Li-Ion Battery Heater System Insulation Resistance Check

LI-ION BATTERY HEATER SYSTEM INSULATION RESISTANCE CHECK

Diagnosis Procedure


WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- Refer to "High Voltage Precautions" Type 2.

CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

1. PRECONDITIONING


WARNING:
Disconnect the high voltage. Refer to "How to Disconnect High Voltage" Service and Repair.
1.Remove Li-ion battery. Refer to "Removal and Installation" Service and Repair.
2.Remove battery pack upper case. Refer to "BATTERY JUNCTION BOX : Disassembly and Assembly" Type 2, see Step-1 to Step-3.
- GO TO 2.

2. CHECK HIGH VOLTAGE HARNESS

Check the harness shield between the heater relay unit and the Li-ion battery heater for scratches and cracks.
Is the inspection result normal?
YES- GO TO 3.
NO- Repair or replace error-detected parts and Li-ion battery controller.

3. CHECK HEATER RELAY UNIT INSULATION RESISTANCE


WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger of damage to electronic devices. Read the insulation resistance tester instruction manual carefully and be sure to work safely.
1.Disconnect high voltage harness connector from heater relay unit.
NOTE:
Check the heater relay with it installed on the battery pack.
2.Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until the value becomes stable.

CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.





Is the inspection result normal?
YES- GO TO 4.
NO- Replace heater relay unit and Li-ion battery controller.

4. CHECK LI-ION BATTERY HEATER


WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger of damage to electronic devices. Read the insulation resistance tester instruction manual carefully and be sure to work safely.
1.Disconnect high voltage harness connector from Li-ion battery heater.
NOTE:
Check the heater relay with it installed on the battery pack.
2.Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until the value becomes stable.

CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.





Is the inspection result normal?
YES- GO TO 5.
NO- Replace corresponding Li-ion battery heater and Li-ion battery controller.

5. CHECK HIGH VOLTAGE HARNESS INSULATION RESISTANCE


WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger of damage to electronic devices. Read the insulation resistance tester instruction manual carefully and be sure to work safely.
1.Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until the value becomes stable.

CAUTION:
Be sure to set the insulation resistance tester to 500V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.





Is the inspection result normal?
YES- INSPECTION END.
NO- Replace high voltage harness.