Day 1 – EV Systems Overview & High-Voltage Safety

• Introduction to EV architecture and key components
• Understanding power flow: batteries, motors, controllers, and more
• High Voltage Power Distribution Units (HVPDU), Precharge Circuits, HVIL
• EV safety hazards and personal protective equipment (PPE)
• Knowledge check: EV systems and safety fundamentals

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Day 2 – Electrical Theory, Tooling & Wiring

• Ohm’s Law, resistance, voltage spikes, and EMI in EVs
• CANbus communication and system isolation
• Tooling essentials: crimpers, depinning tools, connector assembly
• Hands-on practice: wiring, fusing, crimping, connector builds
• Knowledge check: Electrical tooling and wire selection

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Day 3 – Programming: BMS, Inverters & Displays

• Orion BMS 2 programming: cell balancing, contactor control, SOC drift points
• Inverter programming with RMS GUI: tuning, regen, shudder compensation
• Digital display configuration using AEM CAN Dash
• Knowledge check: EV programming concepts and applications

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Day 4 – Wiring Diagrams, Component Layout & Bench Build

• Schematic analysis: motor wiring, BMS, charger, HVAC systems
• Wire management strategies for EVs
• Hands-on: physical bench build using schematics and real components
• Labeling, layout, and system checks before power-up
• Knowledge check: Bench wiring and setup fundamentals

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Day 5 – Drive, Diagnostics & Root Cause Analysis

• Drive and tune a real EV conversion vehicle
• Experience inverter tuning effects in action
• Scenario-based troubleshooting: diagnostics with live faults
• Root cause analysis framework: from problem to solution
• Final reflection, hands-on evaluation, and certificate presentation

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