In the spirit of Halloween, share electrocution horror stories you have working on HV batteries.

500 V DC? Meh. I am amazed how the power-company workers repair and replace 35,000-V-AC wires without disconnecting the power. I saw them replacing the live 35,000-V-AC wires along the whole boulevard once. Insulating gloves, sheaths, boots, and hard hats are all they need.

 

My inner schoolmarm always waggles a finger at the word 'electrocution'.

There are definitely people who have made big sparks, or felt big shocks, and later told the tale. (Even so, as much fun as that may sound, you are much better off doing your absolute darnedest not to join that club.)

However, any people who have been electrocuted are not going to be telling those tales. (Unless, perhaps, we can have those chats after we've gone where they are, which we all, eventually, will do.)

And yes, the Prius hybrid system does have the wherewithal to electrocute you.

 

Here’s one from a few weeks ago: Can't fix this electrical issue. | PriusChat

Besides that PPE and safety equipment, and others—for example, the lift truck boom is probably insulated—the electric utility workers benefit from additional elements of the hierarchy of controls:

• The utility has a policy on when live-line work is and isn’t allowed. Depending on the conditions and the work to be done, the lines and equipment may instead have to be de-energized and grounded.

• The work procedures are well defined, tested in advance, and understood by the entire crew.

• The workers have received classroom and hands-on training on safe working practices; on the inspection, use, and care of PPE and safety equipment; and on how to recognize and avoid hazards.

Toyota and other automakers have applied similar safety engineering principles for hybrid and other electrified vehicles, but they can’t remove every hazard, especially in repair situations in which some of the built-in engineering controls may have failed, as with an isolation fault or a stuck relay, for example.

I strongly recommend to read and follow the precautions explained in the Repair Manual (more info) and in Toyota’s technical training courses.