EV-400 High Voltage Vehicle Training System

EV High Voltage Safety EV-400

ConsuLab Ohm's Law CL-1919 Classroom Pack

ConsuLab Classroom Package of Electrical Trainers

Electric Vehicle Training System

ConsuLab High Voltage EV-400

Model #EV-400

EV High Voltage Safety and Disconnect Trainer

We are proud to announce our newest training system for Automotive and Electric Vehicle classrooms, the EV-400 High Voltage Safety and Disconnect Trainer from ConsuLab.

EV-400: Mastering Electric Vehicles in a Safe, Interactive Environment
The EV-400 is a groundbreaking interactive high voltage trainer designed to revolutionize the way we teach and learn about electric vehicle (EV) systems. This premier tool goes beyond mere demonstrations, empowering students to actively test, explore, and diagnose real-world EV scenarios in a completely safe environment.

Combining fundamental and foundational skills in electrical concepts with EV-specific training content in high voltage circuits and first-responder loops, the EV-400 is a must-have training tool for modern automotive classrooms. With over 90 testable functions, the EV-400 allows students to hone diagnostic skills with a built in fault box emulating common EV High Voltage issues.  It’s not just about demonstration; it’s about active engagement, hands-on learning, and real-world application.

The system provides students hands-on learning in high voltages, EV isolation practices, and gives students safe and effective access to MEASURABLE 400V high voltages.

Available in single training systems or as classroom packages of 12 training systems.

Pricing upon request

Product Documents

Ohm's Law & DC Circuit Trainer

Software package




Unique Features:

  • Measurable 400V: Experience the full power of EV systems with real-world voltage, completely safeguarded for student interaction.
  • Comprehensive Simulation: From start to drive motor, the EV-400 replicates the full functionality of an EV, providing an immersive learning experience.
  • 90+ Testable Functions: Dive deep with over 90 real-world tests using digital multimeters, insulation testers, oscilloscopes, and more.
  • Functional Fault Box: Hone your diagnostic skills with a built-in fault box simulating common EV issues.
  • Compact and Portable: This tabletop unit easily stores and transports, making learning accessible anywhere.

EV-400 transcends the limitations of traditional trainers. It’s not just about demonstration; it’s about active engagement, hands-on learning, and real-world application. This innovative tool is perfect for:

  • Technical training programs: automotive, electrical engineering, emergency response.
  • Educational institutions: universities, vocational schools, community colleges.
  • EV manufacturers and repair shops: upskilling technicians and ensuring safety protocols.
  • The EV-400 is more than just a trainer; it’s an investment in the future of EV education. By providing a safe
    and interactive learning environment, it empowers students to become the next generation of EV experts.
  • The EV-400 is available as a single unit, or as a classroom set with mobile, locking storage cabinet.


Topics, Laboratory Exercises, and Tests

Overview of Electric Vehicles (EVs)
Importance of High Voltage Systems
Safety systems and vehicle construction
What is high voltage?
Effects of high voltage on your body

Safety and operations
Starting and driving an EV
Operational modes of electric vehicles
Emergency Procedures for first responders
Power: what carry’s and stores high voltage

Basic Electric Vehicle Concepts
Electric Vehicle Architecture
High Voltage Components and Systems
Battery Technology and Management Systems

High Voltage System Components
Electric Drive System
Battery Pack and Management
Power Electronics
Charging Systems

Equipment Overview
Equipment Description
Testing equipment with high voltage systems
Setup and Installation Instructions

HandsOn Training Modules
Module 1: High Voltage System Introduction
Module 2: Battery Pack testing and Safety
Module 3: Service disconnect
Module 4: Live dead live testing
Module 5: Electric Drive System Operation
Module 6: Power Electronics Demonstration
Module 7: Testing interlock circuits
Module 8: Testing for high voltage leak test
Module 9: Components and function (DC/DC)
Module 10 Ground testing
Module 11: Contactor testing including precharge circuits

Troubleshooting and Maintenance
Common High Voltage System Issues
Diagnostic Procedures
Preventive Maintenance Guidelines

Case Studies and RealWorld Examples
Analysis of Electric Vehicle Incidents
High Voltage System Maintenance

Certification Testing
Overview of Applicable Regulations Testing

Glossary of Terms
Key High Voltage System Terminology

Learning Topics

  • A6 - Electrical/Electronic Systems
  • Automotive Technology
  • Electric Vehicles and Hybrids
  • STEM

Grade/Skill Level

Designed for:

  • High School
  • Industry
  • K-8
  • Technical College
  • University

Additional information



Automotive I Diesel I Hands-On Training I Electronic Systems I Ohm's Law & DC Circuits Training Systems I Operational Theory of Electrical/Electronic Circuits I NATEF and Red Seal Tasks

ASE Categories

A6, L3

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All ConsuLab products begin as OEM components found in industry. Our team of experts adapt them for educational purposes by making them safer, more visible, and more classroom/training friendly. This includes adding troubleshooting fault boxes where possible so students are learning important diagnostic skills from the very beginning.

This philosophy helps students rapidly develop exceptional critical thinking skills, troubleshooting skills, and industry relevant automotive knowledge for their future careers.

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A Lot Has Changed in Modern Vehicles

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For more than 40 years, ConsuLab has been a manufacturer of high quality, innovative training equipment for vocational and technical training institutions, in addition to various industry companies. Today, ConsuLab is a world leader in this area.

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Our ConsuLab Training Aids segment Transportation Technology Systems into easy-to-digest training areas for students to learn complete and holistic concepts - from fundamentals to advanced. Our training systems are best-in-class, and can be conceptualized by the following form factors:

These classroom tools are great for illustrating and demonstrating complex and hard-to-grasp concepts by revealing the inner workings of any mechanical or electro-mechanical part on the vehicle. Automotive and Diesel Cutaways are an invaluable tool for the classroom.



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All ConsuLab Training Systems are aligned with national and international certification standards such as the ASE Education Foundation (Automotive Service Excellence), NATEF, etc.

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What separates our Automotive and Diesel Training Systems from others? Support, Training, and Quality.

Our team of experts is here for you. From additional training on concepts, to training on our systems, to helping design your curriculum, we're here for you.

Our systems are also built like no other. OEM parts, all welded construction, made to last.