrolyte that can be very harmful to health if the battery is damaged and electrolyte is leaking. It may only be a small amount of electrolyte as only the damaged cells will leak, but even in very small quantities the electrolyte can be very harmful.

 

The biggest risk is electric shock – this occurs when a person touches the vehicle and creates a circuit through their body – this could be between two points on the vehicle or between the vehicle and an earth point. The heart is very vulnerable to electric shock and a small amount of voltage and current is needed to put the heart into ventricular fibrillation, which means that the heart is not pumping blood around the body. Almost all hybrid vehicles and every plug-in vehicle (hybrid or full EV) carry lethal amounts of voltage and current.

 

Fire can happen in any vehicle, it doesn’t matter what type of power source; the risk is that with high voltage vehicles the consequences could be much more severe.

An arc flash is where the electricity jumps an air gap – this superheats the air and can seriously burn a technician if they are close to the arc flash. Equally the arc could ignite substances nearby (fuel vapour from depollution for example) which may cause an explosion.

Batteries do catch fire (although far less than the press reports would have you believe) and they could burn for 3-5 hours, need large volumes of high pressure water (over 10,000 litres or 2,500 gallons) that will require the fire services to establish a pump connection to a fire hydrant. 

 

Electromagnetic fields in a high voltage system can impact heart pacemakers, so anyone that has one of these fitted should not work on one of these vehicles. These vehicles are perfectly
safe to drive, plug in and operate if you have a pacemaker – just do not work on them when they are live.

 

How do you protect yourself from these electrical landmines? -Easy, be trained, have the right HV tools, HV Personal Protective Equipment and follow the manufacturer processes.

 

Training is absolutely essential, vehicle technicians need to use a training provider that is offering accredited and certificated training courses that include awareness of risks, how to work safely and practical assessments. Without these the technicians will not have the right awareness, knowledge of how to complete the work and the confidence to complete high voltage operations.

HV tools range from insulated hand tools, through cat 3, 1000 volt multimeters or voltage detectors and vehicle scan kit.

HV personal protective equipment (PPE) includes class 0, 1000v rated electricians safety gloves, 1000v rated safety footwear or rubber mat, face or eye protection, full length overalls, safety rescue hook, and warning signs and barriers.

Eintac can supply all HV tools and PPE required, have a look at https://eintac.com/shop/ and use Discount Code ES10 for 10% off

Correct processes can be obtained from the vehicle manufacturer and many other sources – see the end of this article for some of those that are available.

 

If the technician has been trained, they have the tools, the PPE and they follow the process then they will be able to avoid the electrical landmines and get home to their families at the end of each working day.

 

Salvage Wire has developed specific and accredited Electric Vehicle dismantling training that is available at 4 levels which equips every person in every recycler with the knowledge, understanding and confidence to work on these vehicles, for more details email training@salvagewire.com

 

 

Resources

Some are free of charge, others do carry a cost.

Training

ARA University has on-line training https://arauniversity.org

Salvage Wire complete accredited training at 4 levels, taking technicians through the process and keeping them safe find out more at https://www.salvagewire.com

 

Education

The ARA Hybrid Vehicle Technology book is available as a free download from ARA University https://arauniversity.org/electric-hybrid-vehicle-technology-guide/

Electric and Hybrid Technology book https://www.tomdenton.org

 

Disconnection and Dismantling Processes

International Dismantling Information Service https://www.idis2.com

Rescue Sheets http://rescuesheet.info/seite_3.html

EV Fire Safe https://www.evfiresafe.com

 

Phone and Tablet Apps

Euro Rescue

You Have To Get Your Feet Wet

 ‘When the priests got to the Jordan and their feet touched the water at the edge, the flow of water stopped…The river went dry…..and the people crossed.” (Joshua 3 14-16)

There is so much leadership wisdom in this short passage - especially when you understand what preceded this.

The Israelites were moving from Egypt to the promised land, they had spent 40 years in the wilderness and had to cross the Jordan River to take control of the land flowing with milk and honey. They didn’t wait for the river to stop flowing or for a bridge to be built. No, they started out and got their feet wet before the river stopped flowing and they could cross into the promised land on dry ground.

In our business lives we should be looking at how to move forward into new pastures or new opportunities and as we do this we see the barriers ahead of us. It could be knowledge, registration or licensing, resource, equipment or much more, so we research, prepare, register, practice but we cannot move forward until we have put our feet into the water. 

The Israelites spent 40 years in the wilderness preparing, they didn’t wait for a miracle to occur before they moved across the Jordan River, they put their feet in and the river stopped flowing. 

