04/06/2024 18:00:34

Isolation/Insulation Test

Correction Code 44000100

Perform the isolation/insulation test when diagnosis requires verification that a circuit or component is properly isolated, or a cable has sufficient insulation.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
When measuring isolation/insulation, the tester will generate high DC voltage up to 1000V. Proper HV PPE must be worn when performing an isolation/insulation test.
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Warning
Residual voltage may still be present in the component after performing an isolation/insulation test – DO NOT TOUCH THE COMPONENT WITHOUT FIRST CHECKING THE VOLTAGE after an isolation/insulation test.
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Warning
Make sure that the insulation meter and leads are capable of handling at least 1000V DC.
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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning
Always wear High Voltage (HV) gloves and safety glasses when handling any high voltage component, including test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired.
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Warning
All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment.
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Warning
Assume that high voltage is present at all times when working on a Tesla vehicle, associated high voltage components, or associated high voltage test equipment until proven otherwise. Be aware that energy states can change during testing, so err on the side of caution.
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Warning
Always have an electrical safety hook in the area when working with HV components. Electrical safety hooks are used to remove an injured person from a live high voltage circuit without risking additional injury.
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Warning
Obey all instructions when using test equipment or servicing a Tesla vehicle or associated high voltage components. If repair instructions are not clear or if there are any questions about how to use the test equipment, escalate a Toolbox session before proceeding.
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Warning
If any test equipment fails to operate as expected, do not attempt to diagnose or repair the vehicle. Follow the appropriate lock out – tag out procedure for the equipment, notify your manager.
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Warning
When using test equipment, make sure that all cables are connected before turning equipment on or otherwise initiating use.
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Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Special tools required for this procedure:

Part Number Description
1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
1130480-00-A Test Probes, Slim, Fluke TP38

Procedure

  1. Inspect the condition of the HV rubber gloves and protective outer gloves. Do not use any PPE that is out of date, leaking, or otherwise compromised.
  2. Inspect the condition of the isolation/insulation tester that it is fit and functional. Do not use any equipment that has frayed or damaged probes, leads, connectors, or exposed metal.
  3. Install the probes to the tester.
  4. Set the tester to measure isolation/insulation MOhms (MΩ) scale.
  5. Set the tester to the test voltage appropriate for the component being measured.
    • HVAC PTC heaters and refrigerant compressors - 250V
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Test voltages greater than 250V will damage PTC heaters and compressors.
    • Charge ports only - 1000V
    • All other components - 500V
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Toolbox article 6230600 for additional information.
  6. Put on the PPE.
  7. Set and hold the probe ends to the locations to be tested.
  8. Press the START/TEST button on the tester to begin the test.
  9. Observe and remember the measured isolation resistance/insulation resistance in MOhms (MΩ).
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    Warning
    Do not remove the probes from the test locations.
  10. Release the START/TEST button, or press a second time, (as appropriate) to end the test.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not remove the probes from the test locations. Removing the probes prematurely prevents the tester from discharging the circuit under test. These videos demonstrate that without proper discharge, high voltages are present
    and dangerous.
  11. Allow the tester to discharge the circuit under test.
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    Note
    For some testers, a measured value will decrement to zero. This video demonstrates proper discharge after measurement.
  12. Verify that there is no indication on the tester of high voltage present in the circuit under test.
    Informational PurposesAn informational icon, calling your attention
    Note
    Indicators on the tester display might be:
    • Lightning bolt icon
    • TEST icon
    • HV icon
    • Attention icon
    • LED lit
    or a combination of these indicators.
  13. Remove the probes from the test locations.
  14. Set the tester to measure high voltage DC.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The tester must not be set to measure isolation/insulation MOhms (MΩ).
  15. Set the probe ends to the same locations previously tested.
  16. If the voltage is greater than 10V continue to hold the probes to the test locations for an additional minute.
  17. If after a minute, the voltage is still greater than 10V and:
    • The voltage is not gradually decreasing - Remove the test probes and escalate a toolbox session to region.Do not touch the component until the voltage is verified to be safe (10V or less).
    • The voltage is gradually decreasing - Continue to hold the probes to the test locations until the displayed voltage is 10V or less.
  18. Remove the probes from the test locations.
  19. Remove the HV PPE.
  20. Refer to Toolbox article 6230600 for component expected isolation resistance specifications and additional information.