Your may want to move your business forward or instigate change in the way it operates, but all you can see is that river in front of you that is stopping you from moving forward. It is time to take action; spend a few months preparing the changes or preparing for that forward movement, but the river doesn’t open up and welcome you in, you have to take a step or a leap of faith, get your feet wet and step into the change, or into that opportunity and watch it open up as you move forward.

You may just get your feet wet, you may go a little deeper and push forward, but there comes a time where the water starts to drop and you are through to the other side, or you may have to retreat, review, change and then put your feet in the water again. There is no fear of failure, if what you are doing doesn’t work then retreat and adapt, and there are two absolute rules here - never go so far that you are in danger of drowning and never retreat and go back in again without reviewing, changing and adapting the plan - a sign of insanity is doing the same thing each time and expecting a different result.

Over the last two years Salvage Wire have developed a number of new programmes for various clients, and in all cases we planned, prepared, and practiced before we took the plunge and made the changes, and as the changes or the new programmes were implemented we reviewed regularly, changed and adapted what we were doing so we could reach the other side. Yes, we got our feet wet, but only our feet and our clients are now on dry ground looking back at what they used to be whilst marching forward towards their new goals.

If you have an idea, and you are seeing a river blocking your way to that new idea, then contact Salvage Insight, enter your details and join us for a free 1-hour consultation where one of our consultants can discuss your idea in more detail and formulate an action plan for you. Find out more at  https://www.salvageinsight.co.uk/

New High Voltage training for vehicle dismantlers and recyclers

Very soon after starting Salvage Wire we identified a need for high voltage vehicle training

specific to vehicle dismantlers and recyclers, so we wrote training and got it accredited. Over the last couple of years we have seen vehicle technology change very rapidly and we have just completed a review and re-write of the training.

Previously there was one training level, now due to the changes we have seen in high voltage technology there will be four training levels for vehicle dismantlers that reflects the increased level of technology in the vehicles and the changing needs in the vehicle salvage and dismantling industry. This new training provides a tiered approach to training that helps develop vehicle dismantling and recycling technicians, raises their knowledge, understanding and competence with these vehicles and the technology, and increases professional standards across the industry.

The training is specifically designed for vehicle dismantlers, it is accredited by the Chartered Institute of Waste Management, and will soon be certified by TUV Rheinland - an organisation that will give global certification for the training; 

The training is at four levels and certification is valid for three years. Level 1 is awareness for leaders and managers. Level 2 is the lower level of technical training for technicians working on the vehicle that has already been made safe. Level 3 is higher level technical training for ‘live’ vehicles and Level 4 is battery strip. 

Level 1 - informs leaders, owners and senior managers about High voltage vehicles, what they need to do to keep their staff, their customers and their business safe; the processes and procedures required along with the risks of these vehicles and the need to invest in training, tools and PPE.

4 hours duration including theory training, practical demonstration, and assessment and this training can be face-2-face or on-line/remote

Level 2 is for vehicle technicians, parts storage and shipping, and drivers collecting vehicles and gives them the knowledge and confidence to work on high voltage vehicles after the vehicle has been made safe; to remove, store, sell and ship high voltage components.

Technicians, parts team and drivers can start at Level 2 - they do not need to complete level 1 first, but they must be working in the vehicle salvage and recycling industry.

8 hours duration including theory training, practical training, and assessment. Training must be face-2-face

Level 3 for vehicle dismantling technicians and drivers collecting vehicles and enables them to safely assess and work on high voltage vehicles that are ‘live’; make them safe and confirm disconnection before continuing to dismantle the vehicle themselves or handing the vehicle to a Level 2 person for further dismantling; they also become the point of reference for technical queries and processes. Candidates for Level 3 MUST have completed Level 2 training within the previous 12 months

8 hours duration including theory training, practical training, and assessment. Training must be face-2-face

Note: A fast track level 2 and 3 training can be completed over a two-day period.

Level 4 – technicians will be able to assess and dismantle high voltage battery packs, store modules correctly and prepare for shipping. They will also understand the process to re-manufacture, balance, and test batteries.

There are 2 entry options for Level 4:

1. Vehicle Dismantlers for Level 4 MUST have completed Level 3 training within the previous 12 months 
2. Battery Dismantlers for Level 4 must have completed Level 1 within the previous 3 months Note: Core product businesses do not dismantle vehicles; they just deal with components that have already been removed so levels 2 and 3 are not appropriate - hence the option for battery dismantlers to jump straight into level 4

8 hours duration including theory training, practical training, and assessment.

So much of the work that Salvage Wire complete is dedicated to helping vehicle recyclers become leaders in their industry and this is another example of how Salvage Wire are raising professional standards, keeping people and businesses safe, helping them to become better, train and retain staff, and grasp the new opportunities that high voltage vehicles bring.